Front dehumidification device of air compressor for steel structure production

Abstract

The invention discloses an air compressor front dehumidification device for steel structure production, belongs to the technical field of air compressor auxiliary equipment, and aims to solve the technical problems that compressed air of an existing air compressor carries water, rear dehumidification equipment is high in energy consumption and poor in dehumidification effect, and blind areas exist in equipment protection. The device comprises an air conditioner dehumidification mechanism and an air compressor, the air outlet end of the air conditioner dehumidification mechanism communicates with an air inlet of the air compressor in a sealed mode, and the air conditioner dehumidification mechanism is arranged at the air inlet front end of the air compressor and used for cooling and dehumidifying normal-pressure air entering the air compressor in advance. The absolute moisture content of inlet air is reduced from the source, condensate water is thoroughly prevented from being separated out from compressed air in a follow-up pipeline, dehumidification energy consumption is greatly reduced, meanwhile, an air compressor main machine and air utilization equipment are comprehensively protected, the structure is simple, adaptability is high, and the energy-saving effect and dehumidification stability are remarkably superior to those of an existing rear dehumidification scheme.

Description

Technical Field

[0001] This invention belongs to the technical field of air compressor auxiliary equipment, specifically relating to a pre-dehumidification device for air compressors used in steel structure production. Background Technology

[0002] Air compressors are core power source equipment in the industrial field, widely used in machinery manufacturing, mining, chemical, power and other industries. Their function is to compress atmospheric air into high-pressure compressed air to provide power for pneumatic equipment, pneumatic valves, spraying equipment and other air-using units.

[0003] During operation, existing air compressors directly draw in ambient air at normal pressure, which generally contains a large amount of water vapor. After the air is compressed by the air compressor, the temperature rises significantly. At this time, the water vapor can be temporarily stored in the high-temperature compressed air and is not easily released. However, when the high-temperature compressed air enters the subsequent air transmission pipeline and air storage tank, the temperature drops rapidly, and the air's saturated water-holding capacity decreases sharply. The originally dissolved water vapor will be released in large quantities to form condensate.

[0004] The presence of condensate can cause a series of serious problems: First, condensate can corrode the air compressor main unit, air pipeline, air tank and air-using equipment, significantly shortening the service life of the equipment; Second, condensate can enter the pneumatic components with the compressed air, causing component jamming and seal failure, leading to equipment failure and shutdown; Third, compressed air containing water can affect the processing quality of processes such as spraying and pneumatic control, resulting in defective products.

[0005] To address these issues, the current industry standard is to install dehumidification equipment at the exhaust port of the air compressor. Common examples include refrigerated dryers and adsorption dryers, which dehumidify the compressed, high-temperature, and high-pressure air. However, this type of post-dehumidification solution has inherent drawbacks: First, dehumidifying high-pressure, high-temperature air requires significantly higher refrigeration power and equipment load, resulting in extremely high energy consumption. Typically, the energy consumption of the post-dryer accounts for 15%-20% of the total energy consumption of the air compressor, leading to high operating costs. Second, post-dehumidification cannot prevent water vapor from corroding the air compressor's internal components during compression, creating blind spots in equipment protection. Third, the dehumidification effect of post-dehumidification equipment is greatly affected by fluctuations in the air compressor's exhaust pressure and temperature, exhibiting poor dehumidification stability under changing operating conditions and failing to completely prevent condensate precipitation. Finally, post-dryers are bulky, requiring complex drainage and sewage systems, resulting in high installation and maintenance costs.

[0006] To date, there is no pre-dehumidification solution in the industry that can solve the problem of water carryover in air compressor intake from the source and significantly reduce dehumidification energy consumption. Therefore, there is an urgent need to develop a pre-dehumidification device for air compressors that is highly adaptable, simple in structure, has stable dehumidification effect, and significant energy-saving effect.

