As a basic industrial equipment, air compressors are widely used in almost all industrial industries such as metallurgical machinery, mines, electric power, building materials and textiles. With statistics, air compressors account for large-scale industrial equipment, fan and water pump boiler air compressors and other power consumption. 15. Air compressor energy loss mainly includes the mechanical loss of compressed air compressor and other losses. At present, the energy utilization rate of most air compressors in China's stone enterprises is very low, mainly due to the poor control of the design and manufacturing technology and the low control mode. Some stone enterprises do not have strong energy-saving awareness, and the control method is still very old. When the output pressure of the air compressor is greater than the fixed value, or the discharge valve is automatically opened, the research is in the direction of mechanical design and equipment, and the energy-saving step motor is idling, which is a serious waste. Energy; or shutdown, frequent start and stop of the motor, affecting the service life of the motor, and the air compressor power frequency starting current is large, the impact on the power grid is large, the motor bearing wear is large, and the equipment maintenance is large. Therefore, how to take effective measures to reduce the energy consumed by the operation of air compressors is very important to improve the economic benefits of stone enterprises.

1 Strengthen energy-saving operation management 1.1 Select energy-saving motor air compressor motor power is large, its efficiency has a great impact on the energy saving of air compressor, in order to save energy, high-efficiency motor should be preferred, and the floating capacity of the selected motor must be reduced. To prevent the bad phenomenon of the big horse-drawn car, so that the motor load rate is always above 80. The efficiency of the factory yA series asynchronous motor is higher than that of the old series motor. Generally, the loss of the ordinary motor is 625 of the input power, and the average loss is 13. After the series, the efficiency of the series asynchronous motor is 0.5, and the efficiency of the motor is 0.5. The average efficiency is higher than that of the motor. 3. In order to reduce the loss of copper and iron, the motor should use magnetic materials with low loss of magnetic permeability, and at the same time improve the design structure and manufacturing process to reduce stray loss. In addition to the above principles, the following factors should be considered in the selection: 1 Due to the difference in rotor efficiency, the squirrel cage motor should be preferred over the wound motor; 2 due to the difference in power factor, the high speed motor should be given priority in the lower speed motor. (3) Due to the difference in voltage levels, when the load is large, the lower voltage motor of the high voltage motor should be preferred.

1.2 Improve transmission efficiency Between the motor and the compressor of the air compressor, the belt belt transmission is adopted, which has the characteristics of simple structure, stable and reliable transmission.

However, it is often necessary to use multiple tapes in parallel, so that the parallel transmission of power is more serious after replacement or repair, or the old and new tapes are mixed to cause the tape to be tight. Only a few or a few loads are included in the several tapes, which greatly reduces the transmission of the air compressor. Efficiency, more energy is consumed. At the same time, the load belt is greatly overloaded due to severe overload operation. Therefore, in order to improve the transmission efficiency of the belt, the pulley and the tape with high processing precision should be selected. When replacing the belt, all replacements should be made. If the belt is found to be tight, it should be replaced immediately to avoid uneven belt. Load phenomenon; improve the installation level, adjust the center distance, and ensure the wrap angle and tension required for the belt drive. However, in any case, the transmission mode of the conventional air compressor, belt drive or gear transmission has a large loss in transmission efficiency. If the coaxial structure of the rotor and the motor is adopted, the energy loss factor caused by the mechanical transmission mode can be completely eliminated, and the air volume operation can be realized not only, but also the rotation speed control can be performed in the whole range.

1.3 Reduce frictional power consumption The internal piston between the air compressor and the cylinder liner is a sliding clearance fit. The size of the gap and its lubrication directly affect the efficiency of the air compressor. If the gap is too large, the air leakage loss will not even work. If the clearance is too small, it is difficult to form an effective lubricating oil film between the piston and the cylinder liner. The frictional resistance of the reciprocating motion of the piston increases, and the friction loss is intensified, resulting in the energy consumption of the air compressor. Increase. Therefore, an effective oil film can be formed only under suitable clearance conditions, maintaining good lubrication and thus reducing friction loss. Ensure that the inside of the air compressor forms a good lubrication path. 20. STONE20 should have strict control of the gap between the piston and the cylinder liner, through careful installation and debugging, timely replacement of the worn piston ring; ensure that the oil cleaning viscosity is appropriate; ensure that the oil circulation is rapid and the oil pool volume can meet the heat dissipation needs; Try to use low-lubricity lubricating oil to reduce frictional power consumption; regularly maintain the air compressor to achieve the best performance of the machine; pay attention to change the different grades of lubricants with the seasons.

