1 ç‹ Safe production to achieve energy saving and efficiency enhancement of air separation equipment
Safety is the eternal theme of the company, and production must be safe. Safety is the biggest benefit, accidents are the biggest waste, and there is nothing without safety. Therefore, ensuring the safe operation of the air separation unit is the energy saving effect of the air separation unit.
1.1 Strict management, establish sound rules and regulations, and strictly enforce
1.1.1 Establishment and improvement of the management system
As a relatively independent production device, small and medium-sized air separation equipment must establish various rules and regulations. It is important to establish a post responsibility system, post security responsibility system; inspection and maintenance operation procedures; production (process) operation procedures; equipment maintenance management system; safety production management system; employee induction training system; Circulation inspection system; Labor discipline management system; Inspection (dimensional) repair safety management system; Staff award and punishment assessment system and equipment inspection (dimensional) repair, fire, ground, send (stop) electricity and other work ticket system. The petrochemical industry will focus on implementing the “four-quantity†patrol inspection system to ensure the safe operation of the installation. "Four All" means "all staff, whole process, all-round, all-weather". The so-called "all staff", including workshop leaders, technicians, team leaders, operators and other workshop staff. “The whole process†means that the entire process of production must be inspected. As long as the device is running, the on-site inspection is uninterrupted to ensure the continuity of the inspection. “All-round†means every device, every part of the device. “All weather†means that under any climatic conditions, no matter whether it is windy or rainy, cold or hot, you must ensure that there is someone on the site.
1.1.2 Grasping the implementation and implementation of various systems
The establishment of the system, in the form of words, regulates the work behavior of various types of personnel and makes them public. The key lies in how the various management personnel and operation (overhaul) personnel can strictly enforce the actual work, and the operation according to the chapter does not violate the rules. This requires the managers of the units where the small and medium-sized air separation equipment is located to make a spur effort, continue to publicize and educate, constantly check and supervise, constantly rigorously assess and manage, so that various rules and regulations are deeply rooted in the hearts of the people, and all kinds of employees are obtained. Understand recognition, and consciously perform according to chapters in their respective jobs.
1.2 Focus on preventing explosion of air separation equipment
1.2.1 Raw material air quality must meet the requirements
The distance between the air inlet of the air separation equipment and the source of harmful impurities such as acetylene and hydrocarbons shall be comprehensively considered according to the environmental quality and the self-cleaning ability of the air separation unit.
1.2.2 Strengthen the removal of harmful impurities in the processing air
In view of the fact that the molecular sieve process removes H 2 O, CO 2, C 2 H 2 and others much better than the switching process, the original switching process should gradually reform the component sieve process to ensure effective removal of harmful impurities in the air. In order to ensure the normal and efficient work of the molecular sieve, the following steps must be taken: 1 Ensure that the quality (strength, particle size, adsorption performance and service life) of the molecular sieve activated alumina is good. 2 In view of the characteristics of increased air temperature and reduced molecular sieve adsorption performance, the air temperature entering the purifier should be as low as possible. This not only improves the ability of the molecular sieve to adsorb impurities; moreover, the temperature of the air is lowered, and the load of adsorbing moisture by the molecular sieve (or activated alumina) is lowered.
3 does not run over the cycle. The purifier operates according to the specified duty cycle and must not be extended for working hours. In particular, when other devices within 200 m of the oxygen plant (station) discharge harmful oxygen gases such as C 2 H 2 , CmHn, CO 2 , etc., the content of the above-mentioned harmful impurities in the purified air should be closely monitored. Once the content of impurities such as CO 2 is increased, the molecular sieve operation cycle should be shortened, and harmful impurities should be rejected outside the air separation tower. 4 Thoroughly regenerate the molecular sieve according to the operating procedures.
