First, the entire plant's energy-saving control technology
1 Monitor the maximum power consumption and power factor of the feed mill and make reasonable adjustments.
2 Reasonably regulate the opening of equipment, especially to open only necessary equipment to reduce the maximum power consumption of the factory and reduce the demand.
3 Use low electricity price period to organize production and reduce production costs.
4 Scientifically arrange the production plan so that the batch production volume of each product can reach the minimum economic production scale, reduce the downtime and no-load time caused by frequent replacement of varieties, and improve energy utilization efficiency. Make coordination between different shifts. Usually, the product order should have an advance time, and the finished product warehouse should have the best finished product reserve. The specific production plan of the workshop is arranged by the workshop director who is familiar with the production operation of the workshop, and is coordinated with the sales department.
Second, the energy-saving technology of boilers and steam systems
1 In order to achieve the most efficient operation with the lowest energy consumption, the boiler and steam system must be in optimal operating conditions. This includes the following aspects:
(1) Correctly soften and chemically treat water to prevent scaling and corrosion on the water side of the boiler.
(2) The correct chemical treatment is used to control the pH of the total soluble solids and water in the steam.
(3) Use the correct sewage program to remove solids and impurities from the boiler water surface and the bottom of the boiler. Avoid excessive sewage.
2 Correctly adjust the burner and air-fuel ratio to achieve clean combustion.
3 Return all unused steam and condense it into boiler make-up water.
4 pairs of boiler installation automatic control system, including shutdown or low fire position control when no steam is needed.
5 Maintain adequate ventilation in the building walls to allow proper replenishment of the combustion air at the lowest pressure.
6 The following measures should be taken to minimize the amount or loss of energy in the production steam:
(1) Do not work at a pressure higher than the pressure required for the machining operations being serviced.
(2) Turn off the system when steam is not needed.
(3) Check whether the boiler water is properly chemically treated as usual and adjust if necessary.
(4) Automatically discharge the system, but do not do excessive sewage operations.
7 Check regularly if the burner is at maximum efficiency. Make sure that the combustion air used is clean and unrestricted.
Check that the fuel system is operating properly, including pressure, flow, temperature, and mechanical operation.
8 Regularly check for steam leaks, whether the steam separator is working properly, and whether the valve is faulty. There are automatic separators available on the market for purchase. Use an infrared heat gun to detect areas with excessive heat build-up, showing a failed steam separator or leak.
9 Return all unused clean condensate to the boiler.
10 If used to maintain the temperature of the liquid component or to track the heating line, use only as needed, do not overheat the liquid or system.
11 For space heaters, only heat the required area and keep the working area temperature at the minimum required. Other heat sources such as infrared heat may work better. Turn off the heat source when not in use.
12 Install an economizer on the boiler to collect the lost heat of combustion to heat the boiler make-up water.
Third, compressed air system
More than 70% of the cost of compressed air is the cost of electricity. A functioning system is important, and improvements in the efficiency of the system have a significant impact on reducing operating costs.
1 The most common cause of excessive power usage in a compressed air system is to operate above the required pressure, and the location of the air leak and air inlet is incorrect.
For example, a leak of 3.175 mm in diameter will leak 251,454 m3 of air a year at a working pressure of 0.7 MPa. This is equivalent to consuming about 24,000 kWh of electricity. At a cost of 0.6 yuan / kWh, the annual loss will be 14,400 yuan.
2 Some rules of thumb for air compressors are:
(1) Most air compressors have an exhaust capacity per kW of 0.147-0.187 m3/min at an exhaust pressure of 0.7 MPa.
(2) An increase or decrease in pressure of 0.014 MPa will affect compressor energy utilization by 1%.
(3) Every 10 °C change in inlet air temperature will affect compressor efficiency by 1%.
(4) The pressure drop across all parts of the system and the pump should not exceed 0.1 MPa.
(5) The following measures should be taken to minimize the energy consumption or loss in the compressed air system:
(6) Do not operate the system above the pressure required.
(7) Use the correct size of the cylinder, vibrator and other operating parts.
(8) Turn off all equipment regularly to detect air loss.
(9) Set the time period for the packaged room to be inflated, and only work when needed, not too often.
(10) It is necessary to know that an excessively high air compressor operating frequency indicates excessive use or loss of air.
(11) Regularly drain the gas storage tank and riser to eliminate water accumulation.
(12) Keep the inlet air clean and filtered.
(13) Find the source of air from the nearest location.
Fourth, the energy-saving technology in the power transmission of feed mills
One of the areas often overlooked in terms of energy savings is the transmission of power through bearings, reducers, drive belts or chains and sprocket drives.
The following measures should be taken to minimize the energy consumption or loss in the power transmission system:
1 Use the right amount of oil or lubricant on the transmission and bearings.
2 Maintain the proper tension of the V-belt, replace the worn belt and use a pulley that matches the belt.
3 Use a toothed belt drive to eliminate stall caused by slip.
4 Keep the drive chain tensioned and there is no vibration of the transmission equipment caused by chain slack.
5 Lubricate the chain to keep it flexible. Use an internal lubrication chain to avoid oil baths.
6 Lubricate the bearings with the right amount and type of lubricant to maintain good environmental and working conditions.
7 Keep the transmission clean and free of dirt and waste buildup to avoid local overheating. Allow free flow of air around the gear reducer.
8 When the equipment must be operated at more than one speed, an AC variable frequency drive is used instead of a mechanical and adjustable belt drive.
9 Raw materials, processed components and finished products are treated several times in feed processing. The type, specification and throughput of the equipment used to move these materials also have an impact on energy consumption. 5. Raw material receiving? A variable speed transmission is installed on the feed conveyor of the feed pit to feed the bucket elevator at maximum load when conveying feed materials of different densities.
10 Operate the receiving system equipment only when the material is actually unloaded or when the material is being transported.
11 Run the system only when using a dust control system.
12 Install a baffle above the grid in the conveying direction to reduce the open area around the grid and reduce the amount of air required by the dust control system on the pit.
13 Wherever possible, replace the conveyor with a self-flowing tube with a self-cleaning buffer tank.
14 For extra long conveyors, such as the feed conveyor at the top of the silo, it should be divided into two separate transmissions, so that when loading the silo inlet close to the first conveyor You don't have to start the entire long equipment.
15 Use or avoid using pneumatic conveying systems as little as possible.
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