1.4 Reduced pressure loss and leakage The air compressor system of the air compressor consists of a filter cylinder suction and exhaust valve piston assembly cooler seal and a gas tank. The outside atmosphere is cleaned and compressed and then passed through the gas pipeline to reach the equipment used. This process has great potential for energy saving. If the piston and the inner wall of the cylinder liner are not tightly sealed, the suction and exhaust valve will be seriously damaged or improperly repaired, which will cause serious air leakage, which will directly reduce the displacement of the air compressor and reduce its efficiency. The leakage of compressed air in the gas pipeline is also an important cause of the increase in energy consumption of the pneumatic system. The energy loss of the pipeline system is mainly lost along the pipeline and the leakage pressure. Reduce pressure loss and leakage. 1 Design and installation, reduce the flow resistance of the system gas path as much as possible to meet the process requirements, to reduce pipeline and accessory coolers, oil-water separators, valves, elbows, tubes Pressure loss such as path reduction. If the suction line is to be short, the elbow and the valve should be installed as little as possible to reduce the loss along the pipeline and the partial pressure loss. 2 Use large diameter, low flow rate air supply. 3 Minimize leakage and clearance volume inside and outside the equipment. The external leakage air directly leaks into the atmosphere or leaks into the human-level intake pipeline, which directly reduces the displacement; the internal leakage gas leaks from the high-pressure stage to the low-pressure stage or the interstage pipeline, causing repeated gas compression, increasing power consumption, and affecting Exhaust pressure and temperature. 4 use safe and efficient pneumatic components. The suction and exhaust valve has a great influence on the energy saving of the air compressor. The suction and exhaust valve requires quick opening and closing, low resistance and good sealing performance. The leakage coefficient should reach 95 or above. Use a new air filter to reduce pressure loss, such as 0 pieces of borosilicate microfibers are compounded with a fluoroethylene folding filter absolute filter. 5 Careful installation and management. Strictly follow the technical data of the installation sequence of each part to reduce the internal and external leakage of the inlet and outlet valve piston ring and stuffing box to a minimum, reduce energy consumption and improve equipment efficiency.

Exhaust volume m5 cabinet 1 air compressor performance curve 1 flow and exhaust pressure curve; 2 flow and power consumption curve is good.

2 reactive power compensation energy-saving air compressor motor is often asynchronous electric motor, asynchronous motor is inductive load, low power factor, and varies with load, high power factor at rated load, low power factor at light load, like Between 0.20.85, the energy loss is large. The reactive power compensation of the asynchronous motor refers to reducing the power loss of the power supply line and the transformer by compensating the power factor of the power line under the premise of ensuring the normal operation of the motor.

The power of the balanced phase line system can be used from the following formula to the optimum working point of the compressor, and the way to save energy in the air compressor can be obtained. The working parameters of the compressor at 1 point are: Q, W The working parameter at point B is P2Q2W2.l, which reflects that when the pressure is reduced from 2 to 2, the power consumption of the air compressor decreases with the pressure. However, the amount of exhaust gas is increased, and the energy consumption is achieved. The increased air volume is also beneficial to improve the working efficiency of the equipment. Therefore, the economic efficiency of working point 6 is better than that of working point 8. Therefore, in the operation of the compressor, the working point should be approached as close as possible. Since the power consumption of the air compressor is proportional to the exhaust pressure, the exhaust pressure can be reduced to save energy. Therefore, according to the actual production demand, the working pressure of the air compressor should be set reasonably. The air pressure of the air compressor should be set as low as possible while ensuring the actual air volume, and the air cooler load should be reduced because the exhaust pressure is set. The lower the shaft power consumed, the less the energy-saving effect is, and the more regularly the pipeline is leaked, ensuring safe and reliable operation of the gas pipeline.

1.5 Improve the exchange heat performance of the cooler The compression process of the gas in the air compressor has isothermal compression adiabatic compression and variable compression = species. Isothermal compression consumes the least amount of cycle work under the same conditions of initial pressure and final pressure. However, the actual compression process is multi-variable compression, and the cooling effect of the air compressor is better, and the closer to the isothermal process, the less the cycle work. In order to improve the cooling efficiency, an intercooler and an aftercooler are generally provided in the cooling water system of the air compressor to ensure that the intake temperature of the compressed air of each stage is substantially the same. Therefore, the heat exchange performance of the intercooler is improved, so that the stage inlet air temperature can satisfy the inlet temperature of the isothermal compression, and the back cooling is ensured; the temperature of each stage cylinder is lowered, so that each stage of the compression process is close to the isothermal compression. The key to energy-saving operation management of air compressors. To improve the exchange heat performance of the cooler, the following measures can be taken: 1 to reduce the temperature of the cooling water population and increase the flow rate of the cooling water; 2 to carefully remove the deposit of the cooler tube bundle, ensure uniform contact between the gas and the tube bundle, and avoid short circuit; 3 soften and cool with water treatment agent Raw water to improve water quality.