1.2.3 Strengthening the detection of carbon dioxide, acetylene and other hydrocarbons
Equipped with an effective measuring instrument to detect the content of carbon dioxide, acetylene and other hydrocarbons at any time. 1 equipped with an on-line detector at the air outlet of the molecular sieve adsorber. When CO 2 ≥ 2 × 10 - 6, the molecular sieve must be switched immediately to ensure that the process air does not contain more carbon dioxide, acetylene and other hydrocarbons. 2 Improve detection methods, use both on-line monitoring and regular inspection. Quality and reliable on-line instrumentation should be configured as much as possible to detect acetylene and other hydrocarbons in liquid oxygen at any time in order to detect problems in time. At the same time, do offline testing at least once a day. When the amount of acetylene and total carbon reaches the alarm value, various measures including increasing the amount of oxygen discharged should be taken in time to dilute their concentrations in liquid oxygen.
1.2.4 Set up a reliable and reliable lightning protection and anti-static grounding device
The most fundamental measure to avoid or reduce the high potential electrostatic voltage in liquid oxygen is to ensure the molecular sieve adsorption effect and prevent the molecular sieve powder from entering the tower. The fundamental measure to avoid or reduce the static electricity generated by the air separation unit is to set up a complete and reliable lightning protection and anti-static device inside and outside the device. The grounding resistance is ≤10Ω and is tested at least once a year.
2 Improve the operation method to achieve energy saving and efficiency improvement of air separation equipment
2.1 Shorten the start time of air separation equipment
The startup process of an air separation plant is an inefficient energy process with only energy input and no product output. The shorter the process, the less energy inefficient and the higher the economic efficiency. Therefore, reducing the startup time has a great relationship with the energy saving of air separation equipment. The specific operation points are as follows: (1) In the initial stage of startup, solve the problem of moisture clogging equipment in the air. 1 The large heating before warming up (heating and purging) must be thorough, and the result of large heating will directly affect whether the booting is smooth. Heating must ensure that the units are dry, the valves are unobstructed, and there is no moisture at the outlet. 2 Grasp the dehydration of the air compressor unit and the dehydration work of the pre-cooling unit is normal, and ensure that the purifier works, so that the carbon dioxide content in the processing air does not exceed the standard.
(2) Take advantage of the opportunity to fly through the carbon dioxide freezing zone to ensure the normal operation of the turboexpander. Control the speed of the expander.
(3) Give full play to the maximum cooling capacity of the expander (piston or turbine). Two turbines are opened, and the piston cam is controlled at the maximum intake position to ensure the maximum intake air volume and increase the pressure difference as much as possible.
(4) Operate the valve in time and accurately, and adjust the switch in time.
Note: When the main cold effusion is used, it is necessary to correctly understand the reason for the slow rise of the liquid level. The slow rise indicates that the cooling capacity generated by the expander has been transferred to the tray, and the rectification conditions have been slowly established. The main cold start work should be adjusted in time to accumulate liquid.
2.2 Lower the tower pressure on the fractionation tower
According to the principle of air separation rectification, the change of the pressure in the upper tower causes the temperature difference between the liquid oxygen in the main condensing evaporator and the nitrogen in the lower tower side; when the upper tower pressure is high, the vaporization temperature of the liquid oxygen is also high, so that the pressure in the lower tower is not In the case of change, the temperature difference between the oxygen and nitrogen in the main cold is inevitably reduced, the heat exchange amount is reduced, and the reflux of the lower tower is reduced, which inevitably causes the pressure of the lower tower to increase, so that the temperature of the nitrogen gas is also increased, thereby satisfying the main cold heat exchange. The requirement for temperature difference. As the pressure of the lower tower increases, the back pressure of the air compressor will inevitably increase, which increases the power of the air compressor shaft and increases the power consumption. Therefore, when adjusting the rectification conditions, it is necessary to minimize the pressure on the upper tower. After the pressure is reduced, not only can the air compressor outlet pressure (ie, system pressure) be reduced, but also the rectification condition of the upper tower is optimized, which is beneficial to the separation between oxygen and argon, argon and nitrogen.
2.3 Improved Purifier Regeneration Process 2.3.1 Purifier Regeneration Gas Source Heating to Air
In petrochemical and other enterprises, the production of nitrogen is the main. Enterprises that have mostly vented oxygen and have a compressed air system can use the compressed air instead of nitrogen to regenerate the purifier in the case of tight nitrogen demand, which not only increases nitrogen production, but also ensures safe production of nitrogen plants; At the same time, it saves resources costs. Taking the HZK-960/40 purifier as an example, the annual cost savings are: 250 × 3 × 3 × 300 × (2 - 012) = 1215,000 yuan = 119.15 million yuan (regeneration yield 250m 3 / h; 3 hours a day, one day Warming 3 times, 300 days in a year, the unit price of nitrogen is 2 yuan / m 3 , and the unit price of compressed air is 012 yuan / m 3).
