Tangshan Mengpai Porcelain Industry Co., Ltd. is a well-known sanitary ware brand manufacturer in mainland China, and has now developed into a group enterprise with three factories and one branch, and its products are at the leading level in China in terms of style, glaze, function, physical and chemical properties.
Mengpai porcelain industry adheres to the principle of high starting point and high quality in production, and the requirements of air compressors are no exception.
In 2024, Dream Porcelain Industry and Baode have formed a relationship and selected Baode's first-class energy-efficient air compressor, professional post-treatment equipment, overall station design and digital management system to provide high-quality and reliable compressed air power for the production of Dream brand ceramics and bathroom products.
Pain points of station management before transformation
01
Because the production is divided into multiple time periods, and the gas demand in different time periods is inconsistent, it is necessary to have a special person responsible for the start and shutdown of the air compressor.
1. Manual management: manual start-up and shutdown are not timely, resulting in serious waste, such as small gas consumption during the break at 18:30, workers forget or other reasons to turn off the air compressor at 19:00, this half an hour wastes about 130KWh of electricity, serious waste of energy, and manual switch-on, often forget to switch on and off the supporting refrigeration dryer.
2. Manual judgment: start the machine according to the experience needs, insufficient gas production and unexpected shutdown of the air compressor occur from time to time.
3. Uneven operation: The equipment running time is uneven, and the equipment running time difference is more than 3,000 hours. Equipment that runs for a long time does not get a rest in rotation, resulting in a high failure rate.
4. Manual meter reading: The air compressor station relies on manual meter reading, which needs to be reviewed during cost accounting at the end of the month, and the accuracy of the data needs to be further improved.
AI-based system design for energy-saving solutions
02
After energy-saving research and analysis, Baode has carried out the following transformation plans for Mengpai porcelain industry:
1. Design optimization: measurement and rationality diagnosis of gas source, pipeline network and gas-using equipment, and optimization of leakage and unreasonable gas consumption.
2. Energy-saving transformation: replace old equipment with Baode first-class energy-efficient inverter two-stage compressor air compressor and energy-saving refrigeration dryer.
3. Digital intelligence management: install an intelligent air compressor station management system, intelligently control the air compressor and the refrigeration dryer, stabilize the gas production pressure, and minimize the operating power of the air compressor. Install flow meters, electricity meters, pressure sensors, etc., to monitor the energy consumption of the air compressor station in real time.
4. Lean improvement: After the transformation, how much gas is used to produce how much gas, and the pressure of the mother pipe of the air compressor station is stabilized at 0.63MPa.
Baode first-class energy efficiency digital intelligent air compressor station
03
Baode first-class energy-efficient digital intelligent air compressor station, based on the Internet of Things and AI, is a first-class energy-efficient digital intelligent air compressor station (as of press time, the industry's only municipal-level digital and intelligent demonstration factory developed an integrated solution of software and hardware), through the on-site data collection of the air compressor station, accurately analyze, calculate, and optimize the key data such as the gas-to-electricity ratio and power consumption of the air compressor station and each unit, and at the same time, combined with the actual demand, the dynamic combination of each equipment, intelligently regulate the loading and unloading of the air compressor unit (how much gas is used to produce how much gas), and reduce power consumption. To extend the life of air compressor unit equipment, real-time energy consumption supervision, automatic meter reading, and remote management can be used on PC and mobile phones to achieve safe production, energy conservation and emission reduction, consumption reduction and efficiency improvement, and lean management for enterprises.
Before the transformation, the unit energy consumption was 0.130476KWh/Nm3, and after the transformation, the unit energy consumption was 0.086878KWh/Nm3, a decrease of 33.41%. The whole station maintains first-class energy efficiency and realizes digital and intelligent management.
1. On-demand start-up: automatically according to the gas demand, the equipment runs automatically, how much gas is used to produce how much gas, the system automatically evaluates which air compressor to open, which air compressor to turn off, and automatically turns on the standby machine when the equipment fails.
2. Intelligent rotation: The equipment balances the running time and automatically rotates the operation at regular intervals.
3. Constant pressure of the whole station: the pressure of the station is constant, the energy waste is reduced, and the electricity consumption is saved.
4. Intelligent joint control: the air compressor and the post-processing equipment are automatically linked to the switch, and the independent automatic valve is equipped to ensure high-quality gas consumption.
5. Energy assessment: real-time automatic allocation of electricity costs of air compressor stations according to gas consumption, lean management, and automatic reports.
The above air compressor station test data will be tested and identified by the national quality supervision agency, and the first-class energy efficiency compressed air station certification certificate will be issued to the customer and awarded.
Here's what the renovated station will look like:
Baode first-class energy-efficient digital intelligent air compressor station, with an average energy saving rate of more than 35% in many successful cases, can reduce costs and increase efficiency for your enterprise and help digital transformation! Reduce your compressed air combined costs to a minimum.
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