Energy costs are rising sharply, and carbon dioxide emissions are rising, which has had a great impact on all aspects of our lives and has drawn great attention from society. In fact, for compressors that use compressed air, energy efficiency has always been a closely related development goal. The trends described above make this goal even more important. Keep in mind that improvements to filtration systems can significantly reduce energy consumption, thereby reducing costs and carbon dioxide emissions.
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Today, industrial and construction companies commonly use oil-injected screw compressors to supply compressed air of various quality standards. The energy required to operate the compressor is approximately 75% of the operating cost. As energy prices continue to rise, energy-saving measures become more important. Compressor manufacturers are developing new systems to improve the conversion of mechanical or electrical energy to thermal energy and increase the energy of compressed air.
To achieve high energy efficiency, the performance of all fixed components of the compressor must be considered in conjunction with interchangeable components such as air purifiers, oil filters and oil separators. These three components form an interactive filter chain.
High efficiency filter development tools
For more than 40 years, MANN+HUMMEL has been involved in the development and production of oil and gas separators for compressed air systems, and its research and development work in this area is focused on reducing residual oil, extending service life and increasing energy efficiency. MANN+HUMMEL uses modern processes to achieve these development goals.
In the early stages of development, MANN+HUMMEL has adopted measures to reduce pressure drop, such as the use of computer fluid dynamics simulation tools. Different colors are used to indicate various flow rates. The flow rate increases and the pressure drop increases, resulting in unnecessary energy loss. The design change can be selected for the range of flow rates found. Applying the corresponding expertise can achieve significant results in a very short time.
Even if the filter and filter media have tiny oil droplets or particles as small as submicron, energy efficiency can be affected. Simulating the dynamic separation process can significantly improve the filter. In the process, the main simulation tools developed by MANN+HUMMEL were used, and other simulation tools available on the market were also used. These fundamental improvements are supported by the scientific results of MAN Hummel's collaborative research projects with leading universities.
These developments have resulted in improved design and construction of the filter media, a significant reduction in pressure drop, improved filter accuracy and dirt holding capacity, and lower energy consumption.
These development tools and technical improvements are used in the relevant filters and filtration systems of compressors. In this process, not only the individual components have been improved, but the entire filter chain and interactive filtering stages of the system have also been improved. This requires a complete system of component system suppliers to fully develop all types of filtration products. Although only minor adjustments are made to the system, it is efficient and maximizes energy savings.
Air filtration
The first step in the compressor filter chain is the air purifier: filtering the inhaled ambient air and directing it to the compressor components. Even in this first step, efficiency can be improved.
For example, the differential pressure is reduced by 10 bar, and the air purifier flow in a 50 hp compressor is about 5 m3/min, which saves about 36 euros (about 342 yuan) per year.
FAD x delta (delta p, minimum differential pressure) x working time x unit energy cost = cost savings
5.32 m3/min x 10 mbar x 4000 hx 0.1 €/kWh = 36 Euro (342 RMB)
Another result of efficient filtration and efficient separation of air is particle separation, which has a beneficial effect on the second step. However, energy savings are not made in the air purifier, but in the subsequent stages.
Separation of oil droplets
The absolute increase in pressure drop in the air intake filtration is lower compared to the latter filtration stage, so the energy savings achieved by the pressure drop is very limited. The detection of the oil separator shows that there is a fairly high drop in the pressure difference. The pressure difference achieved by the oil separator can be as high as 100 mbar, which greatly increases the energy saving potential. For example, in the same application mentioned above, 100 mbar can save 45 euros (about 428 yuan). There are several ways to reduce the pressure drop. The easiest way is to increase the surface area of ​​the oil separator. But this is in contradiction with the goal of maintaining the size of the machine, especially the pressure vessel that is as small as possible. Another method is to use a higher performance separation medium.
However, oil quality, especially the amount of fuel injected, also has an effect on the pressure drop. For example, the structure of the primary filter can affect the amount of oil. Less oil can increase the pressure and residual oil performance of the oil separator.
Oil filter
The oil and gas separator is the most sensitive component for high pressure drop and filtration efficiency and must be protected by a high quality air purifier and high efficiency oil filter, otherwise the pressure drop will increase significantly. Improved filtration performance saves up to 60%.
to sum up
Improved filtration performance increases compressor efficiency for energy savings and reduced CO2 emissions. This requires modern development tools and proven expertise to match and design all of the interactive components in the filtration phase to maximize their respective performance and common performance. Based on this, MANN+HUMMEL offers a filtration system with improved performance and significant energy savings.
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