In the field of industrial production,
Screw Air Compressor as the core power equipment, its energy consumption cost directly affects the economic benefits and market competitiveness of enterprises. How to realize energy efficient operation of screw air compressor has become an urgent problem for many enterprises,
ZAKF screw air compressor supplier, as a professional manufacturer with leading technology and rich experience in the industry, brings a full range of energy-saving and consumption reduction solutions for enterprises by virtue of innovative technology and perfect service to help enterprises effectively reduce energy consumption cost and enhance development momentum while ensuring production.
Accurate Selection, Adaptation to Demand
The accuracy of screw air compressor selection is the basis for realizing energy-saving operation. ZAKF screw air compressor suppliers point out that enterprises should accurately calculate the required exhaust volume, exhaust pressure and other key parameters according to their actual air demand. If the selection is too large, the equipment will operate under low load for a long time, which will result in low efficiency and increased energy consumption; if the selection is too small, it will not be able to meet the production demand, and frequent starting and stopping will also cause energy waste. For example, when a furniture manufacturer expanded its production line, it did not fully assess the demand for air and chose a
Screw Compressor with too large an exhaust volume, resulting in long-term inefficient operation and high energy costs. With the assistance of ZAKF's professional and technical team, the company was able to re-select the appropriate model, which significantly improved the efficiency of the equipment and reduced energy consumption by about 18%.
In the electronics manufacturing industry, a cell phone assembly plant purchased a screw compressor with high pressure but insufficient exhaust volume due to a biased estimation of air demand for precision equipment and pneumatic tools, resulting in frequent loading and unloading of equipment and abnormal energy consumption. ZAKF technicians made on-site calculations and replaced the screw air compressor with a low pressure and large exhaust volume, which not only met the production demand, but also reduced energy consumption by 15%. screw air compressors supplied by ZAKF are equipped with high-efficiency energy-saving motors, with energy-efficiency ratings of IE4 and above, which improve the efficiency of the motors by 10% - 15% compared with ordinary motors, and thus reduce the energy consumption of the equipments from the source.
Frequency conversion speed control, intelligent energy control
Traditional screw air compressors control the exhaust volume by adjusting the inlet valve or bypass bleeder, which has a large throttling loss and serious waste of energy. ZAKF screw air compressor supplier suggests enterprises to introduce intelligent frequency conversion speed control technology, which adjusts the speed of the motor in real time through the frequency converter and realizes the compressor's exhaust volume to be supplied according to the demand. When the production air load decreases, the screw air compressor automatically reduces the speed to reduce power consumption; when the air load increases, the speed is quickly increased to ensure air supply. An automotive parts manufacturer has frequent fluctuations in air demand on the production line. In the past, a large amount of compressed air was released when the fixed-frequency air compressor was under low load, resulting in extremely high energy consumption. After adopting ZAKF's permanent magnet frequency conversion screw air compressor, the system automatically adjusts the motor speed according to the actual air consumption, increasing the energy utilization efficiency by 30%, and saving more than 500,000 yuan in electricity costs every year. In the pharmaceutical industry, there is a significant difference between peaks and valleys in the air consumption of a large pharmaceutical company's production plant. At night, when the equipment is running at low load, the fixed-frequency air compressor is still working at full load, resulting in a waste of energy. With the introduction of ZAKF variable frequency screw compressors and the intelligent cluster control system, the equipment is automatically deployed according to the demand for air at different times of the day, and the overall energy consumption is reduced by 28%, which saves about 400,000 yuan in electricity costs every year. Meanwhile, ZAKF's intelligent frequency control system supports cluster control of multiple compressors, which can automatically adjust the number of operating units and load distribution according to the actual air consumption, further optimizing the overall energy efficiency.
System Optimization to Reduce Losses
Optimizing the management of the whole compressed air system is an important part of energy saving. ZAKF screw air compressor supplier suggests enterprises to reasonably plan the layout of compressed air pipeline network, reduce the length of pipeline and the number of elbows to lower the pipeline resistance, and adopt high-quality pipeline materials and sealing materials to reduce gas leakage. When a beverage manufacturer adjusted the layout of its workshop, it re-planned the compressed air pipeline to reduce unnecessary elbows and excessively long pipelines, which lowered the resistance to gas transportation and reduced the energy consumption of the air compressor by about 6%.
In the machining industry, the original compressed air pipeline of a heavy machinery factory had been in use for a long time, with many aging leaks and a complicated and circuitous pipeline layout. zakf's technical team replaced the pipeline with a new type of high-strength sealing pipeline and re-planned the pipeline to reduce 12 elbows, which resulted in 70% reduction of leakage in the optimized system, and a 12% reduction in energy consumption of the air compressor. ZAKF also provides professional system optimization services, including pressure adjustment, equipment matching, etc., to help enterprises achieve overall energy saving in compressed air systems.
Regular Maintenance, Guarantee High Efficiency
Good equipment maintenance is the key to ensure the efficient and energy-saving operation of screw air compressors. ZAKF screw air compressor manufacturers emphasize that regular cleaning of air filters, replacing lubricating oil, checking the wear and tear of screw rotors and other maintenance work can keep the equipment internally clean, reduce the friction of components and lower energy consumption. A chemical company neglected to clean the air filter, resulting in clogging of the filter, poor air intake of the screw air compressor, and an increase in energy consumption of the motor by about 8%. After regular maintenance under the guidance of ZAKF technicians, the equipment returned to normal energy consumption.
In the food processing industry, the screw compressor of a bakery factory did not change the lubricating oil in time, which led to a decrease in lubrication effect, a rise in the equipment operating temperature, and an increase in energy consumption. zakf's after-sales team drew up a detailed maintenance plan for the compressor, and after regular replacement of the special food-grade lubricating oil and maintenance of the equipment, the operating temperature of the equipment was lowered by 15℃, and the energy consumption was reduced by 10 percent. In addition, ZAKF equipped the equipment with an advanced intelligent monitoring system, which can monitor the operating status of the equipment in real time and anticipate potential failures in advance, avoiding energy wastage and production losses due to equipment failure.
Waste Heat Recovery, Highly Efficient Utilization
Screw air compressor generates a large amount of heat energy during operation, which is not only a waste of energy, but also increases the heat load of the environment if it is directly discharged. ZAKF screw air compressor suppliers equip the equipment with highly efficient waste heat recovery devices, which can recover the heat carried by the high-temperature lubricating oil and compressed gas, and use it to heat the water used in production, heating the workshop, etc., thus realizing secondary use of energy and significantly improving the energy utilization of the enterprise. This can realize the secondary utilization of energy and greatly improve the comprehensive utilization rate of energy of the enterprise. After installing ZAKF's waste heat recovery system, a food processing enterprise can save 1,200 tons of standard coal every year, which significantly reduces the enterprise's energy cost and carbon emission.
In the textile printing and dyeing industry, a large textile factory recovers waste heat from its screw air compressors to heat the water used for printing and dyeing, and ZAKF's customized waste heat recovery system can recover heat equivalent to 800 tons of standard coal per year, which not only meets the demand for part of the heating of production water, but also reduces the use of steam boilers and saves about 600,000 RMB per year.
ZAKF screw air compressor supplier always focuses on customer's needs, and is committed to providing high-performance, energy-saving screw air compressor products and all-around solutions. From equipment selection, technology upgrade to system optimization and maintenance services, ZAKF's professional technical team provides full support to help companies achieve energy efficient operation of screw air compressors and reduce energy costs.