Whether it is an intercooler or an aftercooler, the power of the circulating water comes from the circulating water pump. The energy saving of the pump can not be ignored. Reasonable configuration of the circulating water system configuration, control of the circulating water consumption, and reduce the waterway loss of the pipeline system can effectively save the power consumption of the circulating water pump. The cooling water system has both open and closed configurations. In an open system, the energy of the compressed air is taken away by the cooling water in the form of heat or scattered in the surrounding atmosphere, and the energy is wasted. Therefore, it is necessary to pay attention to the comprehensive utilization of waste heat, provide partial economic effects to compensate for all the heat loss generated by the air compressor, and achieve energy saving, such as bringing this part of water into the bathroom plastic greenhouse in winter and the hot water supply of the hotel; the closed system is for reflow The hot water temperature is rapidly reduced, and a larger area of ​​the circulating pool can be used, or a cooling tower with a watering device can be used. However, care should be taken to properly control the children of the cooling water. The excessive amount of water will increase the power consumption of the circulating water pump.

1.6 Reasonable setting of working pressure Air compressor performance curve is determined by the performance of the compressor itself, which reflects the air compressor exhaust pressure, power Jia with air flow, can, in the case of load power households and voltage unchanged The current is inversely proportional to the power factor. If the same power is delivered, the Joule heat loss of the distribution line resistance is proportional to the square of the current. Therefore, the power loss is inversely proportional to the square of the power factor, ie, the smaller the power factor, the greater the power loss. Therefore, the power factor is used to reduce the power consumption on the distribution line, and the effect is very significant.

Since the active power and reactive power absorbed by the motor during normal operation are transmitted through the distribution line, in order to reduce the reactive power loss of the distribution line, it is effective to install a power capacitor at the power receiving end to improve the power factor. Method. The capacitors of the capacitors are connected in parallel with each other. When the inductor absorbs energy, the capacitor releases the energy, and when the inductor emits energy, the capacitor absorbs energy. Thus, the reactive power absorbed by the motor as an inductive load can be compensated by the reactive power output by the capacitor. The power-saving principle of reactive power compensation is 2.2. The reactive power absorbed by the inductive load from the power supply is the reactive power after the reactive power compensation device is set. The reactive power delivered by the power supply is reduced, and the power factor is called by (3). Raised to, the apparent power is reduced from 5. Reactive power compensation is mainly based on low-voltage medium-sized motors, especially the air compressor motor that is often in continuous operation. The power-saving principle of the transformer compensator 2 reactive power compensation and the more the number of motor poles, the more the economy of reactive power compensation can be realized. Sex.

3 frequency conversion speed regulation energy saving 3.1 air compressor traditional control method The supply and demand relationship of air compressor air volume is mainly the exhaust pressure pressure. The force remains the same. In the production, due to the imbalance of air volume, the air supply volume of the air compressor is much larger than the actual air volume. In order to keep the gas storage pressure constant, it is necessary to adopt the adjustment method. At present, the energy adjustment of the compressor, the hot gas bypass energy adjustment, the split speed, the variable air volume, and the continuously variable speed adjustment. Among them, the intermittent operation or no-load operation of the compressor is used to adjust the energy most often. Intermittent operation of the air compressor will bring frequent start and stop of the compressor, increase the power loss, increase the fluctuation of the power grid, and also affect the life of the equipment; while the power consumption of the no-load operation is still full load 30 60, which Part of the electrical energy is wasted, and the no-load starting current of the air compressor is 57 times of the rated current. It has a greater impact on the power grid and other electrical equipment, and the service life of the air compressor is also shortened. There are also many unavoidable shortcomings. 1 The pressure ratio increases after the intake air is cut off. If the final stage is a double-acting cylinder, the piston force will increase sharply due to the disappearance of the end gas thrust, especially if the exhaust pressure is relatively high, the exhaust temperature will rise sharply, the equipment will be easily damaged, and the maintenance cost will be increased. Increase the fuel consumption by squeezing the oil mist in the crankcase along the piston rod or piston toward the cylinder.