[0007] Especially in steel structure production workshops, air compressors provide power for core processes such as pneumatic cutting, welding, rust removal, and electrostatic spraying. Water carried in the compressed air can directly cause the paint on the steel structure to blister and peel off, and the anti-corrosion layer to fail. At the same time, it can cause rust and damage to pneumatic tools and jamming of pneumatic valves in environmental protection equipment, which seriously affects the production quality and efficiency of steel structure products. Summary of the Invention

[0008] The purpose of this invention is to overcome the above-mentioned defects of the post-dehumidification scheme in the prior art and provide a pre-dehumidification device for air compressors. This device pre-treats the air from the air intake source of the air compressor and completes the air dehumidification under normal pressure, completely solving the problem of water carried in compressed air. At the same time, it significantly reduces dehumidification energy consumption, has a simple structure, and is highly adaptable.

[0009] To achieve the above objectives, the present invention adopts the following technical solution: An air compressor pre-dehumidification device includes an air conditioning dehumidification mechanism for cooling and dehumidifying ambient air at normal pressure, and an air compressor for compressing dry air. The outlet of the air conditioning dehumidification mechanism is sealed and connected to the inlet of the air compressor through a sealed pipeline, so that the ambient air first undergoes dehumidification pretreatment and its absolute moisture content is reduced by the air conditioning dehumidification mechanism before entering the compression chamber of the air compressor for compression.

[0010] Furthermore, the rated processing air volume of the air conditioning dehumidification mechanism is matched with the rated intake air volume of the air compressor to ensure stable intake flow and not affect the normal intake efficiency of the air compressor.

[0011] Furthermore, the air conditioning dehumidification mechanism adopts an air-cooled refrigeration dehumidifier unit, which can control the atmospheric dew point of the incoming air within the range of 2℃-10℃, ensuring that the absolute moisture content of the dehumidified air is far lower than the saturated moisture content under the cooling state after compression, thus completely avoiding the precipitation of condensate.

[0012] The core working principle of this invention is as follows: the saturated water-holding capacity of air under normal pressure is much higher than that under high pressure. After the air is compressed by the air compressor, the pressure increases significantly, and its saturated water-holding capacity decreases sharply. If dehumidification is not performed in advance, a large amount of condensate will easily be released during the cooling process after compression. This is the core reason why existing post-dehumidification solutions have high energy consumption and incomplete water removal. This invention cools and dehumidifies the air under normal pressure, which can condense most of the water vapor in the air with extremely low energy consumption, reducing the absolute moisture content of the air to a level far below the saturated moisture content under high pressure after compression. The pre-treated dry air enters the air compressor for compression. Even if the air temperature rises and then cools down after compression, its moisture content will always be lower than the saturated moisture content under the corresponding operating conditions, and no condensate will be released, fundamentally solving the problem of water carried by compressed air.

[0013] Compared with the prior art, the present invention has the following advantages: 1. Significant energy saving effect: This invention completes dehumidification under normal pressure. Compared with the existing post-dehumidification scheme of high pressure and high temperature air, the cooling power requirement is reduced by more than 60%, and the dehumidification energy consumption accounts for only 5%-8% of the total energy consumption of the air compressor, which greatly reduces the operating cost. 2. Thorough and stable dehumidification effect: This invention reduces the absolute moisture content of the air from the air intake source. The dehumidification effect is not affected by the exhaust pressure and temperature fluctuations of the air compressor, which can completely prevent the precipitation of condensate in the subsequent air transmission pipeline and air-using equipment, and fully protect the equipment. 3. Simple structure and strong adaptability: This invention only requires sealing the air conditioning dehumidification mechanism with the air compressor inlet, without modifying the existing air compressor main structure. It can be directly adapted to most models of air compressors on the market, with low modification cost and convenient installation and maintenance. 4. Comprehensive protection: This invention can prevent water vapor from corroding the rotor and cavity inside the air compressor during the compression process, greatly extending the service life of the air compressor and filling the equipment protection blind spot of the existing post-dehumidification scheme. Attached Figure Description

[0014] Figure 1 is a schematic diagram of the structure of a pre-dehumidification device for an air compressor used in steel structure production according to the present invention.

