How to calculate the gas volume of a factory

The gas consumption calculation of a factory usually involves multiple steps and factors. The following is a general calculation method:

1. Clarify the calculation scope

• New factory: It is necessary to calculate the gas consumption of all gas-using equipment, and consider possible future expansion, leakage and changes in equipment efficiency.
• Existing Factory: The existing air compressor can be checked through actual testing to check whether the gas volume of existing air compressors is sufficient, or determined by estimating the gas volume of existing equipment.

2. Calculate the gas volume

1. New factory

For new factories, the traditional method is to add the gas volume (usually in cubic meters per minute, i.e. m³/min) of all gas equipment, and then consider adding a safety, leakage and development coefficient. This coefficient is often used to consider possible future expansions, leakages, and changes in equipment efficiency. The specific steps are as follows:

• List all gas-using equipment: including production equipment, auxiliary equipment, etc. All equipment that requires gas use.
• Find or calculate the gas consumption of each device:
  • For equipment with nameplate, the gas consumption can be calculated directly according to the gas consumption marked on the nameplate.
  • For equipment without a nameplate or without gas usage marked on the nameplate, it can be calculated by consulting the equipment technical manual, consulting the equipment supplier or using experience formulas.
• Consider safety, leakage and development coefficients: Usually, this coefficient can be set from 1.1 to 1.3, depending on the actual situation of the factory.
• Calculate the total gas volume: Add the gas volumes of all equipment and multiply them by the safety, leakage and development coefficients.

2. Existing factory

For existing factories, the gas usage can be calculated or verified by the following methods:

• Practical testing method: Measurement of gas storage tank and pipeline volume: including the volume of the gas storage tank and the volume of the pipeline between the compressor gas storage tank.
• Full-load running compressor: Ensure that the compressor is running in full load state.
• Close the air valve and reduce the pressure: Close the air valve between the gas tank and the factory air system to reduce the pressure of the gas tank to a certain level (such as 0.48MPa).
• Pump and record the time: Close the vent valve quickly and record the time it takes for the gas tank to pump the air to a set pressure (such as 0.69MPa).
• Calculate the compressor gas volume: Use the formula C=T×PAV(P2−P1)×60​, where C is the compressor gas volume (m³/min), V is the gas storage tank and pipeline volume (m³), P2 is the final pressure (MPa), P1 is the initial pressure (MPa), T is the time (seconds), and PA is the atmospheric pressure (MPa, about 0.1MPa at sea level).
• Estimation method:
  • Add gas consumption of all existing equipment.
  • Consider the gas consumption of post-treatment equipment (such as dryers, filters, etc.).
  • Think about the amount of leakage in the system, it can be determined by actual testing or empirical estimation.
  • Consider reserves to meet possible future expansion or peak gas needs.

3. Consider influencing factors

• Production technology: Different production processes may have different requirements for gases, such as high-temperature smelting, chemical reactions and other processes may require a large amount of gas.
• Equipment efficiency: The working efficiency of the equipment directly affects the gas consumption. Old and inefficient equipment often consumes higher energy, while efficient and energy-saving equipment can ensure production quality while reducing energy consumption.
• Seasons and Climate: In some industries, gas usage demand varies with seasons and climate change. For example, heating demand in winter increases, and cooling demand in summer may lead to changes in gas consumption.
• Leakage and loss: Leakage and loss in the system will lead to an increase in actual gas consumption. Equipment should be inspected and maintained regularly to reduce leakage.

4. Optimization suggestions

• Technical upgrade: Introduce advanced production technologies and equipment to improve energy utilization efficiency. For example, energy-saving equipment, heat recovery technology, etc. are used.
• Energy Management: Establish a complete energy management system to monitor and analyze gas use in real time. Through data-driven management decisions, timely discover energy waste problems and take corresponding improvement measures.
• Employee Training: Strengthen employees’ understanding of the importance of energy conservation and consumption reduction, train them to use and maintain equipment correctly, and reduce energy waste caused by improper operation.

5. Conclusion

Calculating the gas consumption of a factory is a complex process and multiple factors need to be considered. Calculation and evaluation through reasonable methods can provide a scientific basis for the gas supply and management of the factory, reduce operating costs and improve production efficiency. For large factories or complex production processes, it is recommended to consult a professional energy management expert or engineer to obtain more accurate gas usage calculation methods and suggestions.