As a key power equipment, centrifugal air compressor is widely used in many industries such as chemical industry, metallurgy and electric power. However, the proportion of its energy consumption in the overall power consumption of enterprises is often high, so it is important to explore efficient energy-saving measures to reduce the operating costs of enterprises and realize sustainable development. The following is a detailed introduction to energy saving strategies for centrifugal air compressors from multiple dimensions.
Optimize equipment design and selection
The energy saving of centrifugal air compressor starts from the design and selection of the source. The use of advanced three-way flow impeller design technology can significantly improve the aerodynamic performance of the compressor. Through computer fluid dynamics (CFD) simulation, the shape of the impeller, blade angle and other parameters of the refined design, so that the gas flow in the flow channel more smoothly, reducing energy loss, compared with the traditional impeller, can improve efficiency by 10% - 15%. At the same time, when selecting the type, according to the actual gas demand of the enterprise, reasonably determine the compressor discharge volume and discharge pressure, to avoid the phenomenon of “big marat small car”. If the selection is too large, the equipment will run under low load for a long time, the efficiency will be greatly reduced; selection is too small, it can not meet the production demand. In addition, it is also crucial to choose centrifugal air compressors equipped with energy-efficient motors, such as those that meet the IE4 and above energy-efficiency ratings, which can effectively reduce energy consumption.
Intelligent frequency conversion speed control
The traditional centrifugal air compressor often adopts the way of adjusting the inlet guide vane or outlet throttle valve to control the exhaust volume, but this way will produce a large throttling loss. With the introduction of intelligent frequency conversion speed control technology, the speed of the motor is adjusted by frequency converter, which in turn changes the exhaust volume of the compressor and realizes air supply on demand. When the air load decreases, the air compressor automatically reduces the speed to reduce power consumption; when the air load increases, it can quickly increase the speed to meet the demand. Take a chemical enterprise as an example, after the frequency conversion of centrifugal air compressor, the energy consumption of the system has been reduced by 25% - 30%, and the operational stability and response speed have been significantly improved. At the same time, with the advanced control system, it is possible to realize cluster control of multiple compressors, automatically adjusting the number of operating units and load distribution according to the actual air consumption, further optimizing the energy-saving effect.
Waste heat recovery and utilization
centrifugal air compressor will generate a lot of heat in the process of operation, if directly discharged, not only cause energy waste, but also increase the environmental heat load. Through the installation of waste heat recovery device, the compression process will produce high temperature lubricant and compressed gas heat recovery and utilization, can effectively improve the energy utilization rate. For example, waste heat is utilized to heat production water and to heat the workshop. By recovering the waste heat from centrifugal air compressors, a Chinese iron and steel enterprise can save thousands of tons of standard coal per year, while reducing boiler operating hours and fuel consumption and lowering pollutant emissions.
Fourth, regular maintenance and maintenance
Good maintenance is the basis for ensuring the efficient operation of centrifugal air compressor. Regular cleaning of the compressor impeller, expander, worm shell and other components to remove the accumulation of scale and impurities, can maintain the smooth flow path, to avoid the components due to the rough surface of the flow resistance caused by increased resistance and decreased efficiency. At the same time, check and adjust the bearing clearance, shaft alignment, etc., to ensure that the mechanical performance of the equipment is in the best state. In addition, timely replacement of worn seals to prevent gas leakage can also effectively enhance the energy-saving effect of the compressor. According to statistics, centrifugal air compressors with standardized maintenance can increase efficiency by 5% - 10% compared to equipment that lacks maintenance.
V. Optimize System Integration and Management
In addition to focusing on the compressor itself, the optimized integration of the entire compressed air system is also critical to energy conservation. Reasonable planning of compressed air pipeline network layout, reduce the length of the pipeline and the number of elbows to reduce the pipeline resistance; the use of high-quality pipeline materials and sealing materials to reduce gas leakage. At the same time, the establishment of a perfect energy management system, real-time monitoring of compressor operating parameters and energy consumption data, through data analysis to find out the energy waste links in the system, and take timely improvement measures. For example, a large manufacturing company through the comprehensive optimization of the compressed air system, the comprehensive energy saving effect reached more than 20%.