21312 When the purifier is cooled, the nitrogen bypass purifier is regenerated and heated. When the air is blown, the nitrogen gas passes through the hot heating furnace, so that a large part of the cooling capacity is consumed on the furnace body of the heating furnace, which requires more nitrogen consumption and more Power consumption. Before the heating furnace, a shut-off valve is installed to separate the cold nitrogen gas, and then a pipeline is added with a bypass valve, so that the cold nitrogen gas bypasses the heating furnace and directly enters the purifier to achieve rapid cooling. the goal of. Since the simple cooling is greatly shortened, at the same time, the heating furnace only heats and does not perform forced cooling, thereby avoiding frequent overcooling and overheating, thereby prolonging the life of the heating furnace. In addition, since the heating furnace does not perform forced cooling, its heat preservation performance is also good. The next time the temperature is raised, the temperature rises faster, which increases the speed of heating the regenerative purifier, shortens the regeneration time of the purifier, and saves electricity to some extent.
2.4 Reduce the loss of air separation equipment
The cold loss of air separation equipment is mainly manifested in four aspects: insufficient reheating (ie, incomplete heat exchange) loss (Q 2), run cold loss (Q 3), liquid product takeout loss (Q 0), tower Leakage loss (Q 1).
Therefore, the total cooling loss of the air separation plant is Q total = Q 0 + Q 1 + Q 2 + Q 3 . According to the principle of energy conservation, under steady conditions, the cooling capacity of the air separation plant should be balanced with the total cooling loss of the device. The cooling capacity of the air separation plant is composed of the isothermal throttling effect ΔH T of the compressed air and the cooling capacity Q e of the expander without the external cooling source.
Therefore: ΔH T + Q e = Q 0 + Q 1 + Q 2 + Q 3 .
It can be seen from the above formula that reducing the cooling loss can reduce the cooling capacity, thereby improving the economics of the operation of the air separation system. Due to various objective conditions, cold damage cannot be completely eliminated, but certain measures can be taken to reduce it.
2.4.1 Control of insufficient heat loss after reheating
The hot end temperature difference is the difference between the positive air inlet temperature and the arithmetic mean of the temperature of each stream. The greater the difference in temperature at the hot end, the greater the cold loss. Therefore, the temperature difference at the hot end should be reduced as much as possible. The design temperature difference of the hot end of small and medium-sized air separation equipment is 5~7 °C. 1 Several reasons for the expansion of the temperature difference at the hot end: Excessive expansion; The heat exchanger surface is weakened by carbon dioxide, moisture and grease; the product oxygen, nitrogen and distillate are not properly distributed; ; The temperature difference band is shortened. 2 Measures taken: Correctly control the amount of expansion; Strengthen the dehydration of the air compressor unit, and the purifier works normally. At the end of the production cycle, the heating is blown off. If the oil accumulates too much in the heat exchanger, it is degreased with carbon tetrachloride after heating; adjust the opening of the oxygen, nitrogen and distillate gas out of the valve in time; check and adjust the cooling water of the air compressor and purifier (Pressure, temperature) to ensure the cooling effect, the pre-cooling unit maintains normal operation.
2.4.2 Measures to reduce the loss of running cold
In small and medium-sized air separation equipment, the running cold loss accounts for about half of the total cold loss. Measures should be taken to reduce the loss of running cold. 1 Ensure that the cold box casing is tightly sealed. Before filling the pearl sand, it is necessary to check whether the sealing rubber insert at each joint of the box is intact and the screws are tight. 2 Before filling the pearl sand, whether the moisture on the surface of the cold box equipment and the cold box base is removed; it can be dried by dry air. 3 The quality of the filled pearl sand should be good, the water content should meet the requirements, and it should not be filled in the weather with humidity greater than 80%. 4 Filling pearl sand must be dense. The dead corners of the cold box must be insulated. When filling, the wooden hammer can be used to continuously vibrate on the casing of the box. 5 Regularly check the cold sand of the cold box and find that the sinking is timely and replenished. 6 In the operation of the fractionation tower, it is found that the cold box shell is frosted or “sweatingâ€. It may be that the tower leaks or the pearl sand is damp and should be treated in time.
