Application of energy technology air compressor heat recovery unit Ye Wei (Yongan Coal Industry Co., Ltd., Yongan, Fujian 366013), using practice, pointed out that the recovered heat energy can produce high-grade hot water, which is used in the production and life of the factory. Energy saving and consumption reduction plays a big role.
The drilling power of coal mines in Fujian Province is almost always concentrated by the ground air compressor, and the ground bathhouse and drying machine room are all powered by coal-fired boilers. The cost of dust removal facilities for coal-fired boilers is high, resulting in excessive waste gas, high pollution and high energy consumption. Compressed air is the most widely used source of power in the industrial sector. Because of its safety, pollution-free, good regulation performance, convenient transportation and many other advantages, it is more and more widely used in modern industrial fields. The screw air compressor has gradually replaced the original piston air compressor with its unique advantages such as cleanness, safety and convenient operation. As the largest power source for mining and mining operations, it consumes a lot of electric energy during work. When the air compressor is working, the circulating oil and exhaust temperature are as high as 85~95 ft. In order to ensure the normal operation of the equipment at the highest allowable temperature, the air compressor cooling system is designed to adopt air-cooling or water-cooling methods to discharge the waste heat to the surrounding environment. And the heat dissipation device consumes electricity and the maintenance cost is high.
In the coal bathhouse, the bathing water, drying room and locker room are mostly heated by the boiler, and the electricity consumption and coal consumption are large. In order to improve the electricity consumption and coal consumption, the air compressor heat recovery device is used to recycle the oil and gas waste heat generated during the operation of the air compressor, and the cold water is heated by the recovered heat energy for the employees to bathe and dry. And heating. However, due to the limited start-up time of the air compressor, the spring and winter seasons can not meet the requirements of the bath. Therefore, the auxiliary heating must be carried out when the air compressor is shut down (the heat pump water heater is selected, the water temperature can reach 50~60 feet).
In addition, the original boiler heating and drying function is now replaced by a wind energy heat pump C to heat the surrounding air, the air temperature can reach 80* or more, thus completely replacing the high-energy boiler and electric heating dryer, effectively improving the mine. Energy saving and emission reduction work.
1Compressor structure and working principle of air compressor heat recovery system 1.1 The composition of air compressor heat recovery unit consists of water filter, air compressor water heater, heat pump water heater, wind energy heat pump, heat preservation water pipe and heat preservation water tower.
1.2 Working principle (1) Working principle of air compressor heat recovery unit: In the long-term continuous operation process of screw air compressor, the high-temperature heat generated by the high-speed rotation of the air compressor screw and the heat generated by friction, the high temperature generated by these The heat is mixed into the oil/gas vapor by the addition of air compressor oil. The heat of this part of the high temperature oil/airflow is equivalent to 3/4 of the input power of the air compressor, and its temperature is usually 85~95 ft. That is, the air compressor water heater absorbs the excess heat of the screw air compressor and uses the principle of heat exchange to turn the cold water into hot water. At the same time, the operating temperature of the air compressor is reduced to below 80 feet to ensure the good operation of the air compressor.
(2) Working principle of heat pump water heater: The electric energy is used to drive the compressor to do work. The latent heat in the air is absorbed by the working medium circulation, and after being compressed by the compressor, it becomes a high temperature and high pressure gas, and the water is indirectly heated.
(3) The working principle of the heat pump heater: absorb the heat of the air and transfer it to the room, increase the temperature of the drying room, and cooperate with the corresponding equipment to achieve the drying of the material. The heat pump dryer is composed of a compressor, a heat exchanger (internal machine), a flow reducer, a heat absorber (outer machine), a compressor, and the like, and constitutes a circulation system. The refrigerant circulates in the system under the action of the compressor. It completes the gaseous boosting process in the compressor (the temperature is up to 85 ft), and it enters the internal machine to release the high-temperature heat to heat the air in the drying room. Cooled and converted into a liquid state, when it is run to the external machine, the liquid quickly absorbs heat and evaporates again into a gaseous state, and the temperature drops to minus 30 to 30 feet, at which time the surrounding air will continuously transfer heat to the refrigerant. The continuous circulation of the refrigerant realizes the transfer of the heat in the air to the temperature of the air in the heating room in the drying room.
