Compressed air is widely used in the industrial field because of its safety, environmental protection, good regulation performance, convenient transmission, convenient centralized management and application, and good applicability of working environment. With the development of textile industry technology and the upgrading of equipment, compressed air has been widely used in the production process, and has become the second largest power source for textile enterprises after power generation. Although compressed air as an energy source has the above characteristics, its energy consumption output ratio is about 1:7, which is a large energy consumer. Therefore, how to save energy and reduce consumption of compressed air systems is a common concern. Compressed air systems include air compressors, aftertreatment equipment, air supply networks, and ventilation cooling facilities. In the design and planning of the compressed air system, it can be comprehensively considered according to the actual requirements and characteristics of the actual use, and the air compressor can be properly selected to optimize the pipe network to reduce the transmission resistance and lay a solid foundation for energy saving.

1 Ventilation of the air compressor room of the air compressor room seems simple, but it is often overlooked. The goodness of ventilation not only affects the efficiency of the air compressor, but also affects the normal operation of the air compressor and even causes damage to the air compressor. During the operation of the air compressor, a large amount of heat is generated during the operation and compression of the motor. If the heat is not removed in time, the temperature of the equipment room will rise. When the temperature of the equipment room rises, the staff first feels uncomfortable and the unfavorable efficiency decreases. The compression efficiency decreases by 3% for every 11° increase in ambient temperature. It can be seen from the above three points that it is very important to improve the ambient temperature of the machine room.

The air compressor room of the textile enterprise mostly adopts the form of attached room, and there is a shortage of air circulation. This problem also exists in our company's air compressor room. In order to improve the ambient temperature, the heat of the motor is discharged from the outside using a pipe, but the temperature in the machine room is still high when the temperature is high in summer. In order to solve the problem completely, we added the sunroof and the exhaust fan. When the total power of the exhaust fan decreased, the air exchange volume and the number of air changes were increased, and the flow of the air change was more reasonable, and the temperature of the machine room was completely improved.

2 Operation and Management of Air Compressor 1 The intake air compressor of the air compressor uses air as a raw material to ensure the supply of raw materials is necessary. There are two types of air compressor air intake: one is indoor air intake, and the other is outdoor concentrated air intake. The outdoor concentrated 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 indoor air flow and flow speed, which is conducive to maintaining indoor environmental sanitation; Fourth, the initial investment is large, and the pipeline has resistance loss. In comparison, outdoor concentrated air intake is superior to indoor air intake.

Pre-filtering measures not only extend the life of the filter, but also reduce power consumption. There are many forms and methods for pre-filtration, and it is necessary to ensure that the resistance is the lowest. We use a non-woven pre-filtration method, which is simple and convenient. It can be replaced once per shift to keep the resistance to a minimum. It has been used well for many years.

The alarm value of the air filter is generally around 4X103MPa, and it is generally considered that it can be replaced when the alarm is issued. This does not cause any harm to the air compressor, and also meets the operational requirements of the air compressor, but it is disadvantageous from the point of view of energy saving. As the filter resistance increases, the suction of the air compressor also increases and the flow rate decreases accordingly. When the air compressor is running at the alarm value, the flow 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 in a lower range is also a good measure for energy saving.

2 Whether the temperature is single-stage compression or multi-stage compression, the interstage temperature and exhaust temperature seriously affect the operation and efficiency of the air compressor. An important function of the air compressor cooler is to increase the compression efficiency. In terms of temperature, increasing the cooling efficiency is to increase the gas temperature by 10 ° C, and the power consumption is also reduced by 3%. The control temperature is mainly in the summer, for many years. Our company has been conducting a comprehensive inspection, maintenance, cleaning or replacement of the cooling system with poor cooling performance before the high temperature season, replenishing the lubricating fluid, controlling the temperature within the appropriate range, not only stabilizing the operation of the air compressor, And there is no increase in fuel consumption due to temperature. The oil separator can only separate the liquid oil and can not separate the gaseous oil. When the temperature is too high, the oil and gas will easily enter the post-processing equipment with the compressed air. In addition to increasing the fuel consumption, it will also pollute these equipments, or reduce the drying effect, or increase Resistance increases power consumption. Therefore, controlling the temperature not only stabilizes the operation of the air compressor, but also reduces fuel consumption to make the system operate normally, further reducing power consumption.