2.5 Optimize operation, increase product output
The economics of air separation equipment operation has a great relationship with the operation. As long as it is continually explored and boldly practiced, any set of air separation equipment may summarize an optimized operation method and increase the output of the equipment to realize the air separation equipment. Energy efficiency.
"Cryogenic Technology" published in the 6th issue of 1989, "The operation of '150' oxygen generator to produce single high nitrogen" and the "150m 3 / h oxygen generator with argon column production 'three high' published in the fourth issue of 1997 The operation of the product "The contents of the two articles are all the experience that the author has explored in the operation of these two sets of air separation equipment.
In June 1998, our company's KDON2250/ 1500 type equipment (manufactured by Kaifeng Air Separation Group Co., Ltd.) was officially put into operation, at that time, in order to meet the production of nitrogen of 70,000 tons/year polypropylene plant and 10 sets of oil refining equipment, with the original workshop The KZON2150/ 60023 air separation unit operates simultaneously. Later, after nearly half a year of exploration, we made full use of the existing capacity of air compressors and expanders of KDON2250/ 1500 air separation equipment, improved the operation method, adjusted the inlet and outlet valves of the expander, the throttle valves of the fractionation tower, and the regulating valves. Waiting for the opening. Under the premise of ensuring the nitrogen quality (oxygen content ≤ 10 × 10 - 6), the nitrogen production is increased, and the nitrogen production is increased from 1500 m 3 / h to 1800 m 3 / h, and the cycle is operated for a long period of time. In this way, only one set of air separation unit can meet the needs of refining and chemical production, and the KZON2150/60023 oxygen generator is used as a backup. It is estimated that the annual consumption of water, electricity, spare parts and materials will be reduced by more than RMB 3 million, and the workshop operators will be reduced, reducing labor costs. Practice has proved that optimization operations can increase product yield and achieve energy efficiency.
2.6 Extend the operation cycle of air separation equipment
The long running cycle of the air separation plant can reduce the number of opening and stopping times and the number of heating and blowing times, which reduces the time for the invalid operation of the air separation equipment. It saves electricity, steam, cooling water and lubricating oil, saves manpower, reduces labor intensity, reduces equipment wear, and ultimately improves the economics of air separation equipment operation. The main measures to extend the operation cycle of air separation equipment are: (1) Strengthening technological transformation and actively adopting new technologies, new processes and new materials. For example, process pipeline modification, container replacement, various valve replacements are new switching butterfly valves, and 13X molecular sieves are used.
(2) Strictly control the quality of equipment maintenance to ensure the normal operation of the equipment. The focus is on the pre-cooling unit and the fractionation tower. If the pre-cooling unit often fails, the air is pre-cooled and the temperature is high, and the water content increases, which increases the burden of removing moisture from the molecular sieve, thus affecting the removal of carbon dioxide by the molecular sieve, increasing the carbon dioxide content, and accelerating the formation of the resistance of the main heat exchanger. Affected the production cycle. Therefore, the pre-cooling unit should be maintained in time to ensure good operation. The fractionation tower should be repaired and repaired repeatedly for each weld and each joint. The leaks are found and carefully treated. During the bare cold, the flanges of each valve are retightened, and then leaked after cooling. (3) Take measures to prevent blockage of the container pipe. Carefully clean to remove accumulated impurities. After the fractionation column is washed with water and carbon tetrachloride, it is heated and blown off to completely remove carbon tetrachloride and water. The molecular sieve in the purifier, after one cycle, is screened to remove the powder. The purifier molecular sieve powder filter is periodically cleaned to prevent the powder from entering the fractionation column. Clean the air compressor filter frequently to prevent dust from entering the tower. (4) Continuous monitoring of total hydrocarbon content in liquid oxygen using advanced laboratory equipment. Focus on the monitoring of acetylene content, and find measures to exceed the standard in time, such as switching the purifier in advance, discharging part of liquid oxygen. (5) Strengthen the maintenance and management of instrumentation to ensure its sensitivity and reliability. (6) Improve the quality of employees and optimize operations. Strengthen staff training, improve operational skills, and assess the operational status (including output, purity, water and electricity consumption, etc.) for each shift, and realize rewards and punishments.
