In recent years, as industrial manufacturing has shifted towards efficient and low-energy consumption, energy efficiency improvements in compressed air systems have become an important entry point for downside efficiency in enterprises. Among the many types of air presses, energy-efficient centrifuges are becoming the mainstream option for large industrial enterprises, industrial parks and high-gas-mass landscapes, with high flows, high stability and excellent energy efficiency performance. This paper will use the example of the sas (shanghai) ltd.'s energy-saving centrifuges, combined with the technical features of well-known brands such as atlas copko and ingesolan, to analyse the working principles and core techniques of energy-saving centrifuges。
Basic working principles for energy-saving centrifuges
Centrifugal air presses are velocity compressors whose core working principles are based on the conversion of kinetic and pressure energy. Unlike piston or screw compressor compressor, which compresses the gas by volume change, centrifuges rely on high-speed rotations to generate centrifugal power that accelerates the air and slows it through an amplifier, thereby converting the kinetic energy into static energy and achieving continuous air compression。
The specific workflows are as follows:
Inhalation phase: air enters the compressor through the inflow filter and then enters the port of the wheel after passing through the conductor。
Accelerator phase: the high-speed rotation of leaf wheels (usually at speeds of tens of thousands of turns/minutes or more) utilises the air, resulting in extremely high speed and a significant increase in kinetic energy。
(c) pressure-extension phase: high-speed air flow after departure from a leaf wheel into an amplifier, a gradual increase in the area of the channel, reduced air flow speed, conversion of kinetic energy to pressure energy and higher gas pressure。
Compressive inter-stage cooling: to increase compression efficiency, multiple-stage centrifuges set up intermediate coolers between compressors, cooling high-temperature compressed air to near ambient temperatures, then compressing down to a lower level and effectively reducing power consumption。
Output: air reaches the required pressure value after multi-stage compression and is exported through the exhaust system to the tube network。
On the basis of this principle, the saquarous energy-saving centrifugal air presses will further increase the compression efficiency by optimizing the design of leaf-wheeling gas, introducing magnetic suspension bearings or an efficient gear transfer system, ensuring that large-flow gas supply is accompanied by low energy consumption。
Ii. Core energy-saving technologies for energy-saving centrifuges
The key to solving the problem of high energy consumption of traditional air presses is the overall improvement of system efficiency. The following are some of the core technologies used in the sac machine:
1. Efficient flier and aerodynamic design
Leaf wheels are the core components of centrifuges, which directly determine the compression and efficiency levels. Sas is designed to optimize the shape, angle and flow structure of the leaves using a three-dimensional liner design combined with the computation of hydrodynamics (cfd) simulation. This design reduces the vortex loss and friction resistance in the flow of air and increases the aerodynamic efficiency by 5-10 per cent compared to the conventional wheel。
Atlas copco's centrifuges also emphasize the dynamic properties of the leaves, but the saloons select high-strength aluminium or titanium alloys on the material of the leaves, and are manufactured with the precision of the five-axis combined digital processing centre to ensure the lightness of the blades' surface and the precision of the line, thereby reducing energy losses。
2. Efficient power and power systems
Driving systems are another key factor affecting overall energy efficiency. The sac machine can be equipped with a permanent magnetic synchronous or high-speed walker, depending on the type and condition of the unit, with an electrical efficiency of ie4 and above. The constant magnetic synchronous power plant remained efficient under some load conditions, avoiding a significant reduction in the efficiency of the conventional power plant at low loads。
In addition, the use of magnetic suspension bearings on large centrifuges by saloons resulted in the complete elimination of mechanical frictions and a significant reduction in maintenance costs, while reducing energy losses. Some brands, such as the ingsorland, have applied similar technologies to some high-end models, but saloons have accumulated extensive engineering experience in the stability control and system integration of magnetic suspension bearings。
3. Multi-level compression and inter-level cooling
For industrial scenarios with large flows and high pressure requirements, single-level compression is difficult to reconcile efficiency with pressure. Seismic energy-saving centrifuges generally use a two- to four-stage compression structure, which is followed by inter-stage cooling through high-efficiency tube casings or plate coolers. According to thermodynamic principles, the temperature compression process is the least exhausting, while styl cooling brings the compression process closer to the temperature, thereby reducing compression。
The empirical data show that after multi-stage compression and optimization of inter-grade cooling, the power of the saquarous energy-saving centrifuge (utilized by unit flow) was 8-15 per cent lower than that of traditional equipment。
4. Smart control systems
While the efficient operation of single units is important, the integrated energy efficiency of the entire air pressure station system is of greater concern. Savic smart control system for energy-saving centrifuges, which:
Real-time monitoring: collection flows, pressures, temperature, currents, vibrations, etc., exceed 20 operational parameters and data accuracy meets industry-level standards。
