2025-03-10 11:39:45
【TECHNICAL NEWS】Optoelectronics: Power Saving Dryer Upgrade Saves ￥500K Yearly
Recently, EPSEA, in collaboration with its distributor, undertook a project to retrofit seven zero loss blower heat desiccant air dryers in the air compressor station of an optoelectronics industry. The total investment of this project is 1,000,000 yuan. After the retrofit, it is expected to save nearly 500,000 yuan in electricity costs annually, demonstrating remarkable energy - saving effects.
Previously, the air compressor station was furnished with seven sets of heated desiccant combined air dryers. These units demonstrated satisfactory performance in compressed air drying. However, during the regeneration phase, they consumed 10% of the compressed air, resulting in substantial energy wastage. To enhance energy efficiency, the optoelectronics industry user resolved to convert them into zero loss blower heat desiccant air dryers. The novel dryers employ a circulation fan to draw in ambient natural air, which is then utilized to heat and regenerate the adsorbent. Subsequently, an internal circulation is implemented for cooling. By doing so, the new dryers completely eliminate the waste of compressed air, achieving optimal energy - saving effects.
According to the energy consumption comparison data before and after the transformation, the comprehensive energy consumption difference between a single heated desiccant dryer and a zero loss blower heat desiccant air dryer is significant:
Note:
① The specific power of the air compressor is taken as 6.3 kw/(m³/min) corresponding to a pressure of 7 barG
② Average gas consumption power = Compressed air flow rate * Average regeneration gas consumption * Specific power
③ Heater power consumption = Periodic heating time * Heater power
④ Calculation is based on 7,000 hours per year and an industrial electricity cost of 0.75 yuan per kWh
Energy - saving Calculation:
After the actual retrofit of 7 sets of zero loss blower heat desiccant Air dryers, since the air consumption becomes zero, the operating electricity cost of the oil - free screw air compressors can be reduced.
1. The annual electricity cost saved for air compressor operation is: 6.3*(38*10%*7)*7,000*0.75 = 879,795 yuan.
2. The overall annual power consumption increase of the retrofitted zero loss blower heat desiccant air dryers are: (101920 - 47510)*7 = 380,870 yuan.
Energy-saving Effect:
After the transformation of 7 sets of zero loss blower heat desiccant air dryers systems, the overall annual electricity cost savings are: 879,795 - 380,870 = 498,925 yuan.
Although the direct power consumption of the equipment has increased after the transformation, the operating electricity cost of the air compressor has been significantly reduced due to the zero loss design. According to the calculation, the annual electricity cost of the air compressor operation can be saved by about 879,800 yuan after the transformation, while the electricity cost of the newly added zero loss blower heat desiccant air dryers are about 380,900 yuan. Overall, the annual electricity cost is saved by nearly 500,000 yuan, and the energy-saving rate is as high as 41%.
(On-site photos after the transformation )
To sum up, assuming that the air compressor and dryer were running at full load before the transformation, after the transformation, due to the reduction in air consumption while the downstream air consumption remains unchanged, the operating energy consumption of the air compressor decreases. Correspondingly, the operating energy consumption of the zero loss blower heat desiccant air dryer will also decrease. Therefore, the actual energy-saving rate of the zero loss blower heat desiccant air dryer after the transformation will be a little higher.
The successful completion of this transformation project is not only an accumulation of innovative transformation experience for EPSEA in the optoelectronic industry, but also a strong practice of the concept of sustainable development. Every small step of progress in energy conservation and emission reduction is a big leap in promoting the green transformation of the industry and even the whole society. We are committed to driving enterprises toward a low-carbon future through continuous technological innovation and strategic collaboration!
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