EPSEA joint dealers undertook the post-treatment energy-saving renovation project of the air compressor station building located in Guangdong China, a well-known Japanese electronics enterprise. It has been successfully put into use. The program of replacing the Heatless Air Dryer with Zero Loss Blower Desiccant Air Dryer. Data will tell you with the energy efficiency potential.
1.Before and after the renovation of the air pressure station of a well-known Japanese-funded electronics company-Air Pressure Station Room Situation
Before the post-processing transformation：
Air dryer and two 16.8 m³ heatless desiccant dryer
Post-treatment after modification:
Group 1: ① machine + ③ machine
Power consumption record comparison refer to Appendix 1 (before renovation), Appendix 2 (after renovation)
Group 2: ② machine + ③ machine
Power consumption record comparison refer to Appendix 3 (before transformation), Appendix 4 (after transformation)
2.Data summary
3.Cost savings
In the annual 8000 hours, industrial electricity $0.12/KWH calculation:
The electricity cost saved by the Group 1 in a year: The average power saved is 38.22 kW
38.22 × 8000 = $36,691/year
Group 2 saves electricity for a year: The average power saved is 35.5kW
35.5 × 8000 = $34,080 /year
Average savings: (36,691 + 34,080) ÷ 2 = $35,386/year
4.Calculation of regeneration Micro-loss desiccant air dryer
Compressor specific power correction
The average gas pressure of the user is maintained at 0.7MPa. According to the nameplate information of the air compressor ①、③, it is 7.3kW /(m³/min)@8barg. The input power of the Group 1 of units is corrected:
7.3kW /(m³/min)×0.93=6.789 kW/(m³/min)
Similarly, the input power of the second unit is revised to 6.603 kW/(m³/min).
Group 1
Calculate the average compressed air flow before the transformation as:
147.21 kW · ÷6.789 kW/(m³/min)=21.68 m³/min
Average compressed air flow after modification:
105.29kW ÷ 6.789kW /(m³/min)= 15.51m ³/min
The user promises that the gas consumption of the terminal gas equipment will not change, and the heatless desiccant dryer will be calculated – actual operation
(21.68 m³/min-15.51 m³/min) ÷21.68 m³/min=28.5%
Percentage of regenerative heatless desiccant dryer – setting of rated working conditions
(21.68 m³/min-15.51 m³/min) ÷ (16.8×2) m³/min=18.38%
Group 2
Calculate the average compressed air flow before the transformation as:
136.02kW ÷ 6.603kW /(m³/min)= 20.60m ³/min
Average compressed air flow per hour after modification:
96.57kW ÷ 6.603kW /(m³/min)= 14.63m ³/min
The user promises that the gas consumption of the terminal gas equipment will not change, and Percentage of regeneration gas consumption for heatless desiccant dryer calculate – actual operation
(20.60 m³/min-14.63 m³/min) ÷20.60 m³/min=29%
Regenerative air consumption percentage of heatless desiccant dryer – rated working condition setting (20.60m ³/ min-14.63m ³/min) ÷ (16.8×2) m³/min=17.78%
5.EPSEA energy saving calculation software check calculation
Group 1
According to the calculation software developed by our company
Heatless desiccant dryer energy consumption:
Total energy consumption of air dryer and heatless desiccant dryer – Energy consumption of air dryer =33.82-6.53 = 27.29kW
Revised calculation:
Factors to consider:
The specific power in the software is 6.5kW /(m3/min)@7barg, the actual is 6.789;
In the software, the regeneration air consumption of the heatless desiccant air dryer is 13%, and the actual is 18.38%;
There are differences in the processing capacity between the model number of EPSEA blower heat air dryer and the user model, which need to be considered.
Energy saving after calculation software modification:
Heatless desiccant dryer power saving – blower air dryer actual power increase =42.31-4.2 = 38.11 kW
The calculation software is modified to transform the energy saving vs the actual data
(38.11-38.22)÷38.22 = -0.288 %
The error is within 1%, which is within acceptable limits.
Conclusion: The selection software is in agreement with the actual measurement.
Group 2
According to the calculation software developed by our company
heatless desiccant air dryer standard comprehensive energy consumption:
Total energy consumption of heatless desiccant air dryer – Energy consumption of air dryer = 33.82-6.53 = 27.29kW
Revised calculation:
Factors to consider:
The specific power in the software is 6.5kW /(m3/min)@7barg, the actual is 6.603;
In the software, the regeneration air consumption of the heatless desiccant air dryer is 13%, and the actual is 17.78%;
There are differences in the processing capacity between the model number of EPSEA blower heat air dryer and the user model, which need to be considered.
Energy saving after calculation software modification:
Heatless desiccant air dryer power saving – blower heat desiccant air dryer power increase =39.81 kW-4.2 kW = 35.61 kW
The calculation software is modified to save energy vs the measured data
(35.61-35.75)÷35.75 = -0.3%
The error is within 1%, which is within the acceptable range.
Conclusion: The selection software is in agreement with the actual measurement.
Appendix 1: Power consumption record table of ①、③ compressors before transformation
Appendix 2 Power consumption record table of compressor ①、③ after modification
Appendix 3 Power consumption record table of compressor ②、③ before renovation
Appendix 4. Power consumption record table of ②、③ compressors after modification
Appendix 5
According to the calculation of gas consumption, we can see that the blower heat suction dryer is not running at full capacity, the following chart shows the power consumption record from May 26th to July 2nd
The actual number of days used by the user is 32 days
Correction for the power of the blower: 3225 ÷ 32 ÷ 24 = 4.2 kW
