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 adopting advanced foreign electric centrifugal air compressor units for fermentation processes. Based on recent engineering experiences and the preparation of competitive international bidding technical documents, some valuable insights have been gathered. These findings are now shared to provide guidance and reference for future projects. 2. Power Consumption 2.1 Definition of Power Consumption
Power consumption is defined as the ratio of the shaft power input to the compressor to the volumetric flow rate per minute. This metric reflects the energy efficiency of the unit, but it can be challenging to interpret due to various influencing factors in real-world applications. 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. - Imported units often include a main motor, coupling, gear speed increaser, and compressor, but may exclude certain losses from the calculation. 2.3 Volumetric Flow
Three types of volumetric flow are commonly specified: - Inlet volume flow: Measured under suction conditions such as pressure, temperature, humidity, and gas composition. - Actual volumetric flow: Refers to the flow at a specific point under given conditions, which can differ significantly from inlet flow. - Standard volume flow: Calculated by converting pressure and temperature to standard conditions (0.1014 MPa, 15.56°C, dry gas). 2.4 Project Examples
In one case, initial quotations showed significant variations in shaft power (1600–2100 kW), making comparisons difficult. Properly defining parameters like pressure, temperature, and humidity is essential for accurate evaluation. 2.5 Summary
Foreign equipment generally shows better energy efficiency than domestic alternatives, contributing to their market dominance. It is crucial to specify testing procedures and performance criteria in contracts to ensure reliability. 3. Selection of Self-Controlled Actuators
Domestic users often rely on pneumatic actuators, which perform well when instrument air quality meets specifications. However, in cases where an instrument air source is not available, electric actuators may be preferred for simplicity and reliability. 4. Dual Power Supply Non-Stop Switching
Issues with power supply instability led to modifications in older units to include automatic switching. While this reduced downtime, it also introduced challenges related to control system power interruptions. Implementing an online UPS helped resolve these issues effectively. 5. Surge Protection and Regulation
Surge protection systems must be carefully designed to avoid unnecessary shutdowns. A single-factor approach may not be suitable for all regions, especially where voltage fluctuations are common. Clear specifications in bidding documents are essential to ensure stable operation. 6. Automatically Controlled DCS System
Modern DCS systems allow for remote monitoring and control, improving operational efficiency. Operators can start and stop units through a user-friendly interface, enhancing safety and convenience. 7. Conclusion
Several challenges remain, including oil temperature control, noise management, and performance verification. Future articles will address these issues in detail. This article aims to provide practical insights for industry professionals, encouraging the use of reliable domestic solutions while acknowledging the competitive nature of the market. Xuzhou Xinbaisheng Protective Equipnent Co., Ltd. , https://www.xinparkson.com