I. Clarify the parameters of gas-using equipment
To accurately calculate compressed air demand, the primary step is to compile the rated air consumption (Nm³/min) and operating pressure of all end-use equipment. MPa), gas consumption cycle (continuous/intermittent), and the simultaneous-use factor. Avoid simply summing nominal values; instead, adjustments should be made based on actual operating conditions.
II. Calculation of Total Gas Consumption
Total demand = Σ (gas consumption per unit × simultaneous usage factor × load factor) × safety margin (typically 10%– 20% Intermittent air‑using equipment must be sized to the maximum instantaneous flow rate to account for peak demand, thereby preventing frequent compressor cycling or pressure fluctuations.
3. Determination of System Pressure and Pressure Drop
Based on the most remote gas‑demand point with the highest pressure requirement, superimpose the pipeline’s frictional and local pressure drops (it is recommended to reserve 0. 1–0.15 MPa), retroactively determine the air compressor discharge pressure. For every 0 increase in pressure, … 1 MPa Energy consumption increases by approximately 7%, necessitating a trade-off between gas supply reliability and energy efficiency.
IV. Key Criteria for Dryer Selection
The dryer’s capacity must be matched to the air compressor’s air output and meet the downstream dew point requirements (e.g., – 20℃ –40°C, etc.). When selecting equipment, the wet air volumetric flow rate must be converted to the actual operating conditions, and the effects of inlet air temperature, pressure, and ambient humidity on drying efficiency should be taken into account.
V. Key Coordination Points in Compressor Station Design
Air compressors and dryers should be matched as a complete system: the dryer’s inlet temperature should not exceed 40°C, and an aftercooler should be installed if necessary. For multiple compressor units, a common header supply is recommended, along with pressure‑band control and variable‑frequency drive (VFD) regulation, to enhance system responsiveness and energy efficiency. The air receiver tank capacity is advised to be sized for 3–5 minutes of full‑load air demand.