[0015] Explanation of markings in the diagram: 1 - Air conditioning dehumidification mechanism, 2 - Air compressor. Detailed Implementation

[0016] This embodiment is designed for use with screw air compressors in steel structure production workshops to solve the problems of product quality and equipment damage caused by water carried in compressed air during steel structure production.

[0017] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0018] As shown in Figure 1, the present invention discloses a pre-dehumidification device for an air compressor, the core of which includes an air conditioning dehumidification mechanism 1 and an air compressor 2. The air outlet of the air conditioning dehumidification mechanism 1 is connected to the air inlet of the air compressor 2 through a sealed pipeline and a flange seal. The air conditioning dehumidification mechanism 1 is set at the front end of the air inlet of the air compressor 2, forming a unidirectional airflow path of "dehumidification first, then compression".

[0019] In this embodiment, the air conditioning dehumidification mechanism 1 adopts an air-cooled refrigeration dehumidifier unit, whose rated processing air volume is perfectly matched with the rated intake air volume of the air compressor 2. It can stably control the dew point of the outside normal pressure air at 5℃, ensuring that the absolute moisture content of the dehumidified air is ≤6.8g / m³. The sealed pipeline adopts pressure-resistant and corrosion-resistant galvanized steel pipe, and oil-resistant rubber sealing rings are installed at the pipeline connections to prevent the leakage of outside humid air and ensure the stability of the dehumidification effect.

[0020] The specific working process of this embodiment is as follows: The ambient humid air at normal pressure first enters the air conditioning dehumidification unit 1. The air conditioning dehumidification unit 1 cools the air to below the dew point temperature through a vapor compression refrigeration cycle. The water vapor in the air condenses into liquid water when it encounters the condenser and is discharged through the automatic drain valve of the unit, thus completing the dehumidification pretreatment of the air and obtaining dry air with low moisture content. The dehumidified dry air enters the air inlet of air compressor 2 directly through a sealed pipeline. It is compressed into high-pressure dry compressed air in the compression chamber of the air compressor and then discharged to the subsequent air transmission pipeline, air storage tank and air-using equipment. Since the absolute moisture content of the dry air has been significantly reduced under normal pressure, even if the compressed high-pressure air is cooled in the subsequent pipeline, its moisture content will always be lower than the saturation moisture content under the corresponding pressure and temperature conditions, and no condensate will be released, thus completely solving the core problem of water carryover in compressed air.

[0021] Field tests have verified that this embodiment, targeting a screw air compressor with a rated power of 75kW and a rated displacement of 13m³ / min, can reduce the relative humidity of the intake air to below 28% under normal operating conditions of 85% relative humidity and 30℃, with no condensation in the subsequent air delivery pipeline and air storage tank. At the same time, the operating power of the dehumidification mechanism is only 4.2kW, compared to the 12kW operating power of a post-cooled refrigerated dryer of the same specifications, resulting in 65% energy savings. Both the energy-saving effect and the dehumidification effect are significantly better than existing technologies.

[0022] This invention has a simple structure and is easy to implement. It does not require complex modifications to existing air compressors and can be widely applied to air intake pretreatment scenarios for various air compressors. It has strong practicality and promotional value.

Claims

1. A pre-dehumidification device for an air compressor used in steel structure production, characterized in that, It includes an air conditioning dehumidification mechanism for cooling and dehumidifying ambient air at normal pressure, and an air compressor for supplying air to pneumatic equipment and electrostatic spraying in steel structure production workshops. The air outlet of the air conditioning dehumidification mechanism is sealed and connected to the air inlet of the air compressor through a sealed pipeline, so that the ambient air is first dehumidified and its absolute moisture content is reduced by the air conditioning dehumidification mechanism before entering the compression chamber of the air compressor for compression.

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