2025-03-03 08:58:51
【TECHNICAL NEWS】Nitrogen Generator Market Opportunities：Energy-saving Upgrades(图文)
In recent years, the nitrogen generator industry has experienced rapid development, with new technologies continuously emerging and the performance of new equipment significantly improving. However, the coexistence of old and new equipment in the market remains prominent. Many small and medium-sized enterprises, due to financial constraints or insufficient understanding of new technologies, continue to use outdated equipment. These older machines not only operate inefficiently and consume excessive amounts of energy but also suffer from numerous stability issues, imposing significant cost pressures and production risks on businesses.
At present, the molecular sieves and control systems of many old nitrogen production equipment on the market are backward. Under prolonged high-load operation, these machines are not only inefficient but also consume excessive electricity. For example, a chemical company using a ten-year-old nitrogen generator found that its monthly electricity bill was nearly one-third higher than that of a comparable new machine, leading to substantial long-term cost increases. Additionally, the worn-out components of old equipment frequently malfunction. For instance, a food company experienced unstable nitrogen supply during peak production due to equipment failure, affecting critical processes like food preservation and resulting in lost orders. Moreover, old equipment struggles to meet the high-purity nitrogen requirements of advanced production processes.Under prolonged high-load operation, these machines are not only noisy but also consume excessive electricity. For example, a chemical company using a ten-year-old nitrogen generator found that its monthly electricity bill was nearly one-third higher than that of a comparable new machine, leading to substantial long-term cost increases. Additionally, the worn-out components of old equipment frequently malfunction. For instance, a food company experienced unstable nitrogen supply during peak production due to equipment failure, affecting critical processes like food preservation and resulting in lost orders. Moreover, old equipment struggles to meet the high-purity nitrogen requirements of advanced production processes.
To address the energy-saving transformation of outdated equipment, there are currently two main approaches:
1. Control System Upgrade: By upgrading the control system, the equipment can more accurately sense production demands and intelligently adjust operating parameters, thereby avoiding unnecessary energy consumption.
2. Complete Equipment Overhaul: Replacing key high-energy-consuming components, such as installing new control and data monitoring systems, can significantly enhance equipment performance and reduce energy consumption. Although the initial investment for a complete overhaul is substantial, the long-term energy savings and efficiency improvements justify the cost.
Market research indicates that over 80% of nitrogen users do not operate their nitrogen generators at full capacity. For example, a 100Nm³/H nitrogen generator is typically used at around 80Nm³ by 50% of users, 50Nm³ by 30% of users, and ≤30Nm³ by 10% of users. This low-load operation or idle time results in significant energy waste, increasing users' gas costs to the point where they may exceed the manufacturing costs of liquid or bottled nitrogen. To address these issues, EPSEA has developed the VP (Variable Period) core energy-saving technology, bringing new breakthroughs to the industry.
EPSEA's VP energy-saving technology utilizes multi-sensor data feedback to detect users' actual operating conditions in real-time. It automatically adjusts the switching cycle based on changes in nitrogen flow and purity. Our nitrogen generators come standard with necessary sensors and VP control programs, allowing users to set energy-saving parameters according to their specific operating conditions.
The VP control logic is divided into purity control and flow control:
1. Purity Control: Suitable for high-purity, low-flow scenarios, it precisely controls flow, extends the switching cycle, ensures purity remains above the set value, and reduces air consumption.
Purity Control
2. Flow Control: Suitable for scenarios with lower nitrogen purity requirements (≤99.9%), it maximizes the extension of a single cycle, saves air consumption, reduces switching frequency, and extends the lifespan of pneumatic valves, solenoid valves, and electrical components.
Flow Control
Additionally, VP technology does not simply switch based on flow or purity. Instead, it accurately monitors on-site operating data, ensuring that VP conditions are met before triggering control. After 3-4 self-adjustments, it completes a phase of VP control, achieving energy-saving effects.
For intermittent nitrogen usage scenarios, VP technology offers specific optimizations. For example, for processes that use gas for 2 hours and then stop for 1 hour, EPSEA recommends using pressure start-stop control. This method uses the upper pressure limit to pause the PLC program and the lower pressure limit to automatically trigger the equipment start. This approach not only avoids unnecessary consumption when the equipment is not running but also completely eliminates compressed air consumption during standby periods. The longer the downtime, the more air consumption is saved.
In terms of sensor configuration, EPSEA's nitrogen generators come standard with necessary purity, flow, and pressure sensors, as well as flow control VP, purity control VP, and pressure auto start-stop technology. This not only makes it convenient for users in need to directly use it, but also eliminates the need for controller modification or the installation of instrument sensors. Additionally, it will not generate any additional costs or cause production delays due to downtime. Furthermore, these sensors can record 30 days of equipment operation data, helping to analyze whether users have energy-saving potential, truly making data-driven decisions.
EPSEA has always been committed to technological innovation. Leveraging years of accumulated technical expertise and keen market insights, the company has established a comprehensive product system and service network. From research and development, design, and manufacturing to after-sales maintenance, EPSEA provides customers with a full range of one-stop solutions, aiming to create greater value for clients and become a trusted supplier of compressed air system products.
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