1. Solve air compressor leakage and gas use methods
According to authoritative organizations, only 10% of the electricity consumed by air compressors is converted into compressed air, and the remaining 90% is converted into heat energy. It can be seen that compressed air is ten times more expensive than electricity, but we often ignore this point. In most factories, the sound of air leakage can be heard everywhere, but no one cares at all. If we solve the leakage problem, we can save a lot of energy. Therefore, when we hear the leakage, we must take corresponding measures in time.
There are also some factories that have a big misunderstanding in the way of using gas. For example, in circuit board manufacturers, most electroplating lines use vibration to increase the electroplating capacity of small holes. Some manufacturers prefer to use air vibration to achieve this purpose. Little do they know that this consumes more than ten times more electricity than using electric vibration.
Therefore, in order to save energy in air compressors, while timely solving the leakage problem, we must also avoid improper gas use methods.
2. Energy-saving transformation of air compressors
There are two main ways to transform air compressors for energy saving:
1. Frequency conversion speed regulation
The frequency conversion speed regulation method is used to reduce the shaft power output of the air compressor motor. Before the transformation, the air compressor will automatically unload when the pressure reaches the set pressure; after the transformation, the air compressor does not unload, but reduces the air output of the compressor by reducing the speed to maintain the low pressure required by the gas network. There are two places where energy can be saved:
(1) Reduce the power consumption caused by the sudden change from the unloading state to the loading state of the compressor.
(2) The operating frequency of the motor is reduced to below the working frequency, so that the output power of the motor shaft is reduced.
The above two methods have reduced the energy consumption of the air compressor during operation to varying degrees. However, the air compressor generates such a large amount of heat energy during operation and it is dissipated into the air in vain, but it has not received widespread attention from users for a long time. This cannot be said to be a great regret.
2. Centralized control method
A centralized control method is adopted for multiple air compressors. The number of air compressors in operation is automatically controlled according to the gas consumption. Before the transformation, the number of air compressors turned on was fixed.
(1) If the gas consumption is further reduced, the air compressor with good performance will automatically shut down. In the case of (1), the air compressor consumes electricity even when it is unloaded. After the transformation, the corresponding number of air compressors can be shut down, and the number of running units is reduced, which undoubtedly saves electricity.
(2) When the gas consumption is reduced to a certain amount, the air compressor reduces the gas production by reducing the loading time.
III. Waste heat recovery
Air compressor waste heat recovery is a very environmentally friendly energy-saving method, and it is also an energy-saving method strongly recommended by Nak Electromechanical Equipment Co., Ltd. Air compressor waste heat recovery is to transfer the heat of the high-temperature oil of the air compressor to cold water through heat exchange and other technical treatments. The cold water is heated and flows into the insulated water storage tank, so that the purpose of heat energy recovery can be achieved.
Because 73% of the heat energy of the air compressor is in the oil, and technical treatment of the oil for heat exchange will result in a steady supply of hot water, which can not only enable the air compressor to work at a constant temperature, but also meet the hot water needs of the factory or life, killing two birds with one stone. In addition, the hot water produced by the air compressor waste heat recovery technology does not require any additional costs, which reduces the factory's investment in making hot water.