2 air compressor heat recovery device application significance (1) make full use of the excess heat of the air compressor. In the operation of the screw air compressor, the exhaust temperature is between 85 and 95 feet. Such high temperatures are emitted in the air and are a great waste. The air compressor energy recovery device can fully recover the heat energy discharged from the air compressor.
(2) It is beneficial to the heat dissipation of the air compressor, so that the air compressor can operate in a benign manner. Because in the utilization of waste heat, the water heater absorbs most of the heat, so that the operating temperature of the air compressor is between 65 and 85 feet, which can stop the cooling fan, reduce the consumption of electric energy, relieve the aging of the wire joint and the lubricating oil. The problem of deterioration reduces the failure rate of the air compressor.
(3) Zero operating costs. Does not burn oil, coal, does not consume electricity. The use of screw air compressor residual heat, no electricity to build hot water; oil and gas water by its own pressure, flow in, flow out to complete the heat exchange. There is no operating cost between the air compressor and the air compressor water heater.
(4) Reduce the operating cost of the air compressor and improve the operating efficiency of the air compressor. Reduce the operating power consumption of the air compressor cooling fan.
3 Air compressor heat recovery device selection and application 3.1 Air compressor heat recovery device selection (undergraduate), mechanical and electrical engineer, is now the mechanical and auxiliary deputy mine of Jiafu Mine of Fujian Yongan Coal Industry Co., Ltd.
Energy technology \1闱泷Name I thermal energy recovery device has two kinds of water heating methods: direct heating, circulating heating.
The directly heated water heater can realize the heating of the cold water to the required temperature at one time, and the working state of the air compressor is stable, the working temperature fluctuation is small, the waste heat recovery has always maintained high efficiency; the circulating heating water heater has a limited heating temperature rise, and must be repeatedly cycled and heated. In order to achieve the required temperature, the operating temperature of the air compressor changes periodically from low to high, and the residual heat recovery rate also changes periodically from high to low. The circulating heating mode air compressor is unstable and will shorten. The service life of the air compressor is low and the residual heat recovery rate is low. The benefits of a direct heat system are obvious, but the heat recovery unit is technically demanding and must be accurately and professionally matched to the air compressor.
3.2 Air compressor heat recovery unit transformation and installation basic requirements (1) After the transformation and installation, the air compressor operation and maintenance methods are unchanged, and the air compressor performance remains unchanged.
(2) Ensure that the working temperature range of the air compressor is appropriate, the working temperature of the air compressor is too high, and the low temperature is not good. The reasonable working temperature range is 78~85 feet, in order to maximize the working efficiency of the air compressor.
(3) When the heat recovery unit is working, the air compressor is guaranteed to operate normally, and the heat recovery unit can also ensure normal operation when it stops.
3.3 Installation and application of air compressor heat recovery unit The heat recovery unit is installed in the oil circulation line of the air compressor, and the heat in the oil circulation of the screw air compressor is supplied to the primary side through the primary side water supply port. The cold water is heated, and then the converted hot water is sent to the hot water storage tower through the hot water conveying pipe for the employee to take a bath. Since it is considered that the air compressor will not be turned on for a long time, a heat pump water heater needs to be installed in the hot water storage tower as an auxiliary heating facility. Install a temperature sensor and a water level sensor in the water storage tower, and set the water temperature (to take the local temperature and take the low temperature) and the water level (take the high water level and the lowest water level) in the water storage in advance, and realize the automatic control of the water heater through the sensor.