3 Strengthen equipment transformation and maintenance to achieve energy saving and efficiency
3.1 Energy-saving measures for air compressor units
3.1.1 Strengthening the maintenance of the air filter
The content of solid impurities such as dust in the air is generally 5-10 mg/m 3 , which may exceed 50 mg/m 3 in the metallurgical enterprise or around, and the dust particle size is usually below 0115 mm. An air cleaner is installed on the inlet pipe of the air compressor. When air passes through the filter, dust and mechanical impurities adhere to the oil film of the screen or the Raschig ring or the micropores of the paper filter. As the amount of adhering increases, the suction resistance increases, and the air compressor intake decreases, which increases the energy consumption of the air compressor. Therefore, maintenance should be intensified, periodically (3 to 6 months) cleaning or post-purging, to ensure that the amount of solid impurities in the air after removal by air filter is less than 1mg / m 3 . The resistance is 100 to 150 Pa. When it exceeds 400 Pa, maintenance should be performed.
3.1.2 Strengthening the maintenance of air compressors
The air compressor is the single unit with the largest power consumption of the air separation unit. Increasing the isothermal compression efficiency and mechanical efficiency of the air compressor can obtain greater energy saving benefits.
(1) Measures to improve the isothermal compression efficiency of air compressors are as follows: 1 The cooler must have sufficient heat exchange area. 2 Increase the amount of cooling water and reduce the inlet temperature of the cooling water. 3 remove scale and carbon deposits in time. Periodically (one production cycle) Check the carbon deposits in the cooler and cylinder liner and the carbon deposits in the gas passages and remove them mechanically and chemically.
4 Use dry nitrogen to reduce the cooling water temperature. For users who use circulating water and do not use nitrogen gas, they can use the moisture absorption capacity of dry nitrogen to introduce vented nitrogen into the pool of the circulating water cooling tower. After bubbling, the water temperature is lowered.
(2) Measures to improve mechanical efficiency are: 1 “Harmful†clearance (minimum distance between piston and cylinder top). Under the premise that the working state does not cause the piston to collide, the “harmful†clearance is as small as possible, and can be adjusted according to the provisions in the equipment manual. 2 Inlet and exhaust valves should be sealed. When the intake valve is not sealed, the compressed gas returns to the suction pipe, and the pressure is reduced after compression, and the intake air temperature rises. When the exhaust valve is not sealed, the compressed gas returns to the cylinder, the amount of suction is reduced, the discharge pressure is lowered, and the exhaust temperature is increased. In this way, leakage of the intake and exhaust valves will cause a decrease in the amount of air and increase the energy consumption per unit. To this end, the valve should be disassembled for sealing inspection and treatment every one cycle of operation.
3 Eliminate the leak point. External leaks should be promptly discovered and processed in a timely manner. Leakage inside the machine is guaranteed by proper maintenance. Such as the wear of cylinders and pistons; the leaking point of the sealing stuffing box or the cooler should be checked and repaired regularly. 4 reduce the frictional resistance of the machine motion mechanism. Correctly select the lubricating oil, pay attention to the oil quality and oil quantity, and check the oil temperature and oil pressure frequently during use.
31113 Strengthening the equipment renewal and transformation In the use of equipment, the equipment (air compressor) should be modified and updated in time to achieve energy saving and efficiency enhancement.
For example, the 5L - 16/ 50 air compressor is used for oil-free lubrication modification; the 2D8217/ 452 II air compressor is used instead of the 5L216/ 50 air compressor; and the high efficiency centrifugal air compressor is used instead of the piston air compressor.
