Evaluation of three suction pretreatment systems for the air compressor

Abstract

Air compressor, as the power source of pneumatic tools, suffers the problems of low efficiency and high failure rate in summer. In this paper, three suction air pretreatment systems are presented, which are characterized by the cold sources: a vapor compression refrigeration unit, a water chilling unit and a combination of water chilling unit with cooling tower. Models for the thermodynamic and economic performance evaluation of the three systems are established and solved. The moisture diffusion coefficient is applied to consider the influence of the moisture condensation and the Marshall and Swift coefficients is introduced to consider the capital change over time. Formula to calculate the efficiency of refrigeration compressor is adopted. Besides, the system total efficiency, percentage of power saving (PPS) and payback period (PBP) are defined as performance indexes. A comparative study with typical meteorological data of hot-dry regions and hot-humid regions is conducted to analyze the superiority of each system under the operation conditions of varied suction air temperature and volume flow. According to the results, optimal spray water flowrate exists for each operation condition and an air–water ratio of 0.8 is recommended. When the suction air temperature decreases, the PBP of each system increases and a sharp increase occurs when the temperature is lower than the air dew point temperature. A suction air temperature of 26 ℃ is suggested. Direct air cooling with an evaporator is preferred when the suction air volume flowrate is smaller than 60 m3/min for hot-humidity regions. The combined system is significantly superior in hot-dry regions. The PBP of the three systems is all longer than 10 months. How to guarantee the usage rate is the key for enterprises to consider the use of suction air pretreatment systems.