First-Class Energy Efficiency Air Compressor Station Put into Operation for Wind Power Casting in Xuzhou

Background: Wind power casting is featured by fluctuating working conditions, and air consumption varies greatly in grinding, sand blasting and molding processes. The original old air compressor group had low energy efficiency with unstable pipeline pressure. Frequent startup and shutdown caused equipment wear, failing to meet the energy consumption assessment requirements of green factories. Solution: A customized air compression system renovation solution from Atlas Copco was adopted, equipped with first-class energy efficiency variable frequency screw units and an intelligent centralized control system to match the intermittent high air flow demand of the casting workshop. The pipeline layout was optimized to reduce pressure drop, and a waste heat recovery module was added. Waste heat from air compressors was used for workshop heating. The whole system complies with the standard of GB/T 45785-2025 for first-class energy efficiency air compressor stations. Result: This project built the first first-class energy efficiency air compressor station in Xuzhou’s wind power industry. The comprehensive energy consumption of the system decreased by 18%, and pipeline pressure fluctuation was controlled within ±0.02MPa. The frequency of equipment startup and shutdown was reduced, and maintenance workload was cut by 30%. It serves as a model for energy-saving renovation of air compressor stations in heavy equipment casting industry.