Five Key Challenges in the Design and Selection of Air Compressor Units for Fermentation 1. Introduction
With the development of the market economy, more and more enterprises are choosing advanced foreign electric centrifugal air compressor units for fermentation processes. Based on recent engineering practices and the preparation of competitive international bidding technical documents, valuable experiences and lessons have been accumulated. This document aims to share these insights for reference. 2. Power Consumption
2.1 Definition of Power Consumption: It is the ratio of the shaft power input to the compressor to the volumetric flow rate per minute. This specific power consumption indicates the energy efficiency of the unit, but it can be challenging to assess due to complex real-world conditions. 2.2 Shaft Power of the Compressor
The shaft power varies depending on the compressor’s design. For example, domestic E1 series models typically consist of a main motor, coupling, gear speed increaser, and compressor. In contrast, imported units may omit one coupling. The efficiency of the main motor and coupling losses must be considered when evaluating the actual energy use. 2.3 Volumetric Flow
There are three definitions of volumetric flow: inlet volume flow, actual volumetric flow, and standard volume flow. Each has its own measurement conditions and should be clearly defined in technical specifications to ensure accurate comparisons. 2.4 Project Examples
In initial quotations, the range of shaft power can vary significantly (e.g., 1600–2100 kW), making data comparison difficult. Detailed parameters such as atmospheric pressure, inlet temperature, and exhaust pressure are essential for accurate evaluations. 2.5 Summary
Domestic and foreign equipment show significant differences in energy efficiency, which is a key factor in market competition. Proper documentation and testing procedures are crucial to ensure reliability and performance. 3. Selection of Self-Controlled Actuators
3.1 Research on Domestic Users
In 2002, five users were interviewed regarding the selection of pneumatic actuators. While most were satisfied with their performance, reliability issues arose when instrument air quality was not maintained. 3.2 Electric Actuators
In cases where an instrument air source system was unavailable, electric actuators were preferred. They offer greater flexibility and reduce the need for additional infrastructure. After over a year of operation, no issues were reported with the electric actuators used. 4. Control of Dual Power Supply Switching
4.1 Operating Faults
High-voltage control systems generally perform well, but low-voltage power supply faults are more common. To reduce downtime, some older units were modified to include automatic dual power switching. 4.2 Contract Terms
A clause in the contract required a dual power automatic switching device, but the term “non-stop switching†caused confusion. Eventually, the issue was resolved by adding an online UPS to prevent power loss during switching. 5. Surge Protection and Regulation
5.1 Basic Requirements
The compressor’s characteristic curve should rise continuously from the rated point to the surge point. It should operate without bypassing at flows above 10% of the surge flow. 5.2 Manual Surge Protection
Older units relied on manual regulation, which was safe but inefficient. Modern systems require automated surge protection and regulation to improve efficiency and reduce waste. 5.3 Engineering Case Study
An expansion project encountered frequent shutdowns due to voltage instability. The solution involved modifying the control system and adding an online UPS to stabilize the power supply. 6. Automatically Controlled DCS System
6.1 Survey Situation
New units often require manual operation, limiting real-time monitoring. A DCS system allows centralized control, improving efficiency and ease of use. 6.2 Implementation
The DCS system enables operators to start, monitor, and adjust the compressor remotely. It also provides graphical interfaces for better visibility and control. 7. Conclusion
Despite progress, challenges remain, including oil temperature control, environmental oil mist removal, and noise management. Future discussions will explore these topics in detail. This article aims to provide practical guidance for industry professionals and encourage the adoption of domestically produced units. work gloves,safety gloves,best work gloves Xuzhou Xinbaisheng Protective Equipnent Co., Ltd. , https://www.xinparkson.com