Analysis of the Innovation Preset of the Latest Compressor Tanning System
1 analysis of the current status of air compressor operation
CHMVC Power Class has 4 air compressors, 3 Japanese-made centrifugal and 1 domestic piston. The performance parameters are shown in the table below.
The number of air compressors running is determined by the air load of the production plant.
Normally, the gas load is about 130 m3/min on the company's working day. Therefore, the operation mode of the air compressor is a large (95 m3/min) and a small (40 m 3 / min) combined gas supply; When the company worked overtime on public holidays and the gas load was only about 40 m 3 / min, it was obviously uneconomical to open a 95 m 3 / min air compressor, causing unnecessary waste.
2 1 Problems in the operation of the air compressor
Through the analysis of the operating conditions of the air compressor, it is not difficult to see that: 1 The air compressor has a large energy-saving advantage in the case of a small air load (40 m 3 / min).
1 The load adjustment device of the air compressor is mechanically adjusted as shown. It adjusts the preload of the adjusting spring and introduces the system air pressure according to the system load condition to control the opening and closing of the intake valves of the 1st and 2nd cylinders respectively, so as to achieve the purpose of automatic load adjustment.
The mechanical adjustment device has the advantages of simple structure and low cost.
However, the common problem is that the housing of the regulating valve, the adjusting spring, the valve core, etc. are prone to rust, resulting in the valve not operating or malfunctioning, and the adjustment precision error is too large. Therefore, when the air compressor is operated in parallel with the Japanese-made TA-E air compressor, the load adjustment is performed only by the self-unloading device of the TA-E air compressor, and the air compressor is always operated at full load (due to the above) The reason is that the automatic adjustment of the load cannot be performed).
3 1 Reconstruction of air compressor load adjustment device
In response to the problems with the air compressor, we decided to replace the existing mechanical adjustment with a more reliable electrical adjustment.
The core of the electric adjustment device is: solenoid valve and pressure switch. As shown, by adjusting the setting of the highest (low) pressure of the pressure switch (power supply support), the pressure switch determines the pressure of the system (using the air load), outputs (or interrupts) the electrical signal, and then commands the solenoid valve to be turned on ( Or disconnect) control the air path of compressed air to achieve automatic adjustment of the air compressor load.
In actual operation, it was found that the air sucked by the air compressor, although filtered, still contains a small amount of impurities. After a period of operation of the air compressor, due to the flushing of the exhaust gas flow and the wear of impurities on the exhaust valve plate, the airtightness of the exhaust valve is reduced, and the high pressure gas discharged after the compression is returned to the intercooler. The residual pressure remaining in the intercooler will cause the intercooler safety valve to start. In response to this phenomenon, we have installed a safety device on the basis of electrical regulation, that is, adding a time relay and evacuating the solenoid valve to make the first-stage cylinder within a few seconds after the load adjustment (self-setting), conducting The solenoid valve switch allows the intercooler to quickly release pressure and ensure the normal operation of the intercooler and safety valve.
The modified air compressor load adjustment device was put into operation after commissioning and achieved the expected results. When the system pressure reaches the preset pressure, the adjustment device immediately adjusts the load of the air compressor, and the movement is accurate.
4 performance comparison before and after the control system transformation
1 After the air compressor is modified, it can independently supply air to the system or be used in parallel with other types of air compressors. The control system operates accurately.
According to statistics, when the gas load is about 40 m3 / min, a TA-E air compressor is started, and the average daily power consumption is 8 500 kW h; while with 1 air compressor, the average daily power consumption is less than 6 000 kW. h, daily average power saving 1 500 kW h.
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