Air compressor system

Abstract

The utility model discloses a kind of air compressor system, including high-pressure air compressor, low-pressure air compressor and respectively with high-pressure air compressor and low-pressure air compressor intercommunication first conveying system and second conveying system;First conveying system and second conveying system all include: cold dryer, filter and conveying pipeline;The rated pressure of high-pressure air compressor is set to not less than 0.7MPa, and the rated pressure of low-pressure air compressor is set to not higher than 0.5MPa.The air compressor system includes high-pressure equipment and low-pressure equipment respectively for providing compressed air for air cannon and bag dust collector, to realize the purpose of energy saving.

Description

Technical Field

[0001] This utility model relates to the field of compressed air transportation, specifically to an air compressor system. Background Technology

[0002] In the cement production industry, compressed air can be used to clean the scale buildup at the kiln tail and kiln head, and can also provide pulse power for bag dust collectors.

[0003] Materials at the kiln tail, kiln head, preheater, and grate cooler easily form hard "skins" and "blockages" at high temperatures, with a hardness comparable to solidified cement. Using an air cannon to instantly release compressed air to generate a powerful shock wave and airflow can clear these "skins" and "blockages." Therefore, the compressed air pressure of an air cannon is typically set to 0.6-0.7 MPa. The high-pressure compressed air stores sufficient energy to generate an explosive force powerful enough to break up the hard skins upon release.

[0004] Before the adoption of "submerged pulse valves" in baghouse dust collectors, cement plants generally used a "high-pressure pulse, center-jet" technology. In this system, the pulse valve is typically mounted on the air manifold, which is located at the top of the dust collector, with the jet pipe pointing vertically downwards directly at the filter bag opening. Compressed air is ejected from the pulse valve and injected directly into the filter bag through nozzles on the jet pipe; this is known as "center-jet." To ensure effective cleaning, especially for longer filter bags, higher pressure is needed to transmit the airflow intensity to the bottom of the filter bag. Therefore, the jet pressure in baghouse dust collectors typically needs to be 0.5–0.7 MPa.

[0005] In summary, the centralized air supply air compressor equipment in the air compressor system of a cement plant is usually selected with a rated pressure of 0.75MPa.

[0006] However, a new submerged pulse valve technology has emerged for baghouse dust collectors. With this type of valve, the valve is directly installed on the side wall or bottom of the air chamber, with its outlet submerged inside the chamber, directly drawing in compressed air. Once the pulse valve opens, the airflow rushes out at high speed from the chamber and is guided to the filter bag through a venturi tube. The venturi tube induces several times the volume of surrounding clean air to form a large "air mass" that enters the filter bag. This is known as "airflow-induced jet cleaning." Due to the induced synergistic effect of the venturi tube, a powerful cleaning airflow can be generated without very high pressure, distributing energy more evenly throughout the entire length of the filter bag. Therefore, by using a submerged pulse valve, the pressure of the compressed air used in the baghouse dust collector is significantly reduced; a pressure of 0.3–0.4 MPa is sufficient.

[0007] When the pressure of compressed air in a baghouse dust collector needs to be reduced to 0.3-0.4 MPa, using the previous compressed air system would require depressurizing the high-pressure air, resulting in energy waste. Utility Model Content

[0008] The purpose of this invention is to provide an air compressor system, which includes high-pressure equipment and low-pressure equipment for providing compressed air to an air cannon and a bag dust collector, thereby achieving the goal of saving energy.

[0009] To achieve the above objectives, this utility model provides an air compressor system, including a high-pressure air compressor, a low-pressure air compressor, and a first conveying system and a second conveying system respectively connected to the high-pressure air compressor and the low-pressure air compressor;

[0010] Both the first and second conveying systems include: a refrigerated dryer, a filter, and conveying pipelines;

[0011] The rated pressure of a high-pressure air compressor is set to be no less than 0.7 MPa, and the rated pressure of a low-pressure air compressor is set to be no more than 0.5 MPa.

[0012] Preferably, multiple high-pressure air compressors are provided, and the multiple high-pressure air compressors are connected in parallel and then connected to the first conveying system.

[0013] Preferably, multiple low-pressure air compressors are provided, and the multiple low-pressure air compressors are connected in parallel and then connected to the second conveying system.

[0014] Preferably, at least two filters are provided, with multiple filters located at both ends of the refrigerated dryer, for removing oil and ash from the compressed air.

[0015] Preferably, the first delivery system is connected to the air cannon via a compressed air storage tank.

[0016] Preferably, the air compressor system is equipped with a first cooling system for cooling the high-pressure air compressor and the low-pressure air compressor.

