Save a total of 1.915 million yuan in electricity bills a year 丨Tecbell helps LED optoelectronics industry
with energy-saving transformation case sharing
LED Light Pearl Light Industry Air Compressor and Vacuum Pump Case Sharing
In the manufacturing process of LED lamp beads, the compressed air power provided by the air compressor is crucial to the stable operation of the production line. It is mainly used for the normal operation of high-precision equipment such as demoulding machines, glue injection/adhesive machines, robotic arm automation, purge air, vacuum exhausters, etc., so as to realize the automation and intelligence of LED lamp bead production.
A certain optoelectronic technology company in Guangxi is a high-tech enterprise dedicated to independent research and development, packaging, sales and service of high-quality LED optoelectronic products. It has 33,000 square meters of modern industrial plant and more than 1,000 employees.
The company has a high degree of production automation. As the company's production scale continues to expand, the original air compressor equipment can no longer meet the current production gas demand.
At the beginning of 2024, the company proposed to expand the scale of production, improve production efficiency, and increase the demand for energy-saving and low-carbon production equipment.
The professional team of Tecbell has carried out precise supporting design for the company's production plant air compressor system.
The Tecbell team fully communicated with customers based on their actual needs, and used professional equipment to conduct on-site measurements and evaluations of gas consumption, gas pressure, pressure dew point, pipe network layout, and other aspects.
The specific plan is as follows:
According to the customer's expansion of production scale, increase in gas consumption and low energy consumption requirements, two 200KW Tecbell two-stage compression permanent magnet variable frequency screw air compressors were finally used, with a specific power of 4.7kW/(m³/min).
The comprehensive specific power of the air compressor after the transformation is 5.436kW/(m³/min), and the total exhaust volume reaches 228.58m³/min, which effectively improves production efficiency and reduces resource waste.
During the on-site inspection, engineers from Tecbell found that 4 of the old air compressors with a total power of 171KW had been used for a long time, were noisy, and had unstable air pressure, which resulted in high energy consumption and waste of resources.
It was learned that the customer needed to run the compressor 24 hours a day, that is, 8,000 hours a year.
After running for a period of time, the results showed that Tecbell's air compressors were stable and reliable, more efficient, and more energy-saving.
The total annual power saving was as high as 1,514,113.92 kWh, with a comprehensive electricity fee of 0.8 yuan/kWh, and an annual electricity saving of up to 1.211 million yuan.
Comparison Before and After Modification
| Comparison | Before Modification | After Modification | Remark |
|---|---|---|---|
| Number of machines (units) | 8 | 6 | After the modification, it includes 2 200KW Tecbell double-stage compression permanent magnet variable frequency screw air compressors |
| Total Power (KW) | 766 | 995 | — |
| Comprehensive specific power KW (m³/min) | 6.264 | 5.436 | — |
| Electricity saving per cubic meter of gas (KW·h/m³) | — | 0.0138 | — |
| Current production gas consumption (m³/min) | — | 228.58 | — |
| Annual electricity savings | — | 1,514,113.92 kWh | Annual operation: 8000H |
| According to electricity 0.8 yuan/KWH | — | 1,211,291 yuan | Annual electricity savings |
Equipment nameplate drawing before renovation
Energy-saving transformation plan for vacuum system equipment
There are nearly 800 rotary vane vacuum pumps in the workshop, which have many problems, such as large number, messy site, inconvenient maintenance and management, high maintenance cost, serious no-load waste, unstable vacuum degree, etc.
Finally, Tecbell uses 3 37KW and 1 75KW screw vacuum pumps to form a central vacuum system, replacing nearly 800 370W rotary vane vacuum pumps.
Compared with the old rotary vane vacuum pumps, it is easier to centrally control and manage and save energy.
The total installed capacity is about 110KW, and the comprehensive energy saving rate is as high as 35%.
Customers need to start the machine 24 hours a day, that is, 8,000 hours a year, and the comprehensive electricity fee is 0.8 yuan/kWh, saving a total of 704,000 yuan in electricity bills per year.
The company has achieved remarkable energy-saving effects after upgrading and using Tecbell's new equipment.
The permanent magnet frequency conversion screw air compressor saves 1.211 million yuan in electricity bills annually, and the vacuum pumps save 704,000 yuan in electricity bills annually. The total annual electricity cost savings is as high as: 1.915 Million Yuan
Later, due to production needs, a 2-step hydrogenation purification nitrogen production system with a purity of 99.999% was added.
Hydrogen-nitrogen mixed gas is mainly used in wire welding and chip bonding processes. Nitrogen is used to protect the welding process from oxidation, blackening, and cold welding. The equipment can purify nitrogen to 99.9995% and set the residual hydrogen to 0.5–5%. Nitrogen is used as an anti-oxidation gas and hydrogen is used as a metal protection gas in the welding process to ensure that the metal properties do not change after high temperature.
High-performance heavy-duty inverter
High-performance heavy-duty inverter, vector control technology, frequency conversion start, constant pressure air supply, reduce energy consumption by 30%~50%.
High-efficiency motor
Motor efficiency is as high as 97.4%, exceeding the first-level energy efficiency standard.
38UH permanent magnet 180°C does not demagnetize, SKF bearings, IP55, increased base size, F-level insulation level, B-level temperature rise design.
High-efficiency energy-saving host
"Tecbell" independently developed and designed high-efficiency energy-saving host, near-isothermal compression, full series of first-level energy efficiency, oil injection in the direction of the screw tooth groove, reduce resistance, and improve compression efficiency.
Intelligent control system
Full-color touch screen, rich control function interface, dynamic display of the operating status of the air compressor, real-time intuitive display of pressure, temperature, parameters and current working curve.
After the optoelectronic technology company confirmed the plan and signed the contract, we delivered it to the door for installation as soon as possible. Now the machine is in normal operation, with stable operation, low noise, significant energy saving and consumption reduction, intelligent operation of the machine, simple operation, and visualization of operating data, etc. Many advantages have been highly recognized and praised by customers.
