Compressed air is widely used in the industrial field due to its safety, environmental protection, good adjustment performance, convenient transmission, convenient centralized management and application, and good working environment applicability. With the development of textile industry technology and the replacement of equipment, compressed air has been more and more widely used in the production process, and has become the second largest power energy source for textile enterprises after electricity. Despite the above characteristics of compressed air as an energy source, the output ratio of its energy consumption is about 1: 7, which belongs to large energy-consuming households. Therefore, how to save energy and reduce consumption of compressed air system is a common concern of everyone. The compressed air system includes an air compressor, post-processing equipment, air supply network, and ventilation and cooling facilities. In the design and planning of the compressed air system, comprehensive consideration can be made according to the requirements and characteristics of actual use, and an air compressor can be reasonably selected to optimize the pipeline network to reduce transmission resistance and lay a solid foundation for energy saving and consumption reduction.
Ventilation of the air compressor room The ventilation of the air compressor room may seem simple, but it is often overlooked. The quality of the ventilation not only affects the efficiency of the air compressor, but also affects the normal operation of the air compressor in severe cases, and may even cause damage to the air compressor. During the operation of the air compressor, a large amount of heat will be generated during the operation and compression of the motor. If this heat cannot be removed in time, the temperature of the machine room will increase. When the temperature of the computer room rises, the staff first feels uncomfortable and the unfavorable efficiency decreases. When the ambient temperature rises by 11 ° Q, the compression efficiency drops by 3%. From the above three points, it can be seen that improving the ambient temperature of the machine room is of great significance.
Textile companies' air compressor rooms mostly adopt the form of attached rooms, and there is a shortage of air circulation. In order to improve the ambient temperature, the heat of the motor is discharged outside by pipes, but the temperature in the machine room is still high when the temperature is high in summer. In order to solve the problem completely, the skylight was added and the exhaust fan was added. When the total power of the exhaust fan fell, the air exchange volume and the number of air exchanges were increased, and the flow direction of the air exchange was more reasonable, and the temperature of the machine room was completely improved.
Operation management of the air compressor: the intake air compressor of the air compressor uses air as the raw material to ensure the supply of raw materials. There are two types of air compressor air intake: one is indoor air intake, and the other is outdoor concentrated air intake. Outdoor centralized air intake has the following characteristics: first, it is convenient for centralized pre-filtration treatment; second, it is not affected by indoor temperature and oil and gas; third, reducing the flow and speed of indoor air is conducive to maintaining indoor environmental hygiene; Fourth, the initial investment is large, and there is resistance loss in the pipeline. In comparison, outdoor centralized air intake is better than indoor air intake.
Taking pre-filtration measures can not only extend the service life of the filter element, but also reduce power consumption. There are many forms and methods of pre-filtration, no matter which one must ensure low resistance to be effective. We adopt the method of non-woven fabric pre-filtration, which is simple and convenient. It can be replaced every shift to keep the resistance low.
Air filters are generally considered to be replaced when the alarm occurs. This does no harm to the air compressor, and also meets the operation requirements of the air compressor, but it is unfavorable from the perspective of energy saving. After the filter resistance is increased, the suction power of the air compressor will increase, and the flow rate will decrease accordingly. When the air compressor is running under the alarm value, the flow rate will lose about 5%. Therefore, regular maintenance and replacement of the filter according to the local environmental conditions to keep the resistance of the filter within a low range is also a good measure for energy saving.
Whether it is single-stage compression or multi-stage compression, the temperature between the stages and the exhaust temperature seriously affect the operation and efficiency of the air compressor. An important role of the air compressor cooler is to increase the compression efficiency. In terms of temperature, increasing the cooling efficiency is to increase the air temperature by 10 ° C. The power consumption is also reduced by 3%. The control temperature is mainly in summer. The system conducts comprehensive inspection, maintenance, cleaning or replacing coolers with poor cooling effect, replenishes lubricating fluid, and controls the temperature within an appropriate range, which not only stabilizes the operation of the air compressor, but also does not increase fuel consumption due to temperature. . The oil separator can only separate liquid oil but not gaseous oil. When the temperature is too high, oil and gas are easily generated and enter the post-processing equipment with compressed air. In addition to increasing oil consumption, these equipment will also be polluted, or the drying effect will be reduced, or the Resistance increases power consumption. Therefore, controlling the temperature can not only stabilize the operation of the air compressor, but also reduce the fuel consumption and make the system operate normally, further reducing power consumption.
Any transmission has a pressure drop, and reasonable control of the pressure drop is conducive to energy saving and consumption reduction. In order to obtain the required pressure when the pressure drop increases, the air compressor must do more work. When the pressure drop increases by 0.01MPa, the power consumption increases by 0.3% ~ 05%. For any air compressor, the increased power consumption is very large every year. Oil separators, precision filters, and dryers are the main parts that increase the pressure drop. Therefore, replacing oil separators and precision filters in a timely manner, and regularly cleaning the air channels of the dryer are effective measures to reduce the pressure drop. Extending the use time of oil separators and precision filters does not save operating costs. Moreover, the consumption of oil into the post-processing system and the pipe network system will cause accidents.
In the case of meeting the gas point process and use requirements, reduce the gas supply pressure as much as possible, and excessive supply is also a waste. When the air supply pressure decreases by 0.01MPa, the power consumption decreases by 0.3% ~ 05%. The pressure is for the entire system, and the energy saving potential is large. Therefore, according to the change of gas consumption, timely adjust the load of the air compressor or adjust the opening stage of the air compressor in time, and adopt other pressure automatic control systems to stabilize the pressure, which is more important for energy saving.
In the management of air compressors, we should develop the following good habits: turn off the power and close the isolation valve after the air compressor stops. If the power is not turned off, the computer board and the transformer continue to supply power, causing waste; if the isolation valve is not turned off, some control gas will continue to consume and cause waste.
According to the different seasons, adjust the timing of the electromagnetic drain valve in time, reduce the empty discharge time, and avoid the waste of gas and electricity.
When performing maintenance or troubleshooting on the air compressor, it is necessary to consider it as far as possible to avoid long-term debugging or opening and stopping of the air compressor.
Periodically check the valves for manual drainage and exhaust to prevent leakage caused by inadequate valve closing.
The textile industry is a machine-intensive industry. It has many equipments, long pipelines and many joints. There are many types of takeover materials and joint forms, which determines the number of leakage points. Therefore, the management of the pipeline network is not only the work of the gas supply unit, but also the work that all gas points pay attention to. Only in this way can we prevent leakage, save energy and reduce consumption. Therefore, regular leak detection and timely plugging are very important.
(1) According to different processes, set the appropriate auxiliary spray pressure to meet the production needs and ensure the quality of the grey cloth. The auxiliary spray pressure should never be set too high to avoid waste. If the auxiliary injection pressure is set too large, it is necessary to not only increase the air supply pressure and increase the operating cost, but also increase the single unit's gas consumption.
(2) Regularly check pipe joints and auxiliary spray solenoid valves, timely maintenance and replacement, and prevent leakage. An auxiliary spray solenoid valve is normally open, which is equivalent to adding two more solenoid valves. When the leakage solenoid valve accumulates to a certain number, the gas load will continue to increase, and then the plugging work becomes very important.
(3) When there is a large change in the gas load, the gas department should contact the gas supply department in time to adjust the number of air compressors or the load of the air compressor in time to avoid waste caused by excessive supply.
The energy saving and consumption reduction of the compressed air system has a long way to go. Only by paying attention to every detail in the work and starting from the bit by bit, can the energy consumption of the compressed air system be reduced.