312 Energy saving measures for air separation pre-cooling unit The air pre-cooling unit functions to cool the saturated air from the air compressor from 30 to 35 °C to 3 to 5 °C, and to deposit a large amount of water contained in the air. When the air enters the molecular sieve adsorber, the amount of water brought in is greatly reduced, and the adsorption value of the carbon dioxide and acetylene contained in the air at a low temperature is increased. The molecular sieve filling amount is reduced, the molecular sieve adsorber volume is reduced, the regeneration gas amount is reduced, and the regenerative power consumption is lowered. In particular, units that require nitrogen can increase nitrogen production and create conditions for long-term adsorption. In addition, the temperature at which air enters the cold box is relatively reduced.
Chemical companies with ammonia stations can use surplus ammonia feedstock to cool the air, saving investment and low energy consumption. Pay attention to the use of pre-cooling unit: 1 Steamer (heat exchanger) to prevent leakage. 2F212 (R222) Refrigerant charge meets design requirements. If the filling amount is insufficient, the cooling capacity is small, and the air temperature does not meet the requirements. If the filling amount is too large, the compressor suction and exhaust pressure is too high, the cooling capacity is reduced, and the power consumption is increased. 3 Dry filter should be maintained. It is easy to block, throttle, and frost, affecting the normal operation of the pre-cooling unit.
3.3 Energy saving measures for molecular sieve purifier
(1) The raw material air should be dry without oil. Minimize moisture and oil in the air before entering the purifier. Properly and timely blow off the oil-water separators at all levels to carry out deoiling water. Automatic steam traps can also be installed and checked to ensure good operation.
(2) Reduce the temperature of the air before entering the purifier. The lower the adsorption temperature, the better the adsorption effect.
(3) The regeneration of the molecular sieve purifier should be thorough. The temperature of the inlet and outlet is well controlled when heating. When blowing cold, nitrogen bypasses into the adsorber, shortening the regeneration time and saving nitrogen consumption. When the equipment is shut down for a long time, it should be filled with dry nitrogen and sealed to prevent molecular sieve poisoning.
(4) Strictly control the life cycle. According to the air temperature and pressure, the impurity content after purification is measured to make a switching curve.
Add a balancing valve to reduce the impact on the stability of the fractionation tower during switching.
(5) Reduce the resistance of the valve pipe. Valves, pipes, and elbows should be matched to reduce the pressure on the upper tower.
3.4 Energy saving measures for expanders
The pressure of the compressed air and the cooling efficiency of the expander are the main factors of the cooling capacity. The higher the pressure of the compressed air, or the higher the cooling efficiency of the expander, the more the cooling capacity, and vice versa. When the cooling demand of oxygen production is a certain value, the efficiency of the expander is increased, the pressure of the air compressor is correspondingly reduced, the load is reduced, and the electromechanical consumption of the air pressure is reduced, thereby saving electricity.
(1) Measures to improve the efficiency of the piston expander are as follows: 1 The intake and exhaust valves should be sealed. 2 Strictly control the cylinder clearance. 3 Avoid high-pressure air throttling, try to avoid using the front throttle to adjust the inflation. 4 When starting, increase the high pressure and reduce the medium pressure to increase the pressure difference before and after the expander. The increase in production capacity, in turn, can further reduce the high pressure. 5 Reduce the friction heat of the expander, and the cylinder liner should be cooled well.
(2) Using a turbo expander instead of a piston expander, the gas bearing turboexpander has an adiabatic efficiency of 74 %.150m 3 / h air separation plant, replacing the PZK2 1413/ 4026 with a PLK28133 × 2/ 2026 turboexpander The piston expander saves about 130,000 kWh per year and eliminates the need for consumable spare parts and lubricants, reducing equipment failures and ensuring long-term production. If the user uses oxygen as the main source of nitrogen, the turbo expander can change the air bearing to a nitrogen bearing to achieve energy saving and efficiency. Because: 1 nitrogen is clean and dry without molecular sieve powder, thus extending the life cycle of the turbo expander. 2 Since the nitrogen gas is discharged from other storage tanks, the outlet pressure is controlled by the automatic valve of the instrument at 016 MPa, so the pressure is stable and there is no pulse; and the continuous output is not affected by the power supply, so a sudden accident will not cause damage to the turboexpander. .
