As a general-purpose machine, industrial compressors currently consume more than 200 billion kWh of electricity per year, which is 6% of the country's total electricity consumption. In the textile and chemical fiber industries, the proportion of electricity used has reached 40%.
Compared with other industrial fluid media such as water, steam and natural gas, since compressed air comes from the atmosphere, leakage will not bring pollution and safety problems. The leakage of compressed air and the energy saving of compressed air systems have been paid attention to in many enterprises. relatively low. In recent years, some companies have been forced to reconsider the energy consumption of compressors due to energy-saving pressures, and compressors have begun to become the focus of energy conservation.
Compressors differ from many industrial equipment in that their cost of purchase is less than 10% of their full life cycle cost, while more than 80% is power consumption. For example, a 250 kW compressor has an annual operating power of about 2.16 million kWh, equivalent to an electricity bill of 1.5 million yuan, and a five-year operating electricity bill of up to 7.5 million yuan, and its purchase cost usually does not exceed 500,000 yuan. Therefore, the economic benefits brought by the selection of a high-efficiency compressor and a compressor group control network that constructs intelligent matching loads are particularly significant.
Around the energy saving of a single compressor, the current manufacturers are mainly dedicated to low-power operation technology at non-full load, for example, using a wide-load high-efficiency motor to reduce the pressure inside the oil and gas separation barrel during unloading, built-in variable frequency motor, automatically shut down after a certain time of unloading, setting Empty the automatic adjustment device, etc. For the energy saving of multiple compressor units, load matching gas supply technology has become its main line, such as compressor frequency conversion, compressor group expert control system, compressor number control, and end pressure remote control.
Recently, the commonly used Prognostics and Health Management (PHM) technology in the aerospace industry has also begun to be used in compressors, which allows users to monitor whether the compressor is always in an efficient and healthy state.
As the upstream equipment of the compressed air system, the compressor is energy-saving, although it has good energy-saving benefits, it is still limited by process pressure and process flow. The overall energy saving of the compressed air system also needs to stand in the perspective of system energy saving, paying more attention to the end gas equipment. We must not only change the phenomenon of big horses (called "energy saving"), but also make the car lighter (called "saving energy"). Usually, the effect of energy saving is more obvious. For example, in the energy-saving retrofit of the system that supplies air to more than 5 compressor units in our center, the load of the compressor room matches the energy supply of the gas reform by 5%~10%, while the optimization of the pipeline, the modification of the end gas equipment and the plugging can contribute. 15% to 20%.