[0017] Preferably, the first cooling system includes a circulating cooling water pump, a cooling tower, cooling water pipes embedded in the high-pressure air compressor and the low-pressure air compressor, and an aftercooling device for cooling the compressed air. The circulating cooling water pump drives the cooling water to circulate in the cooling tower, cooling water pipes and aftercooling device.

[0018] Preferably, the air compressor system further includes a dedicated air compressor base station, which includes a dedicated air compressor, a third conveying system, and a second cooling system;

[0019] The second cooling system is set to air-cooled.

[0020] According to the above technical solution, the high-pressure air compressor of this utility model can generate high-pressure compressed air, while the low-pressure air compressor can generate low-pressure compressed air. The high-pressure compressed air and the low-pressure compressed air are output through the first conveying system and the second conveying system, respectively. The high-pressure compressed air is input to the air cannon, and the low-pressure compressed air is conveyed to the bag dust collector system. The rated pressure of the high-pressure air compressor is set to not less than 0.7 MPa, preferably 0.75 MPa, to ensure that it can provide compressed air of not less than 0.65 MPa to the air cannon; the rated pressure of the low-pressure air compressor is set to not more than 0.5 MPa, preferably 0.5 MPa, to ensure that it can provide compressed air of approximately 0.45 MPa to the bag dust collector.

[0021] In this way, the air compressor system includes two sets of compressed air supply devices. The high-pressure compressed air generated by the high-pressure air compressor is sent to the medium-pressure air cannon through the first conveying system, while the bag dust collector, which requires low-pressure compressed air, is directly supplied by the low-pressure air compressor. In this way, the huge energy waste caused by compressing the air to 0.65MPa and then depressurizing it to 0.3MPa is avoided, and theoretically, energy consumption can be saved by more than 30%.

[0022] In fact, this air compressor system has been applied in several cement plants, and can reduce the power consumption of the air compressor system by 12 to 15%.

[0023] Other features and advantages of this invention will be described in detail in the following detailed description section. Attached Figure Description

[0024] The accompanying drawings are provided to further illustrate the present invention and form part of the specification. They are used together with the following detailed description to explain the present invention, but do not constitute a limitation thereof. In the drawings:

[0025] Figure 1 This is a schematic diagram of an air compressor system;

[0026] Figure 2 A schematic diagram of the operation of a low-pressure air compressor

[0027] Figure 3 This is a schematic diagram of the operation of a specialized air compressor.

[0028] Explanation of reference numerals in the attached figures

[0029] 1. High-pressure air compressor 2. Low-pressure air compressor

[0030] 3 Refrigerated dryer 4 filters

[0031] 5. Delivery pipelines 6. Compressed air storage tank

[0032] 7 dedicated air compressors and 10-bag dust collectors

[0033] 20 Packaging Lines Detailed Implementation

[0034] The specific embodiments of this utility model will be described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are for illustration and explanation only and are not intended to limit the scope of this utility model.

[0035] In this invention, unless otherwise stated, directional terms such as "both ends" and "circulation" in the terminology only represent the orientation of the term in its normal use or are common terms understood by those skilled in the art, and should not be regarded as limitations on the term.

[0036] See Figure 1 The air compressor system includes a high-pressure air compressor 1, a low-pressure air compressor 2, and a first conveying system and a second conveying system respectively connected to the high-pressure air compressor 1 and the low-pressure air compressor 2;

[0037] Both the first and second conveying systems include: a refrigerated dryer 3, a filter 4, and a conveying pipeline 5;

[0038] The rated pressure of high-pressure air compressor 1 is set to be no less than 0.7MPa, and the rated pressure of low-pressure air compressor 2 is set to be no more than 0.5MPa.

[0039] Through the implementation of the above technical solution, high-pressure air compressor 1 can generate high-pressure compressed air, while low-pressure air compressor 2 can generate low-pressure compressed air. The high-pressure compressed air and low-pressure compressed air are output through the first conveying system and the second conveying system, respectively. The high-pressure compressed air is input to the air cannon, and the low-pressure compressed air is conveyed to the bag dust collector system. The rated pressure of high-pressure air compressor 1 is set to be no less than 0.7 MPa, preferably 0.75 MPa, to ensure that it can provide compressed air of no less than 0.65 MPa to the air cannon; the rated pressure of low-pressure air compressor 2 is set to be no more than 0.5 MPa, preferably 0.5 MPa, to ensure that it can provide compressed air of approximately 0.45 MPa to the bag dust collector.

