Shanghai Energy Saving and Energy Saving Technology and Products Ingersoll Rand Air Compressor Heat Recovery Solution Shanghai Yingge Solan Compressor Co., Ltd. Liu Yang Tang Yong Wang Wenzhen mainly discusses the recovery of these compressed heat to improve energy efficiency.
There are various thermal energy conversion devices, energy-using devices, and chemical reaction devices in industrial production processes, which generate a large amount of unused waste heat. In China's industrial enterprises, waste heat resources account for 7.3% of the total input energy, while waste heat recovery rate is only 34.9%. 111. Compressed air is one of the most widely used power sources in industrial production. 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. However, in order to obtain high-quality compressed air, it consumes a lot of energy. In most production enterprises, the energy consumption of compressed air accounts for 10% of the total electricity consumption. According to industry survey and analysis, the operating cost of the air compressor system is 5 years: Initial equipment investment and equipment maintenance costs accounted for 23% of the total cost, while electrical energy consumption (electricity) accounted for 77%, almost all system waste is ultimately reflected in electricity costs | 31. Air compressor system in the long-term continuous During operation, more than 85% of the input power is converted into heat, which is discharged with untreated air compressor oil/gas vapour, which is discharged to the outside world, 85% of which can be utilized, equivalent to air pressure. More than 80% of the shaft power. Under the premise of ensuring the stable operation of the air compressor, it is of great practical significance to make full use of the residual heat resources of the air compressor and comprehensively improve the energy utilization rate.
Depending on the type of air compressor, Ingersoll Rand divides the air compressor heat recovery system into two categories: heat recovery from screw air compressors and heat recovery from centrifugal air compressors.
After the waste heat is recovered, the heat is in the form of hot water. The hot water can be used for boiler hydration, heating, domestic water, R0 pure water preheating according to the user's heat demand temperature. The specific application should follow the energy cascade utilization. principle. Some applications for air compressor heat recovery are given.
Shanghai energy-saving energy-saving technology and products Shanghai energy-saving boiler preheating building heating process water sanitation water air compressor heat recovery application 1 screw air compressor heat recovery according to compressed air process in the compression chamber with or without lubricant, screw air pressure The machine is divided into oil-injected screw air compressor and oil-free screw air compressor. Therefore, Ingersoll Rand's heat recovery of screw air compressor is also divided into oil-jet screw air compressor heat recovery and oil-free. Screw air compressor heat recovery.
1.1 Injection screw type air compressor heat recovery In the prior art, the working principle of the oil-injected screw air compressor is as follows: air filters the dust or impurities in the atmosphere through the suction filter, and then enters the compression by the intake air control. The main engine is mixed with the injected cooling oil during the compression process, and the compressed mixed gas is discharged from the compression chamber into the oil separator to obtain high temperature and high pressure oil and gas, respectively. Due to the working temperature requirements of the machine, these high temperature and high pressure oils and gases must be sent to their respective cooling systems. The compressed air is cooled by the cooler and finally sent to the compressed air pipe network. The high temperature and high pressure lubricating oil is cooled by the oil cooler. After that, return to the oil circuit and enter the next cycle.
In the above process, the heat carried by the high temperature and high pressure oil and gas is approximately 85% of the power of the air compressor shaft, and the oil temperature is usually between 80 ° C and 100 ° C. If the heat is not discharged in time, it can cause the temperature of the motor and the temperature of the exhaust, which not only affects the service life of the air compressor, but also affects the quality of the compressed air. However, the heat is directly discharged through the cooling system, which not only wastes energy but also causes thermal pollution. Therefore, the main function of the heat recovery system of the oil-injected screw machine is to replace the original cooling system, produce high-temperature hot water, and take away the heat of the lubricating oil in the operation of the air compressor.
For oil-injected screw air compressors, the main source of heat recovery is compressor oil. The most common heat recovery method for oil-injected screw air compressors is to install a heat recovery device in the oil separator, using oil and The heat contained in the air heats the cold water, which transfers the heat from the compressed air to the water to complete the heat recovery.
