10 steps to save energy with compressed air systems

6. Optimize Your Piping Network for Efficiency.

Many compressed air systems are not fully optimized for performance. Designing a piping system that effectively transfers compressed air at the required pressure and flow to its final destination is crucial. For instance, upgrading a pipe diameter from two inches to three inches can potentially halve the pressure drop. Additionally, minimizing the distance that air must travel can lead to a further reduction in pressure loss of approximately 20-40 percent. It's important to note that as the flow rate through a pipe increases, so does the pressure drop; the relationship is quadratic, meaning if the flow is doubled, the pressure loss can increase by four times. Therefore, the piping used for air distribution should have adequate diameter to keep pressure drop to a minimum.

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Author: Bella Zhang

The advancement of technology and enhancement in air quality across diverse industries have led to a steady rise in demand for oil-free air compressors. In contrast to conventional oil-lubricated piston compressors, oil-free screw compressors are preferred for their lower noise levels, stable airflow, and reduced failure rates, offering significant advantages to users. These oil-free screw compressors are classified into dry oil-free and water-lubricated models. Notably, the water-lubricated variety further divides into single-screw and twin-screw systems, with the single-screw version being more prevalent in the market today.

The water-lubricated screw compressor presents several advantages:

• With equivalent power and pressure settings, these compressors often deliver higher displacement and greater energy savings compared to dry models.
• Single-stage compression can achieve maximum pressures of 16 kg, while two-stage setups can exceed 40 kg, addressing pressure limitations often encountered with dry oil-free options.
• The near-isothermal compression achieved in these systems minimizes temperature increases, thus ensuring optimal operational stability.
• These systems contain no oil in their self-lubricating bearings and compression mechanisms, ensuring that both intake and exhaust gases remain free of oil, preventing any contamination whatsoever.
• Maintenance costs are reduced significantly, requiring only the replacement of air and water filters as consumables, with automatic replenishment of lubricating water, enhancing convenience.
• Constructed using food-grade materials like SUS304, they adhere to stringent hygiene standards applicable in the food and pharmaceutical industries.
• Water used for lubrication introduces fewer impurities, ensuring cleaner compressed air.
• Thanks to inherent safety features such as near-isothermal processes and corrosion resistance, these compressors are suitable for specialized gas applications.

However, there are prevalent misconceptions regarding single-screw water-lubricated compressors:

• Many believe that compressed air from these units is excessively moist; in fact, a well-functioning unit does not discharge liquid water, resulting in a saturated but oil-free output with lower moisture levels than traditional oil-injected counterparts.
• A common misconception is that these systems require excessive water, yet they judiciously utilize water, needing to be replenished only occasionally, thereby saving both water and money.
• Some confuse water lubrication with water cooling, whereas lubrication is akin to using oil for injectors; cooling methods vary and can include both air and water cooling.
• Concerns about potential bacterial contamination from the compressed air are misplaced; while filters help mitigate bacterial presence, it's essential to implement post-processing measures to ensure total purity for sensitive applications.
• Lastly, doubts often arise regarding the effectiveness of water as a lubricant, yet these compressors are engineered for longevity and efficiency, achieving service lives of 25 years or more.

After extensive market analysis, the single-screw water-lubricated screw compressor has transitioned from a novel solution to a trusted option in diverse sectors. With increased production capabilities and competitive pricing, it is gradually replacing traditional oil-based systems and will continue to do so, benefitting wider industrial applications.

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