[0040] In this way, the air compressor system includes two sets of compressed air supply devices. The high-pressure compressed air generated by the high-pressure air compressor 1 is sent to the medium-pressure air cannon through the first conveying system, while the bag dust collector 10, which requires low-pressure compressed air, is directly supplied by the low-pressure air compressor 2. In this way, the huge energy waste caused by compressing the air to 0.65MPa and then depressurizing it to 0.3MPa is avoided, and theoretically, energy consumption can be saved by more than 30%.

[0041] Compressed air contains three harmful impurities: ash, water, and oil. Before being delivered to its destination, the compressed air needs to pass through filter 4 and refrigerated dryer 3 to remove these three impurities.

[0042] Oil in compressed air exists primarily in the form of oil vapor and droplets, posing a threat to almost all equipment it passes through. First, oil damages precision pneumatic components. Modern factory cylinders, solenoid valves, proportional valves, and other components have precise clearances and orifices. At high temperatures, oil deposits form carbon deposits, which act like glue, sticking to moving parts and causing valve jamming, slow cylinder movement, or even complete malfunction, leading to production failures. Second, oil causes lubrication failure. The oil carried in compressed air differs from specialized lubricating oil. It washes away, dilutes, or deteriorates the specialized grease inside the equipment, rendering it ineffective and accelerating wear. Finally, oil clogs filters and throttling orifices: oil in compressed air combines with ash to form sludge, or at high temperatures, oil itself can turn into sludge, which quickly clogs the tiny gaps or pores of precision instruments.

[0043] Air naturally contains water vapor. When air is compressed, the amount of water vapor per unit volume increases dramatically, and the compression process generates high temperatures, causing this moisture to exist in a gaseous (water vapor) state. When the high-temperature compressed air leaves the air compressor and cools in the air tank and pipelines, the water vapor condenses into liquid water. This liquid water corrodes pipes and equipment. Liquid water can cause steel pipes, cylinders, pneumatic motors, and other components to rust and corrode, shortening equipment lifespan. Furthermore, if liquid water enters the interior of precision pneumatic components, it can cause pneumatic tools and precision instruments to jam or malfunction.

[0044] Filter 4 effectively removes oil and ash from the air. After compressed air is compressed, the content of oil and ash in the same volume is significantly increased. Therefore, installing filter 4 at the outlet of high-pressure air compressor 1 or low-pressure air compressor 2 can improve filtration efficiency.

[0045] The function of the refrigerated air dryer 3 is to remove liquid water and most of the water vapor from the compressed air. In one embodiment, the refrigerated air dryer 3 lowers the "pressure dew point" of the compressed air to 2°C to 10°C. This means that as long as the ambient temperature of the compressed air pipeline is not lower than this dew point temperature, no liquid water will precipitate. Therefore, although the refrigerated air dryer 3 cannot completely remove water vapor, it can still prevent problems caused by water accumulation in subsequent pipelines and equipment.

[0046] Preferably, a compressed air storage tank is installed at the front end of the conveying system. This compressed air storage tank can act as a "buffer tank" and a "primary sedimentation tank" in the system. The compressed air storage tank can alleviate the pulsation of the gas discharged from the air compressor, so that the compressed air pressure in the conveying system tends to be stable and avoids large pressure fluctuations. After being pressurized, the compressed air expands in volume within the compressed air storage tank, and the temperature naturally decreases. As the temperature decreases, a large amount of liquid water and oil will initially condense and settle at the bottom of the tank, and be discharged through an automatic drain at the bottom.

[0047] In this embodiment, preferably, multiple high-pressure air compressors 1 are provided, and the multiple high-pressure air compressors 1 are connected in parallel and then connected to the first conveying system.

[0048] In this embodiment, preferably, multiple low-pressure air compressors 2 are provided, and the multiple low-pressure air compressors 2 are connected in parallel and then connected to the second conveying system.

[0049] In cement plants, certain process positions, such as the packaging line, require compressed air, but these positions are only open during the day. Therefore, the air compressor system also needs to address the issue of high compressed air consumption during the day and a sharp drop in consumption at night. In one implementation, the air compressor system also includes a central controller that links all air compressors, namely high-pressure air compressor 1 and low-pressure air compressor 2. When the packaging system shuts down and the actual compressed air consumption drops significantly, the system automatically identifies and unloads or stops some air compressors, keeping only the necessary air compressors running. This provides a minimum guarantee of air supply for users with continuous production processes, such as the kiln system, thereby completely eliminating the waste of energy through "idle operation."

