Energy saving is the most popular topic in the current screw air compressor industry.
There are many articles describing the energy saving of screw air compressors, but because the energy saving of screw air compressor system is more about the integration and application of technology, and institutions with research strength focus on the energy saving of manufacturing equipment. So far, there is no more complete and concise theoretical guidance for users.
Energy saving is the most popular topic in the current screw air compressor industry. There are many articles describing the energy saving of screw air compressors, but because the energy saving of screw air compressor system is more about the integration and application of technology, and institutions with research strength focus on the energy saving of manufacturing equipment. So far, there is no more complete and concise theoretical guidance for users.
This article tries to use an easy to understand way, borrowing the basic concept of “five elements” in the theory of total quality management, which is very familiar to manufacturing enterprises, to transform the air compressor system into the five elements of energy saving: “people, machine, use, method and environment”. To enrich the practical operation guidance of the user level in the energy saving of air compressor system.
Management guru Peter Drucker said, “The entrepreneur is to do two things, the first is marketing, the second is to reduce costs.” In order to maximize the profit continuously, the manufacturing enterprises can “open source” by increasing sales and “reduce costs”. In the current industry market growth is slowing down, the management and control of enterprise operating costs is particularly important to ensure and improve enterprise profits.
It is because of the “internal driving force” described above that the existence basis of the energy saving of the air compressor system is formed. This is the fundamental factor, not state advocacy or coercion.
Generally speaking, about 20% of the power consumption of the factory is consumed by the air compressor, and some industries even up to 80%. Even if only for intuition, the energy saving of screw air compressor system is imperative.
So, what do you do when users are already aware of the need to save energy to reduce energy costs? This is the focus of this paper. It may be very different from the scheme promoted by air compressor manufacturers. The piling of all kinds of high-tech equipment does not necessarily meet their energy saving needs, and sometimes it has the opposite effect.
First of all, it is necessary to realize that compressed air has a cost. This cost not only includes the energy consumption of the air compressor producing compressed air, but also includes all kinds of abnormal losses of compressed air.
Therefore, a basic concept is that the energy saving of the air compressor system is not only the energy saving of the air compressor, but the systematic energy saving of the whole compressed air system. Note that the key word here is “system”, not “system of equipment”.
Most of the air compressor salesmen common to users are product salesmen of manufacturers, who tend to sell products, so the most common way for them to save energy is to “change an energy-saving air compressor”. Of course, this method must be effective, otherwise there is no need to change.
But if we only rely on this way to save energy for the air compressor system, the limitations are obvious. Because, in many cases, this only solves the problem of whether the air compressor is energy-saving and efficient, and the proportion of the air compressor body in all the energy-saving space of the whole compressed air system is unknown. If the proportion is large, the energy saving effect is good, otherwise it is unsatisfactory.
Assuming that the air compressor itself can save energy in the whole system only accounts for 10% of the space, which means that if you just replace the air compressor, the other 90% of the energy-saving space is still hidden somewhere like an hourglass passing your money.
Common some possible energy saving space, ways:
(1) efficient compressed air production and treatment equipment;
(2) unit selection, control mode and pipeline optimization design;
(3) Adjust the gas pressure and the on-site management of the compressed air system;
(4) Control pressure loss, leakage and improve the efficiency of gas device;
(5) Using energy recovery devices to reduce comprehensive energy consumption;
…
Each of the above points will be a big topic. We cannot force users to fully grasp all the details, but at least we should have a more comprehensive understanding of the energy saving of the air compressor system. The basic concepts of “person, machine, use, method and environment” in the theory of total quality management, which is very familiar to the factory, are borrowed below to help sort out and understand.
person, machine, use, method, environment
Screw air compressor system energy saving (user) five elements: people, machine, use, method, environment
The system energy saving of air compressor, for the user level, the five main factors are: person、machine、use、method and environment.
The meanings are as follows:
1.People
The air compressor system, or called the compressed air system, is a set of complex “man-machine system”, in which people: as workers, controllers（from nrcan.gc.ca）, monitors.
Analysis of “people” :
- Do managers pay enough attention?
- Is there a specific person responsible?
- Are the processes and systems complete?
- Are the skills sufficient?
- Is the training in place?
“Energy saving” is above all a way of thinking. It is not an exaggeration to say that it is with this way of thinking that it is possible to implement the real energy saving of air compressor system. All directions and ideas depend on the “people” factor.
In the theory of these five elements, people are at the center. Just like driving a car, after determining the destination, it is necessary to choose a reasonable driving route. If there is no driver, the car will of course only stay in place.
2.Machine
All the equipment and facilities used in the air compressor system are the basic conditions for the energy saving of the screw air compressor system. The simplest way is to choose more energy-saving compressed air production equipment. Another way is to increase energy recovery devices to reduce comprehensive energy consumption.
Analysis of “machine” :
- Is the selection optimized?
- Are the supporting facilities complete?
- Is maintenance and maintenance correct?
- Energy recovery?
“Machine” is divided into two aspects, that is, selection and maintenance.
Selection is the key to ensure the smooth implementation of energy saving programs. It should be noted that the selection of the best performance equipment is certainly a way, but from the perspective of investment, it is not necessarily the most reasonable. The establishment of selection scheme is very professional and usually needs the help of professional companies.
Maintenance is to keep the performance of devices intact. This is what the user needs to focus on. The key of equipment management is to establish a perfect spot inspection and maintenance system, which can confirm the status and performance of equipment according to certain standards, detect equipment abnormalities as soon as possible, and prevent the unexpected use of equipment. And maintenance is according to the characteristics of equipment, according to a certain time interval to repair equipment, prevent equipment deterioration, prolong the service life of equipment, is an important part of equipment management.
3.Use
Compressed air system energy saving, can not only focus on the reduction of energy consumption in the production of compressed air, reduce the consumption and loss of compressed air is also a very important part.
Analysis of “use” :
- Is there a waste of air?
- Is the airequipment efficient?
- Are the process requirements for compressed air reasonable?
- Are leaks effectively managed?
For users, this is a way to realize energy saving of air compressor system through their own efforts, which is less dependent on external assistance. This is the same as the concept of electricity saving and water saving. The compressed air produced by the air compressor is the same as water and electricity, which can be saved and achieve the purpose of energy saving.
4.Method
The “method” of energy saving of screw air compressor system refers to the operation and operation management method of compressed air system. Different from the general operation requirements only for the stable operation of air compressor, the purpose of the “method” here is to obtain compressed air with as little energy cost as possible on the premise of meeting the normal production of the factory.
Analysis of “Law” :
- Is the operation setting of air compressor system energy saving?
- Compressed air system operation management method?
- Adjust system operation plan according to production situation?
- Application of Internet of Things in Energy Saving of Air Compressor System?
- Air compressor system field operation management?
Compared with “machine” and “use”, which mainly aim at hardware, “method” mainly refers to the software level. Even for the same compressed air system, using different operation schemes and on-site management, the results may be very different. Professional energy efficient companies are particularly concerned with operational management.
5.Environment
Which is often overlooked. The impact of some environmental factors is obvious when the equipment is put into use (this part will be emphasized when the equipment is installed), while the adverse impact of some environmental factors is relatively long-term and hidden, which should be paid more attention to.
Analysis of “environment” :
- Air compressor suction air quality?
- Air pressure room cooling problem?
- Compressed air duct?
- Safety and environmental measures?
The above environment is just a concrete scene. The “environment” here can also be understood as the environment, the good use of policies and regulations conducive to energy saving, and the avoidance of risks that may be caused. For the energy saving of the air compressor system, it also needs enough attention.
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