3.5 Energy saving measures for air separation towers
(1) The fractionating tower should be thoroughly purged and cleaned regularly. (2) Master the essentials for starting the operation, shorten the startup time, operate in time, and adjust it in place. (3) Reduce the cold loss of the air separation tower and reduce the energy consumption. First, the insulation is good, and the second is to reduce the low temperature liquid discharge. (4) Increase the extraction rate of oxygen and nitrogen products. (5) According to the power supply, oxygen and nitrogen demand, the user adopts intermittent production, which is a good way to save energy. It is necessary to pay attention to increase the pressure before stopping, and carry out pressure and cold preservation.
3.6 Energy-saving measures for the operation of air separation equipment circuits
Increasing the power factor of the operation of the air separation equipment circuit can achieve energy saving. (1) Install a motor power saver on the motor circuit and install a power factor automatic compensator on the switchboard. (2) Use a variable frequency motor, etc.
3.7 Equipment Management Energy Saving Measures
Establish a post responsibility system, implement charter maintenance, and manage all equipment. Formulate regular planned maintenance (small repairs per month, repairs in each quarter, overhaul every two years) System, and at the same time, carry out equipment transformation and improvement in combination with the actual situation, so that the equipment is in good working condition, achieving energy saving and efficiency.
Strengthen the daily management of equipment and implement “daily inspection, weekly inspection and monthly assessmentâ€.
Equipment management, in addition to large, medium and small planned maintenance, strict implementation of maintenance procedures, to ensure the quality of maintenance, strengthen the on-site daily maintenance of equipment, the implementation of "daily inspection, weekly inspection, monthly assessment" is to ensure the safe and smooth operation of air separation equipment A proven method. "Daily inspection, weekly inspection, monthly assessment" is a key part of the complete set of air separation equipment, important indicators, and regular inspection and assessment. “Daily check†is checked by the on-duty cadres of the workshop every day (including the operator's on-duty inspection), and the problems are promptly contacted and handled. The “Weekly Inspection†workshop full-time equipment technicians conduct a comprehensive and careful professional inspection of all the equipments of the equipment, and find out the problems and timely formulate measures and plans, and contact the relevant units for processing. The “Monthly Assessment†workshop conducts a comprehensive assessment of equipment operation, maintenance and management status every month.
In conjunction with the "daily inspection, weekly inspection, monthly assessment" situation, the equipment management, maintenance and operation personnel are assessed, and linked to the current month's bonus, the implementation of rewards and punishments.
4 comprehensive utilization of air separation products to achieve energy efficiency
4.1 Utilization of oxygen, nitrogen and argon venting
Air separation equipment products mainly include oxygen, nitrogen, argon and liquid oxygen, liquid nitrogen and liquid argon. They are widely used in industry, agriculture, technology, medical care and people's daily lives. However, in the production of air separation equipment in China, especially medium and small air separation equipment, the comprehensive utilization is poor. Steel, metallurgy, machinery and other enterprises mainly produce oxygen, and most of the nitrogen is vented; while petroleum, petrochemical, and fertilizer companies mainly produce nitrogen, most of which is vented; argon is used less. The comprehensive utilization of oxygen, nitrogen and argon can greatly improve the economics of air separation plants. Therefore, the production and construction of oxygen plants (stations) in steel or petrochemical enterprises must consider the comprehensive utilization of oxygen and nitrogen. In addition to the use of this enterprise, it should also be oriented to the society, extensively develop the market, and create more benefits.
4.2 Purifier recycling of recycled nitrogen
The air separation plant, which mainly produces nitrogen, can recycle the purified nitrogen from the purifier and save resources. Main measures: (1) Process: The regenerated nitrogen after the purifier is cooled by the tubular heat exchanger, enters the oil-water separator, removes the condensed moisture in the nitrogen, and then passes through the nitrogen buffer tank (or nitrogen balloon). After the nitrogen compressor is compressed, it is sent to the storage tank for reuse.