[0050] By setting up multiple high-pressure air compressors 1 and low-pressure air compressors 2, and connecting multiple air compressors in parallel and putting them all into operation, more compressed air can be provided to the first or second conveying system. When the demand for compressed air decreases, the central controller can stop one or more high-pressure air compressors 1 and / or low-pressure air compressors 2 respectively, thereby reducing the amount of compressed air provided by the compressed air supply end.

[0051] Preferably, the packaging line is integrated into the first conveying system, and when the packaging line stops production, one or more high-pressure air compressors 1 can be stopped.

[0052] In this embodiment, preferably, at least two filters 4 are provided, with multiple filters 4 located at both ends of the refrigerated dryer 3, for removing oil and ash from the compressed air.

[0053] The two filters 4 are respectively set as a pre-filter and a fine filter, wherein the pre-filter is set before the refrigerated dryer 3 and the fine filter is set after the refrigerated dryer 3.

[0054] The pre-filter can remove larger solid particles and small amounts of liquid water, preventing them from entering the refrigerated dryer 3, contaminating the heat exchanger surface, and reducing heat exchange efficiency. Furthermore, installing a pre-filter can significantly reduce the workload on the downstream fine filter and extend its service life.

[0055] After being processed by the pre-filter, the compressed air enters the refrigerated dryer 3. As the primary dehumidifier, the refrigerated dryer 3 uses refrigeration technology to forcibly cool the compressed air to 2–10°C. At this temperature, most of the water vapor condenses into liquid water and is completely discharged through the automatic drain. Therefore, after passing through the refrigerated dryer 3, the pressure dew point of the compressed air is reduced to approximately 10°C. This means that as long as the ambient temperature is not lower than the dew point temperature, no liquid water will precipitate in the pipes.

[0056] After passing through the refrigerated dryer 3, the air becomes dry and can then enter the fine filter. The fine filter can remove residual oil mist, aerogel, and the smallest solid particles from the compressed air. The fine filter uses the principle of agglomeration, causing tiny oil droplets to coalesce into larger droplets as they pass through special filter media. Finally, these larger droplets drip off due to gravity.

[0057] This combined filtration method can effectively remove oil, ash, and water from compressed air.

[0058] In this embodiment, preferably, the first delivery system is connected to the air cannon via a compressed air storage tank 6.

[0059] Air cannons are intermittent air-consuming devices, with a large instantaneous air consumption but a low frequency. A large-capacity air tank can store enough gas during air compressor operation to meet the instantaneous explosion requirements of the air cannon. This allows the air compressor to operate at a lower average load and even have longer unloading and downtime, reducing energy consumption caused by frequent loading and unloading of the air compressor.

[0060] Therefore, setting up a large-capacity compressed air storage tank 6 can fill the gap in the air compressor's air supply capacity during peak air demand periods. The function of the compressed air storage tank 6 is to "shave the peak and fill the valley," storing air during low air demand periods and supplying air during peak air demand periods.

[0061] In one implementation, the peak air consumption of equipment such as air cannons operating simultaneously in a cement plant is 30m³. 3 / min, while the total air supply capacity of high-pressure air compressor 1 is 20m³. 3 / min, the peak air consumption of the air cannon lasts for 30 seconds, or 0.5min. The rated working pressure of the air cannon is P1 = 0.7MPa, and the minimum pressure is 0.65MPa. Therefore, the allowable pressure drop of the system is ΔP = 0.7 - 0.65 = 0.05MPa, and the atmospheric pressure is 0.1MPa.

[0062] Therefore, the capacity of compressed air storage tank 6 can be designed as: V = (30-20)*0.5*0.1 / 0.05 = 10*0.5*2 = 10m³ 3 .

[0063] In one embodiment, the capacity (in L) of the compressed air storage tank 6 is approximately equal to the rated flow rate (in m³ / s) of the high-pressure air compressor 1. 3 The calculation method is relatively simple, but it is still applicable to general situations. It is 10-20% of the value per minute.

[0064] In this embodiment, preferably, the air compressor system is provided with a first cooling system for cooling the high-pressure air compressor 1 and the low-pressure air compressor 2.

[0065] When an air compressor compresses air, it generates a large amount of heat energy, which accounts for about 80% of the motor's input power. This results in very high temperatures for the compressed air and the machine itself, sometimes even reaching 80-100°C.

[0066] Therefore, the air compressor itself needs to be cooled during operation. The compressor head, compression oil, and other components need to be cooled in a timely manner to prevent overheating, shutdown, or even damage. Simultaneously, the compressed air also needs to be cooled. High-temperature compressed air contains a large amount of water vapor, which must first pass through a cooling system to lower its temperature, causing most of the water vapor to condense into liquid water and separate out, thus reducing the load on the subsequent refrigerated dryer.

