The energy saving and emission reduction of screw air compressor equipment has always been a hot issue concerned by various enterprise users. It is usually not a simple method to save energy by keeping the original operating power efficiency of the air compressor, but the following methods can be used to try:

1、 Improve the transmission efficiency of air compressor motor and host

The air compressor often uses V belt to realize the transmission between the motor and the compressor. Although the V belt has the advantages of stable transmission, it is usually necessary to choose a parallel mode of multiple tapes. The belts may have uneven load due to poor tightness - or errors in the pulley groove, which reduces the transmission efficiency, wastes power, and reduces the service life of the V belt. Select high-quality and high-precision pulley and tape. When the load is uneven, replace all tapes at one time. Carefully adjust the center distance during installation to ensure that all tapes are under the same tension, which can effectively improve their transmission efficiency. However, the use of V-belt transmission mode can not completely eliminate the energy loss in transmission. The use of rotor and motor coaxial structure can completely solve this problem. It also increases the air volume operation and realizes the speed control of the air compressor in a full range.

2、 Reduce the friction power consumption of the core host of the air compressor

The clearance and lubrication between piston and cylinder sleeve affect the efficiency of air compressor. If the clearance is too large, air leakage loss will occur. If the clearance is too small, effective lubrication cannot be formed. The friction loss will increase, which will increase the energy consumption of the air compressor. Only with proper clearance can effective lubrication be maintained. The measures to reduce the friction power consumption are: precisely control the clearance, timely replace the worn piston rings, ensure the proper viscosity of the oil, rapid circulation, and carry out regular maintenance. In addition, pay attention to changing the lubricating oil according to the change of season and climate, and select the lubricating oil with low viscosity as far as possible under the premise of good lubrication performance to further reduce the running resistance and reduce power consumption.

3、 Reduce the exhaust pressure loss of air compressor

The air passage system consists of air filter, suction and exhaust valve, cooler, etc., which can transport compressed air to the equipment. If the suction and exhaust valves are out of repair or improperly repaired, air leakage will occur, reducing the exhaust volume, thus reducing the operating efficiency of the air compressor. To reduce the pressure loss, first of all, the flow resistance and pressure loss of the gas path system should be reduced as much as possible on the premise of meeting the process requirements, for example, the minimum number of valves should be installed, and the suction pipeline should be as short as possible; Secondly, the gas path system with large pipe diameter and low speed air supply mode shall be used; Thirdly, reduce the leakage inside and outside the equipment and reduce the clearance volume; Fourth, high-quality pneumatic components should be used, such as the suction and exhaust valves should have good sealing performance and low resistance, and the air filter should choose a new ND filter, etc; Fifth, the installation and daily management shall be well done, and regular inspection and maintenance shall be carried out to ensure the safe and reliable operation of the gas circuit system.

4、 Improve heat exchange performance

There are three kinds of compressed gas of air compressor: isothermal compression, adiabatic compression and polytropic compression. Theoretically, the energy consumption of isothermal compression is the smallest, but in actual operation, it is polytropic compression. In order to reduce the energy consumption in the compression process, it is necessary to improve the cooling efficiency. There are intercoolers and aftercoolers in the cooling water system, which can improve the performance of the intercooler, make the temperature of the secondary air intake more close to the temperature under isothermal compression, and ensure perfect cooling. The cooler performance can be improved by reducing the temperature of cooling water, increasing the flow rate, removing the sediment in pipes and equipment, and using water treatment agents to improve the water quality. Reasonable allocation of water pumps, control of water consumption, and reduction of water loss can effectively reduce power consumption. In the open cooling water system, energy is wasted in the form of heat, and energy conservation can be achieved through comprehensive utilization of waste heat. For example, by introducing water into hot water supply such as bathrooms, energy can be reused. I In the closed cooling water system, the cooling rate of hot water can be accelerated by increasing the area of the circulating water pool, but the cooling water consumption should be controlled to avoid increasing the energy consumption of the circulating water pump.

5、 Reactive compensation energy saving

The air compressor usually uses asynchronous motor, and the power factor of asynchronous motor is relatively low, mostly between 0.2 and 0.85, which varies greatly with the change of load and has large energy loss. Reactive compensation is to improve power factor and reduce energy loss under the premise of normal operation of motor. The installation of power capacitor at the receiving end can effectively improve the power factor, especially suitable for low-voltage medium motors that often operate continuously.

6、 Energy saving of frequency conversion speed regulation system

Variable frequency speed regulation energy saving realizes motor speed regulation by installing frequency converter between power grid and motor to change voltage and motor frequency. The speed of the air compressor is controlled by the frequency converter to adjust the energy, meet the needs of light load operation, and match the exhaust volume with the gas consumption. Proved by practice; The frequency conversion speed regulation method can improve the working efficiency of the air compressor under light load operation, reduce the energy consumption of the air compressor, and create better economic benefits for the enterprise. The system controls the output pressure, connects the feedback signal to the frequency converter, compares it with the given signal, sends the comprehensive signal to the input given end after PID adjustment, and adjusts the speed and power of the motor according to the pressure change.

7、 Energy saving of multi unit group control system

In the situation where the gas consumption is large and the gas load fluctuates greatly, it is difficult to use a single large capacity air compressor to meet the needs of gas volume regulation, and multiple air compressors are often used. Multi unit group control technology is one of the effective methods to achieve energy saving under the operating conditions of multiple air compressors. It selects the required machines and number of units according to the actual gas consumption, eliminates unnecessary waste, and has significant energy saving effect.

Final summary:

Equipment, operation management and other factors affect the energy consumption of the air compressor. Only through comprehensive analysis, comprehensive consideration, and selection of advanced technology, reasonable and feasible methods and supporting measures, can the energy saving, stable and safe operation of the air compressor be ensured. While applying advanced technologies and methods such as frequency conversion and speed regulation, the staff should carefully perform daily operation management and maintenance of equipment, save energy and reduce consumption on the basis of ensuring production, so as to improve economic benefits and save enterprise resources.

Atlas air compressor accessories

Atlas air compressor impeller

Atlas air compressor high and low speed shaft rotor

Atlas air compressor High and low speed bearing

Atlas air compressor High and low speed oil seal and gas seal

Atlas air compressor high-grade special lubricating oil

Atlas air compressor oil cooler

Atlas air compressor core of Air cooler

Atlas air compressor Inlet air filter

Atlas air compressor Oil filter