It is best to implement integrated control using industrial computers and PLCs.

By utilizing PLC technology to retrofit air compressor groups, enterprises can achieve "configuration control" across all air compressor stations, enabling a holistic management of the enterprise's air compression system. This approach allows for more precise, economical, and refined utilization of air compressor equipment, achieving balance and optimization of air consumption throughout the enterprise, and fundamentally eliminating electrical energy waste. In larger enterprises with multiple air compressor stations, factors such as varying loads and operating conditions, as well as differences in the skills and operational habits of operators, can inevitably lead to significant electrical energy waste. These issues can only be ultimately resolved through PLC-based integrated control and group control of air compressors. By implementing intelligent control, the system minimizes its simple reliance on human operators, ensuring more scientific and rational operation. It also allows for the setting of parameters such as operating time, number of units, and operating conditions of air compressors according to demand, significantly optimizing working conditions for employees and making the principle of people-orientation more tangible within the enterprise.

Reduce Pressure Loss

The air circuit system, comprising intake filters, intake valves, coolers, etc., transports compressed air to the using equipment. Problems such as neglected maintenance or improper repair of intake valves can cause air leaks, reducing exhaust volume and thereby decreasing the operating efficiency of air compressors. To reduce pressure loss, it is essential to minimize flow resistance and pressure loss in the air circuit system while meeting process requirements, such as by minimizing the number of valves installed and keeping intake piping as short as possible. Additionally, using air circuit systems with larger pipe diameters and low-speed air delivery methods, reducing internal and external leaks in equipment, employing high-quality pneumatic components (e.g., intake valves with excellent sealing performance and low resistance, and selecting new-type ND-disc air filters), and ensuring proper installation and daily management through regular inspection and maintenance are crucial for ensuring the safe and reliable operation of the air circuit system.

Improve Heat Exchange Efficiency and Enhance Waste Heat Recovery

The compression of gas by screw-type silent air compressors can occur through isothermal, adiabatic, or polytropic compression processes. Theoretically, isothermal compression consumes the least energy, but in practice, polytropic compression is more common. To reduce energy consumption during the compression process, it is necessary to improve cooling efficiency. The cooling water system includes intercoolers and aftercoolers. Enhancing the performance of intercoolers can bring the secondary intake temperature closer to that under isothermal compression, ensuring complete recooling. Lowering the cooling water temperature, increasing flow rate, removing deposits in pipelines and equipment, and using water treatment agents to improve water quality can all enhance cooler performance.

Reasonably configuring water pumps, controlling water consumption, and reducing losses in the water circuit can effectively reduce power consumption. In open cooling water systems, energy is wasted as heat, so strengthening waste heat recovery and adopting comprehensive waste heat utilization measures can achieve energy-saving goals. For example, introducing water into hot water supplies such as bathhouses enables energy reuse. In closed cooling water systems, measures such as increasing the area of the circulating water pool can accelerate hot water cooling, but water consumption should be controlled to prevent increased energy consumption by circulating water pumps.