Foundry industrial compressed air system, energy saving potential test analysis and optimization case Qin Hongbo 2 Wang Guoxing 21. Shanghai University of Technology 2. Shanghai Energy Conservation Service Center with the actual situation of the original system, the application of optimized piping system and stable system pressure to improve the entire compressed air system The efficiency has a typical role.
Compressed air has been widely used in various industrial fields because it is clear, transparent, harmless, non-polluting, and dangerous. It is even called energy source. However, compressed air is also a very expensive energy source, especially because of high operating costs. The whole life cycle analysis theory, the purchase cost of the compressor only accounts for about 10 of the life cycle cost, while the energy cost accounts for about 75. The data is clearly modified through energy conservation, such as the application of pipe network optimization technology, frequency conversion technology, pressure control technology and central control technology. Etc. Many compressed air systems can achieve the above energy saving effects. Of course, each compressed air system is different, and the applicable energy-saving technologies are also different. The motor system energy-saving project is responsible for cooperating with experts of the United Nations Industrial Development Organization to conduct energy-saving assessment and enterprise case development of compressed air systems.
The application of technology should be based on a comprehensive analysis of the dynamic characteristics of the system. 3 Blind implementation of the unsuitable energy-saving technology is difficult to achieve the expected energy-saving effect. The energy-saving retrofit project of the air compressor system of the foundry branch of Shanghai Kasby Pump Co., Ltd. introduced in this paper, through comprehensive testing and analysis, put forward practical solutions, and achieved the expected energy-saving effect after implementation.
1Compressed Air System Overview Shanghai Kasby Pump Co., Ltd. is a casting plant compressed air system consisting of a 2, Ingersoll Rand screw air compressor and 3 10, 3, 1 piston air compressors. Its unit configuration such as compressed air system 1.
Manufacturer Ingersoll-Rand Zhejiang Yuyao General-purpose machine type screw type control mode Constant pressure download number of rated flow 14 maximum working pressure, casting plant compressed air is mainly used for casting sanding and other processes, due to low air quality requirements There is no air aftertreatment system in the air compressor station. The air goes directly from the air compressor outlet to the gas storage tank, and then arrives at the workshop through the main pipe. The workshop only performs simple degreasing treatment on some processes with slightly higher gas quality. Under normal circumstances, the system runs three air compressors, one 200 and two piston machines in the morning, and the piston air compressor is turned off in the afternoon and evening.
2 System Test and Analysis 2.1 System Test In the system operation law and process requirements, fully understand the sensor accuracy pressure sensor and power quality analyzer for the compressed air system manifold flow manifold pressure air compressor outlet pressure and air compressor power Weekly test, in order to objectively reflect the dynamic changes of the system, the sampling interval is set to 53, the field manifold flow and pressure test installation.
2.2 Test results Analysis System efficiency has a very large lifting space. Through the analysis of system flow pressure and air compressor power curve 3, it is found that when 200 air compressor and piston air compressor run simultaneously to supply air to the system, 200 air pressure The machine is often in an inefficient state of operation, and the piston air compressor is sometimes downloaded very frequently. Since the flow pressure change of the compressed air system is a dynamic process, the working state of the air compressor not only has its own inefficient work, but also causes the system pressure to fluctuate drastically, which not only leads to a decrease in system efficiency, but also sometimes affects the work. The connecting pipe diameter of the pipe is 1 and the capacity is 20, and the pipe diameter of the connecting pipe of the air compressor and the main pipe is only 5. According to the test of the outlet pressure of the air compressor and the pressure of the system main pipe, the pressure drop of the pipe is The energy consumption of the compressed air system at 4 PCT is proportional to the supply pressure of the system. The higher the system air supply pressure, the greater the energy consumption of the air compressor. The energy consumption of the compressed air supply increases by about 78. The minimum pressure fluctuation of the compressed air system must meet the most demanding pressure requirements of the system, that is, the minimum value of the system pressure fluctuation is higher than the maximum value of the process demand pressure.
From the perspective of energy saving and system reliability, the more stable the system pressure, the higher the system reliability and the lower the system energy consumption. The greater the range of system pressure fluctuations, the higher the average supply pressure of the system and the higher the energy consumption of the system. 4 is the curve of system pressure with time. It can be seen that the lowest pressure in the system is only 4. The highest pressure is 6.7, and the pressure fluctuation range is up to 2.6. This indicates that the system meets the requirements of the process. There is a large energy saving space, and it also shows that the system supply pressure has a certain downward adjustment space under the premise of meeting all the casting process requirements.
System leakage test Through the test of system flow 5, it is found that when the zero-point workshop production stops, the system flow rate is still about 7, and it is relatively stable, and this part of the flow is basically caused by system leakage.
Partial pipeline resistance loss is too large According to the pipeline configuration of the air compressor station, the piston machine and the total 3 system optimization measures are exported to the system manifold 50, the pipeline, eliminating unnecessary resistance loss, so that the air compressor power consumption can be reduced. At the same time, remove the one-way control valve on the pipe outside the outlet of the air compressor.
Tested and repaired for obvious leaks.
3.3 Installation pressure flow control system According to the characteristics of large system pressure fluctuation, install the pressure flow control system in the system main pipe, stabilize the system supply pressure, set the outlet pressure of the voltage stabilization system to 45, and use the air compressor exhaust pressure and stability. The pressure difference of the manifold after the pressure system stores the constant gas volume.
3.4 Changing the air compressor control mode The constant pressure control mode of the 200 air compressor is converted into the loading and unloading control mode to improve the operating efficiency.
4 Energy-saving effect Through the implementation of the project, the system lOmVmiI1 piston machine stopped running, and the power saving rate reached 15.84 through comparison test.
4.2 Other aspects of energy-saving effect Stable system supply pressure through the project implementation, the system supply pressure is basically stable at 0.45 cubits; not only reduces the system air consumption, but also the stable system supply pressure is conducive to process production.
Improved system reliability In the original system, only the lOmVmin piston machine was in the standby state when the production peak was reached. The number of standby machines was doubled and the production reliability was improved. In addition, through the pressure flow control system, the pressure difference between the gas storage tank and the system main pipe can be used to store the compressed air. When the machine is improperly shut down, the system pressure drop time is prolonged, which increases the reaction time of the operator.
5 Conclusion The dynamics of the compressed air system are different, and the comprehensive diagnosis of the compressed air system is the basis for the correct evaluation of the energy-saving space of the compressed air system.
The energy-saving measures of the compressed air system should be formulated according to the specific conditions of the system. Not every energy-saving measure is applicable in any system.
The system optimization plan should not only consider the high efficiency of the current system, but also consider the future development of the system, and the system efficiency is still efficient.
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