4 Innovative point of air compressor heat recovery system (1) When the water temperature of the insulation tank does not reach the required temperature, or when the water tank is full, the control system will stop replenishing cold water, automatically convert to hot water circulation, and improve the recovery of air compressor waste heat. Or, after the water in the water tank is heated to the required temperature, the cold water can be replenished. The system ensures that the water temperature of the tank reaches the temperature required by the hot water at all times.
(2) The cooling fan of the original air compressor is controlled by the oil temperature. When the exhaust temperature of the air compressor is within a reasonable normal temperature range, the cooling fan is turned off, and when the exhaust temperature of the air compressor exceeds a certain reasonable range, the cooling fan operates. This can maximize the recovery of the thermal energy of the air compressor while ensuring the normal operation of the air compressor.
(3) The heat exchanger with high efficiency and low resistance technology is used. After installing the waste heat recovery system, the air compressor control system is unchanged, the working performance is unchanged, and the operation and maintenance mode is unchanged. If there is any fault in the waste heat recovery system, even if the waste heat recovery water heater system is shut down or deactivated, the original air compressor system can operate as usual.
(4) Fully automatic control of the hot water recovery system using the air compressor residual heat. It is linked with the operation of the air compressor: when the air compressor is running, the corresponding heat energy recovery device automatically runs; when the air pressure stops running, the corresponding heat energy recovery device also stops running.
(5) The heat pump system is used as auxiliary supplementary heating. It can run simultaneously with the air compressor waste heat system, or it can operate independently. They are independent and organically combined, and they do not interfere with each other, but they are smoothly connected. In summer and autumn, the amount of hot water for workers is reduced, and the hot water recovered from the residual heat of the air compressor can meet the needs of workers for bathing, so the heat pump can be deactivated.
5 Air compressor heat recovery unit economic benefit analysis (1) Air compressor heat production calculation: (calculated by 2 common units) llOkW air compressor produces heat per hour: 31685kJ2 machine used for 12h work (heat energy recovery according to 80 %).
That is, the heat that can be utilized by each sky press is about 7.536 million kj. The inlet water temperature is 10 ft. The heat generated by the air compressor can be increased by 45T per day: hot water (burning coal heat unit: lkg=29000J, the effective utilization rate is generally 75%).
The annual cost is about 104,000 yuan / d (calculated according to the rainy weather of 9 months per year).
(4) Air compressor cooling fan saves electricity costs (according to 2 sets of llOkW air compressor cooling fan, working for 12h per day is 48,000 yuan / a. Through the above calculation: the annual direct savings can reach about 150,000 yuan.
Other indirect savings: solved the high-temperature operation state of the air compressor, and enabled the air compressor to operate at the optimal temperature, which improved the efficiency and service life of the air compressor; Fuzhou first released PM2.5 data. Fuzhou citizens have been waiting for a long time. The PM2.5 monitoring data was finally released on October 31. 2012-10-30, PM2.5 daily average concentration of 6 monitoring points are: five 40|xg/m3; fast, 39|xg/m3; Gushan, 38|xg/m3, all lower than the national secondary standard (75|xg/m3), which is greater than the national level standard (35|xg/m3). In the future, citizens can log on to the website of Fuzhou Environmental Protection Bureau to find the daily average concentration of monitoring and the latest hourly monitoring data. Fuzhou will also add PM2.5 monitoring points.
By the end of the year, Fuzhou will also release environmental air quality indicators including sulfur dioxide, nitrogen dioxide, carbon monoxide, ozone, PM10 and PM2.5, so that citizens can learn from Jiangsu Electric Power Company before it reaches a million-kW class wind power base. Nantong City's wind power grid-connected capacity has reached 1.038 million kW, accounting for 55.5% of the province's wind power grid-connected capacity, becoming the first million-kilowatt wind power base in Jiangsu Province. According to the wind power development plan of Jiangsu Province, the installed capacity of wind power in the province will reach 10 million kW by 2020, including 3 million kW of land wind power and 7 million kW of offshore wind power. The annual output value of the wind turbine manufacturing industry will reach
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