The design load of the condensation recovery device is determined according to the most unfavorable working conditions, but in actual operation, the feed concentration and air volume change every day with the production rhythm: the load rises when the output climbs, and the load falls again when the output is reduced. The device runs hard according to the fixed mode, the load is high, the yield is high, the emission risk is high, and the load is low, the cold quantity is white. What the load adjustment needs to solve is to let the output of the device follow the actual working conditions-neither the yield nor the energy consumption will suffer losses. The adjustment is based on data, not feeling. There is also a benefit to doing a good adjustment-the equipment is not hard-supported under extreme conditions, and the life and failure rate are improved accordingly.
There are leading indicators for load change: inlet temperature and concentration-the feeding change of evaporation process is reflected on the inlet parameters within a few minutes; Pressure difference in condensation section-when the load rises, the air speed rises and the pressure difference rises first. Condensate volume-hourly condensate volume is compared with the design value, and the deviation range is the intuitive scale of load deviation. By making these three parameters into an operation kanban, the change trend of the load can be seen on one screen, the adjustment changes from passive response to advance prediction, and the trend is made clear during the shift change, thus the operation has continuity. The data of Kanban is pushed to the management side synchronously, and the corresponding relationship between output and energy consumption is clear at a glance.
The means of adjustment are arranged according to the response speed: air volume adjustment-the variable frequency fan adjusts the rotation speed according to the inlet concentration, the load is small and the air volume is small, and the cooling consumption decreases synchronously; Cold capacity adjustment-the refrigeration unit is loaded and unloaded or the number of units is controlled, and operates according to the outlet temperature target; Bypass regulation-when the load is extremely low, part of the air flow bypasses to maintain the main flow rate to avoid deviation. The three methods are used in combination: the air volume is adjusted with the feed, the cooling capacity is adjusted with the air volume, and the bypass is used as the bottom of extreme working conditions. The target value of adjustment is set according to the export concentration, the yield standard is the bottom line, the energy consumption optimization is done above the bottom line, and the sequence relationship between the two layers cannot be reversed.
| Segment | Basis for judgment | Adjustment arrangements |
|---|---|---|
| load judgment | Inlet parameter Pressure difference Condensate volume | Kanban pre-judgment in advance |
| Airflow adjustment | Inlet concentration change | Variable frequency fan speed regulation |
| Cooling capacity regulation | Outlet temperature target | Unit loading and unloading |
| bypass regulation | Very low load condition | Maintaining main flow rate |
| Energy saving period | Night and overhaul trough | Load reduction on-demand start-stop |
| Seasonal correction | Cooling water temperature difference | Two sets of target values in winter and summer |
The energy-saving space is the largest during the low load trough period: the low load at night and during the maintenance period, the refrigeration unit is operated under load reduction, and the water pump is started and stopped as required; The condensing temperature is corrected according to the season-the cooling water temperature is low in winter, the power consumption of the unit is lower under the same cold output, and the operation target value is set at two sets according to the season. The start-stop frequency of frequency conversion equipment is also included in the management, the loss of frequent start-stop is higher than the inefficient operation, the adjustment of the amplitude and frequency to leave a buffer zone. The data are rewritten on a monthly basis: the energy consumption curve per unit of recovery, the monthly backtracking working condition records with abnormal fluctuations, and finding out the reasons and determining the countermeasures, so that the energy-saving account can be counted as real. Adjust the record and the data curve to keep the file, and then take over the person according to the record, less detours.
The system with complete parameters has fast response and is not easy to miss judgment. Automatic is the first choice. The transition period before the automation transformation is manual, but the adjustment basis should be written as a card and pasted on the operation position. No one can tell the reason for the fluctuation of the hand feeling adjustment.
Proper adjustment does not affect: the outlet concentration is the target constraint of adjustment, and energy saving is only when the yield reaches the standard. At the initial stage of operation, the outlet concentration of each load gear will be measured again, and the target value will be calibrated according to the measured value, so the adjustment will be accurate.
The adjustment space of the device with full load all the year round is small, but the load change of the seasonal correction and maintenance window is still there. At least the seasonal target value and the start-stop sequence are solidified, which is more reasonable than a set of parameters all year round.
This article by LuoyangWohong PetrochemicalEquipment Co., Ltd. arranges that the company provides design, manufacturing and operation and maintenance services for condensation recovery, membrane separation recovery and complete solvent recovery devices for chemical and pharmaceutical enterprises. If you need process evaluation or scheme configuration, please contact and exchange.
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