3 Pressure drop Any transmission has a pressure drop, and reasonable control of pressure drop is conducive to energy saving. When the pressure drop is increased, in order to obtain the required pressure, the air compressor has to do more work. When the pressure drop increases by 0.01 MPa, the power consumption increases by 0 3% to 05%. For any air compressor, the annual increase in power consumption is large. Oil separators, precision filters, and dryers are the main parts of the pressure drop increase. Therefore, timely replacement of oil separators, precision filters, and regular cleaning of the dryer air passages are effective measures to reduce pressure drop. Extending the use time of oil separators and precision filters does not save operating costs. Take the Sullair 300HP air compressor as an example. When the pressure difference of the oil separator reaches 0, it will alarm. If you continue to extend the use of half a year of oil, the consumption of 20kg is about 4000=31500 (.h). If you charge 06 yuan per kilowatt hour, the electricity fee will be increased by 18,900 yuan. And the consumption of oil into the aftertreatment system and pipe network system will bring accidents.

4 When the pressure meets the requirements of the gas point process and the use requirements, the supply pressure is reduced as much as possible, and excessive supply is also wasted. When the gas supply pressure is reduced by 0 01 MPa, the power consumption is reduced by 0 3% to 05%, and the pressure is directed at the entire system, and the energy saving potential is large. Taking 5 sets of 300HP air compressors as an example, when the pressure drops by 0.01MPa, the corresponding power consumption will also drop. 5 Due to the existence of the winder in the pipe network of the original weaving fabric of our company, the whole gas supply pressure is controlled at Q62MPa in order to reduce The supply pressure separates the winding from the weave and incorporates another pipe network. Adjusting the weaving process and gradually reducing the supply pressure. Comparing the operating current of the air compressor with the number of looms and the small change in efficiency, it is confirmed that the power consumption is significantly reduced. The efficiency of the air machine is relatively lower. The old "ishingH" gas supply pressure should be relatively stable. Unloading does not affect the production. The larger the pressure change range, the greater the energy saving potential of the system. Therefore, according to the change of gas consumption, timely adjust the load of the air compressor or adjust the opening of the air compressor in time, and use other pressure automatic control system to stabilize the pressure, which is more important for energy saving.

25 Unconscious waste In the air compressor management we have to develop the following good habits: the air compressor should be turned off and the isolation valve should be closed after stopping. If the power is not turned off, the computer board and the transformer continue to supply power and waste; if the isolation valve is not closed, some control gas will continue to be consumed, which will cause waste.

According to the season, 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 an air compressor, consider as much as possible to avoid long-term commissioning or opening and closing of the air compressor.

Regularly check the valves for manual drainage and exhaust to prevent leakage due to poor valve closing.

3 pipe network management The textile industry is a machine-intensive industry with many equipments, long pipelines, many joints, various types of joint materials and joint forms, which determines the number of leaks. Therefore, the management of the pipe network is not only the work of the gas supply unit, but the work that all the gas points pay attention to in order to prevent leakage, energy saving and consumption reduction. A set of data on leakage and power consumption is shown in the table: 1 Table 1 Leakage and power consumption data items Leakage diameter / mm Power pipe network leakage caused by the huge waste, many small leak points are not easy to detect. A 1mm hole causes a power waste of about 24,001 W.h a year. Therefore, regular leak detection and timely plugging are very important.

4 The consumption of compressed air in the production workshop is mainly used to drive valves, cylinders, pressurization, knotting, etc. on the spinning, and the gas consumption is less and stable. It is mainly used for weft insertion on the loom, and the gas consumption is large, and the gas load has a large change with the efficiency of the loom.

The gas consumption and energy saving of the loom are discussed as follows: (1) According to different processes, the appropriate auxiliary spray pressure is set to meet the production needs and ensure the quality of the grey fabric. The auxiliary spray pressure should not be set too high to avoid waste. We have done the test of the auxiliary spray pressure and the air consumption of the loom. Taking the A-e190 air jet loom as an example, the relationship between the speed of the 780 gas supply pressure of 0 56MPa and the air consumption of the loom is shown in Table 2. The relationship between pressure and air consumption of the loom Auxiliary spray pressure / MPa loom gas consumption / m As can be seen from Table 2, the auxiliary spray pressure setting is too large, not only to increase the supply pressure, increase the operating cost, but also increase the gas consumption of the single machine. .

(2) Checking the pipe joints and auxiliary injection solenoid valves in time, timely maintenance and replacement, to prevent leakage. A common injection solenoid valve is normally open, which is equivalent to adding two more solenoid valves. When the leakage of the solenoid valve accumulates to a certain amount At the same time, the gas load is increasing, and the plugging work becomes very important.

(3) When the gas load has a large change, the gas department should contact the gas supply department in time to adjust the number of air compressors or the air compressor load in time to avoid waste caused by excessive supply.

5 Conclusion The energy saving of the compressed air system has a long way to go. Only pay attention to every detail in the work, and start from the bit by bit to make the energy consumption of the compressed air system lower.

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October 23, 2024