[0067] In this embodiment, preferably, the first cooling system includes a circulating cooling water pump, a cooling tower, cooling water pipes embedded in the high-pressure air compressor 1 and the low-pressure air compressor 2, and a post-cooling device for cooling the compressed air. The circulating cooling water pump drives the cooling water to circulate between the cooling tower, the cooling water pipes, and the post-cooling device.

[0068] The circulating water pump drives the cooling water to circulate in the cooling tower and air compressor. Specifically, the cooling water flows out of the cooling tower, enters the circulating water pump, is then pumped into the cooling water pipe and the post-cooling equipment, and finally returns to the cooling tower to cool down.

[0069] In the aftercooling equipment and cooling water pipes, cooling water cools and lowers the temperature of the compressed air and air compressor, respectively.

[0070] In this embodiment, preferably, the air compressor system further includes a dedicated air compressor base station, which includes a dedicated air compressor 7, a third conveying system, and a second cooling system;

[0071] The second cooling system is set to air-cooled.

[0072] Since some positions, such as the packaging line, may only be in production for a certain period of the day, production scheduling can lead to periodic consumption of compressed air. To address this, dedicated compressed air stations can be set up specifically for these discontinuous production workstations.

[0073] By setting up dedicated air compressor base stations, the impact of shift-based operation on the stability of air supply for continuous production in the kiln system can be avoided. Furthermore, by using air-cooled cooling equipment to cool the air compressors, the construction and operation costs of dedicated air compressor base stations can be significantly reduced.

[0074] Since positions like packaging line 20 are relatively small in scale and have relatively low air consumption, air-cooled air compressors are perfectly adequate. This saves on the fixed investment in water-cooling systems, as well as daily water and electricity consumption and complex maintenance work, thus greatly reducing equipment costs.

[0075] The preferred embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the specific details of the above embodiments. Within the scope of the technical concept of the present invention, various simple modifications can be made to the technical solution of the present invention, and these simple modifications all fall within the protection scope of the present invention.

[0076] It should also be noted that the various specific technical features described in the above specific embodiments can be combined in any suitable way without contradiction. In order to avoid unnecessary repetition, this utility model will not describe the various possible combinations separately.

[0077] Furthermore, various different embodiments of this utility model can be combined in any way, as long as they do not violate the spirit of this utility model, they should also be regarded as the content disclosed by this utility model.

Claims

1. An air compressor system, characterized in that, It includes a high-pressure air compressor (1), a low-pressure air compressor (2), and a first conveying system and a second conveying system respectively connected to the high-pressure air compressor (1) and the low-pressure air compressor (2); Both the first and second conveying systems include: a refrigerated dryer (3), a filter (4), and a conveying pipeline (5); The rated pressure of the high-pressure air compressor (1) is set to be no less than 0.7 MPa, and the rated pressure of the low-pressure air compressor (2) is set to be no more than 0.5 MPa.

2. The air compressor system according to claim 1, characterized in that, Multiple high-pressure air compressors (1) are set up, and the multiple high-pressure air compressors (1) are connected in parallel and connected to the first conveying system.

3. The air compressor system according to claim 1, characterized in that, Multiple low-pressure air compressors (2) are set up, and the multiple low-pressure air compressors (2) are connected in parallel and connected to the second conveying system.

4. The air compressor system according to claim 1, characterized in that, At least two filters (4) are provided, with multiple filters (4) located at both ends of the refrigerated dryer (3) to remove oil and ash from the compressed air.

5. The air compressor system according to claim 1, characterized in that, The first delivery system is connected to the air cannon via a compressed air storage tank (6).

6. The air compressor system according to claim 1, characterized in that, The air compressor system is equipped with a first cooling system for cooling the high-pressure air compressor (1) and the low-pressure air compressor (2).

7. The air compressor system according to claim 6, characterized in that, The first cooling system includes a circulating cooling water pump, a cooling tower, cooling water pipes embedded in the high-pressure air compressor (1) and the low-pressure air compressor (2), and a post-cooling device for cooling compressed air. The circulating cooling water pump drives the cooling water to circulate in the cooling tower, cooling water pipes and post-cooling device.

8. The air compressor system according to claim 1, characterized in that, The air compressor system also includes a dedicated air compressor base station, which includes a dedicated air compressor (7), a third conveying system, and a second cooling system; The second cooling system is set to air-cooled.

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