3.2 Frequency control and energy saving control The frequency conversion speed regulation mainly controls the air volume per unit time of the air compressor by changing the rotation speed of the motor, thereby achieving the pressure of the control pipeline and adjusting the energy of the air compressor, which has obvious energy saving effect. It can continuously adjust the energy in a certain range to meet the operation requirements of the air compressor under light load, so that the air volume is matched with the actual air volume. Since the speed of the asynchronous motor is determined after the air compressor motor is determined, the 3 and the constant are , the motor speed is proportional to the power frequency, so changing the power frequency of the motor can change the motor speed, thus achieving variable frequency speed regulation. According to the principle of electromagnetic induction, in the case of variable frequency speed regulation, as long as the magnetic flux remains little and the motor stator voltage is proportional to the power supply frequency, the output power of the motor changes with the change of the power supply frequency. As long as the input voltage on the stator side is changed, the frequency of the motor can be adjusted. This is the control method of the constant voltage ratio. When the air compressor adopts the frequency conversion speed regulation technology for the constant pressure air supply control, the system frame 3. The pressure value of the pipe network measured by the pressure transmitter is compared with the set value of the pressure to obtain the deviation, and is calculated by the Dan 0 regulator. After the frequency converter acts on the frequency value of the asynchronous motor, the inverter outputs the alternating current of the corresponding frequency and amplitude to obtain the corresponding speed on the motor, so the air compressor outputs the corresponding compressed air to the gas storage tank to change the pressure. Until the pipe network pressure is the same as the given pressure value.

The air compressor frequency conversion speed regulation has the following advantages: The motor can realize soft start, reduce the starting current, and start smoothly, without mechanical shock, thus prolonging the life of the mechanical equipment and reducing the influence on the power grid; the gas transmission pressure is stable and adjusted. The reliability is high; the most important thing is that the energy saving effect is obvious, and the power saving is 3040, which can bring more energy saving effects to the enterprise. Take the 41408 air compressor of a stone plant air compressor station as an example. The original control mode is intermittent control operation, that is, when the output pressure is greater than the fixed value, the discharge valve is automatically opened to make the asynchronous motor idle. This not only seriously wastes energy, but the motor starts and stops frequently, which seriously affects the service life. In addition, there are the following problems: large noise, low automation, slow output pressure regulation, low precision, and instability; air compressor power frequency starting current is large, impact on the power grid is large, motor bearing wear is large, and equipment maintenance is large. . In response to these questions, it was decided to adopt and operate the inverter on the air compressor. 88 people 0560 inverter is selected, the control system consists of the following parts: inverter programmable controller reactor pressure transmitter oscillation sensor contactor air switch cable current voltage button transformer and so on. The parameters tested before the transformation are as follows: the motor power is 75kW, the outlet pressure is 5.96.5MPa, the running time is 12, the annual operation is 320 days, the loading current is 130 people, and the load-shedding current is 90 people. It has been tested to have a power saving rate of 30 or more. The annual power consumption is calculated according to 30. The following advantages reduce the noise of the machine; the use of 10, and the inverter realizes the soft start of the soft start of the machine, avoiding the high power grid when the air compressor is started, and overcoming the shortcomings of manual adjustment of the original system.

5 Conclusion Air compressor is a high-power equipment for stone enterprises. It has the characteristics of large power, long running time, high power consumption and large cooling water consumption. Therefore, how to effectively save energy and reduce the operating cost of air compressors has become a top priority for stone enterprises. There are many factors affecting the energy consumption of air compressors, including the control methods of equipment and accessory structure operation management methods. Only comprehensive analysis and comprehensive considerations can be adopted to ensure the safe and reliable operation of energy conservation. Among them, the adjustment mode of air compressor is closely related to energy saving. The use of variable frequency speed control technology to adjust the operation of air compressor is a relatively advanced and effective energy saving method, which can produce significant energy saving effect and greatly improve economic benefits. And social benefits, has a very broad application prospects, worthy of reference and reference for stone enterprises.

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Li Wenhua, Wei Ruirui, Zhang Yi sample. Energy-saving technology to improve the operation of air compressors.

Tang Siwang. Air compressors use reactive power to compensate energy-saving analysis of metal mines, Wang Jing, Yang Xiuqin. Air compressor energy saving analysis 叽 coal mining machinery, 2002, 23 Cao Jinli. Application of energy-saving reactive power compensation in power plant circulating water pump motor 叽Science and Technology Information Development and Economics 2003,1358687.

Zhu Youhui, Yan Caibang. Energy-saving renovation of crane air compressors, energy saving, 2, 2, 28f73941.

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