(2) Key problems to be solved: 1 The pressure after the regeneration of the nitrogen purifier is about 0101 MPa. When the nitrogen is pumped by nitrogen, the negative pressure of the buffer tank should be prevented; the resistance of the purifier regeneration system is increased, and the pressure fluctuation of the fractionation tower should be prevented. . 2 equipment to be matched. Such as heat exchangers, oil-water separators, buffer tanks, nitrogen presses, etc. 3 After the nitrogen is recovered, the water content in the nitrogen gas slightly increases. If the water content is required to be small, a dryer may be added.
4.3 Rational use of oxygen, argon and nitrogen products of different purity
Nitrogen is widely used as a protective gas in industrial enterprises. However, the user's purity requirements for nitrogen are not the same. Industrial nitrogen is 9915%, pure nitrogen is 99199%, and high-purity nitrogen is 991999%. The higher the purity of nitrogen extraction, the more electricity it consumes, that is, the high-purity nitrogen production cost is higher than that of pure nitrogen and nitrogen. Therefore, it is necessary to distinguish the different requirements of nitrogen purity and provide nitrogen of appropriate purity to achieve energy saving and consumption reduction.
Our workshop KZON2150/ 6002 III air separation plant produces nitrogen purity of 99195%, which is pure nitrogen. The KDON2250/ 1500 air separation plant produces a purity of 991999% nitrogen, which is a high purity nitrogen. The price in the take-away market is different. The volume of a bottle (40L) is 1417MPa. The standard volume is 6m 3 pure nitrogen, and the market price is about 20 yuan.
High purity nitrogen can be sold to 80 yuan. In addition, in the steel industry, the use of sewage nitrogen instead of pure nitrogen for the injection of bituminous coal can also achieve energy-saving purposes.
The same is true for oxygen. The purity of industrial gaseous oxygen qualified products is 9912% (first grade 9915%, superior grade 9917%), mainly used for industrial cutting and welding, and the price is cheap (10 yuan / bottle). High purity oxygen qualified purity It is 991995%, which is used for the production of scientific research integrated circuits and semiconductor devices, and is of course expensive.
Argon: The argon purity of the bulb is 84%-85%, pure argon 99199%, high purity argon 991999%, the purity grade is not the same, its use is different, of course, the price is not the same. Therefore, by utilizing the difference in purity of oxygen, nitrogen, and argon products, comprehensive utilization can create more benefits.
4.4 Utilization of oxygen, nitrogen and argon cryogenic liquids
Liquid nitrogen is widely used as a new refrigerant. In high-tech industries, it is used in high-energy physics, controlled thermonuclear reactions, satellites, ultra-high vacuum, lasers, and low-temperature electronics. In terms of resource development, it is used for mine fire extinguishing, soil freezing, and low temperature crushing. In the electronics industry, it is used in special bulbs, tube vacuuming, and device oxidation prevention.
In the mechanical industry, it is used in low temperature cutting, cold processing, and cold sleeve assembly. In the petroleum industry, it is applied to the freezing of petroleum storage and transportation. In agriculture and animal husbandry, it is applied to the preservation of seeds, seedlings and livestock semen and embryos. In the light industry, it is applied to the refrigeration of food and the preservation of vegetables and fruits. With the development of China's modernization and the advancement of science and technology, the use of liquid nitrogen is becoming more and more widespread.
In addition, the liquid products liquefied by oxygen, nitrogen, argon and other gases can be reduced in transportation costs after being promoted and used. In industrialized countries, low-temperature tank trucks are generally used to transport industrial gas liquefaction products to various users, and they are used in situ to achieve “centralized production and dispersed gas supply†to achieve energy conservation and efficiency. This is also the trend of China's gas industry development.
The main consumption of air separation equipment is the cost of electric energy and the cost of equipment inspection and maintenance, and the cost of accessories materials, followed by labor costs. By adopting the above four measures, the operating costs of air separation equipment can be greatly reduced, the economics of small and medium-sized air separation equipment can be improved, and energy conservation, consumption reduction and production efficiency can be realized.
Gear Hobbing Machine With Chamfering Unit
Gear Hobbing Machine With Chamfering Unit,Gear Manufacturing,Gear Hob,Gear Tooth Chamfering Machine
Zhejiang Toman Intelligent Technology Co., Ltd , https://www.tomanmachines.com