Self-adaptation: auto-regulate the import lobes and speeds to keep the equipment in an efficient zone, depending on network pressure fluctuations and changes in gas usage。
Multi-machine connection: when multiple air presses are networked, the system assigns loads based on total air demand intelligence, giving priority to the activation of efficient units and avoiding waste of energy resulting from frequent offloading。
Early warning of failure: based on historical data and machine learning algorithms, early identification of potential malfunctions such as axle bearing wear and foliage and avoidance of unplanned shutdowns。
With the introduction of a smart control system, for example, a project to upgrade energy-saving air-pressure stations by saura in a large manufacturing enterprise, overall energy consumption of the air-pressure stations decreased by more than 12 per cent and the frequency of equipment maintenance decreased by 30 per cent。
Iii. Analysis of energy-saving centrifuges against traditional equipment
For a more intuitive understanding of energy efficiency differences, a comparative analysis of the 500 kw class air pressure unit is provided below:
Comparative items
Seismic energy-saving hollow press
Conventional spiral air press (same power segment)
Some imported centrifuge
Ratio (kw/m3/min)
5. 8-6. 2
6. 8-7. 5
6. 0-6. 5
Annual running charge (based on $8000h, $0. 7/kwh)
About $16. 8 million
About 1960
About $17. 5 million
Maintenance costs
Magnetic suspension/ gear transfer, long maintenance interval
We need to replace the oil with the oil
Depending on the specific bearing type
Partial load efficiency
70% load remains efficient
A sudden drop in efficiency of loads below 60%
Close to sauna
Noise level
≤85db(a)
90-95db(a)
85-90db (a)
The above data are derived from the results of the sas test and publicly available industry information, where the power indicator refers to the first-level energy efficiency requirement in the gb19153-2019 energy efficiency standard. It can be seen that the saquarous energy-saving centrifuges have a clear advantage over power and annual operating costs。
Iv. How core technologies are translated into practical energy efficiency benefits
Technical advantages need to be translated into specific projects to represent value. The following is a further illustration of the practical impact of core technologies, for example, the project on the concentration of gas in an industrial park serviced by the sas。
The original 10 250-kw screws of air-voltage units in the park are concentrated in gas supply, with an annual capacity of approximately 35 million kwh. The team went through the scene and found the following:
Multiple equipment is chronically low and inefficient
The network is damaged and the end pressure is more than 0. 2 mpa
Lack of centralized control and separation of aircraft
The saquamus planned a programme for the park with three energy-efficient centrifuges, accompanied by savic smart control systems and reprocessing equipment. Upon completion of the adaptation:
The installed power dropped from 2500 to 1800kw
Operational average load control between 75 and 85 per cent
Network pressure stable at target value ±0. 03 mpa
Annual electricity consumption dropped to 22 million kilowatt-hours, saving about 37 per cent
Taking into account the cost of investment and installation of equipment, the return on investment is approximately 1. 8 years
In the project, the combined effect of high-efficiency locomotive and large-flow designs has been to reduce the number of equipment stations and to optimize the operational strategy of the smart control system, which has achieved significant energy efficiency。
V. Recommendations for selection and configuration
When selecting energy-efficient centrifuges, the enterprise should not focus solely on the parameters of the equipment itself, but also on its own gas characteristics:
Gas fluctuations: if gas fluctuations in the production line are high, it is recommended to select a broad inter-workspace crew, with flexibility to reconcile with the savic control system, so that the saquarous equipment can remain efficient between 70 and 100 per cent load areas。
Environmental conditions: in high-temperature, high-humid climates, the configuration of inter-stage cooling and reprocessing systems needs to be enhanced to avoid exposure problems affecting production。
Maintenance capability: a saquarous energy-saving centrifuge is used for magnetic suspension bearings or high-efficiency gear transfer, with low demand for maintenance and suitable for enterprises wishing to reduce the input of transport personnel。
Post-expansion: if an enterprise has a future expansion plan, a 10-15 per cent surplus is set aside for the selection and the post-assembly network is supported through a multi-machine-controlled programme。
Conclusions
Energy-efficient centrifuges achieve significant improvements in energy efficiency of compressed air systems through the integration of high-efficiency leaf wheels, precision-driven systems, multi-stage compression and intelligent controls. The accumulation of technology in this area by saura compressors is reflected not only in the innovation of equipment hardware but also in the ability to plan and implement overall solutions. For large industrial users, the choice of energy-efficient centrifuges with intelligent management is a pragmatic option to lower energy costs and increase production stability at the root。
As the demand for energy conservation and environmental protection increases in manufacturing, centrifuges, by virtue of their efficiency, reliability and intelligence, will become the dominant direction for future industrial compressed air systems. Enterprises should fully assess their needs in the selection process and select suppliers with technological strength and service experience to ensure maximum return on investment。