If the user uses insufficient heat, the oil recovery temperature of the heat recovery device is higher than the design temperature, and the lubricating oil is further cooled by the original oil cooler to ensure the normal operation of the air compressor. Schematic diagram of Ingersoll Rand injection screw air compressor heat recovery device.
Ingersoll Rand injection screw air compressor heat recovery system is a system installed outside the air compressor. It can be connected to the air compressor through the oil pipe and connecting parts, which can lubricate the high temperature and high pressure generated by the screw air compressor. Cooling of the oil not only improves the gas production efficiency of the air compressor, but also enables the enterprise to obtain the hot water required for production and living. The maximum temperature of the effluent water is above 70 °C (the winter effluent temperature can reach above 50 °C). Ingersoll Rand injection screw air compressor heat recovery system covers any brand of fuel injection screw filter from 55KW-350KW original temperature control oil cooler cooler head low temperature oil temperature; from low temperature water bureau warm water Temperature sensor oil separation barrel waste heat recovery device ball valve and Ingersoll Rand injection screw machine heat recovery system schematic Shanghai energy-saving technology and product rod machine, thus solving the problem of corporate hot water.
The heat recovery device can simultaneously satisfy: 3) a neat appearance, a safe and reliable system to ensure stable operation of the system; 4) waste heat utilization, energy conservation and environmental protection, reduction of greenhouse gas emissions, and good economic and social benefits.
At present, there are many brands in the market for the heat recovery of oil-injected screw air compressors. Each manufacturer has released its oil-suppressed screw air compressor heat recovery products, which can be said to be the “Red Sea Marketâ€. Ingersoll Rand believes that for the spray Oil screw air compressor heat recovery This "Red Sea market" still needs air compressor heat recovery system - S series injection screw air compressor high efficiency heat recovery system, S series in the first two generations of Ingersoll Rand Oil screw air compressor heat recovery system is efficient, stable and safe. At the same time, according to market demand, PLC control system, more efficient heat exchange components and other technologies are introduced, and the oil-injected screw air compressor heat recovery control is introduced. It is connected to the control system of the air compressor, and the heat recovery device can be controlled according to the operating state of the air compressor, and the heat recovery of the oil-injected screw air compressor is brought into the digital age.
A transmission equipment company in Shanghai has a total of seven 160kW oil-injected screw air compressors. After using the Ingersoll-Rand injection screw air compressor heat recovery system, it can produce 300t of hot water at 70°C per day, equivalent to annual Saving standard coal 1t, hot water produced by air compressor heat recovery can be used for office heating, boiler hydration preheating, staff bathroom hot water, etc., and achieved good energy saving effect.
1.2 Oil-free screw air compressor heat recovery oil-free screw air compressor works the same as the oil-injected screw air compressor, the biggest difference between the two is the drive mode: oil-free screw air compressor The motor is driven by a motor or a gas turbine to drive the speed increasing gear, and then the speed increasing gear is used to drive the two screws to achieve gas compression. The oil-injected screw air compressor is driven by a motor or a gas turbine directly through a coupling to drive the male screw, and then the male screw drives the female screw to achieve gas compression. The lubrication parts of the two are different. The former is on the speed-increasing gearbox and the bearing, the latter is in the compressor casing and on the bearing|41. The difference in the driving mode determines that the oil-injected screw air compressor sprays a small amount into the casing during the compression process. The lubricating oil, the oil enters the casing and is converted into an oil mist, and then mixed with the compressed air in the casing to be effectively compressed between the slots of the rotor. Unlike the oil-injected screw air compressor, there is no contact between the oil-free screw and the casing, and there is no need for internal lubrication, so clean compressed air without oil can be obtained.
Because there is no lubricating oil cooling in the compression chamber of the oil-free screw air compressor, the compression process is closer to adiabatic compression. In other words, it can recover more compressed heat, higher exhaust gas temperature, and better heat recovery effect.
For the oil-free screw air compressor, the heat recovery source is the compressed local temperature compressed air, and the compressed air is cooled by the heat recovery device and sent to the gas end; the circulating water is exchanged with the compressed air through the heat recovery device. The circulating water after the temperature rise is sent to the cycle with the hot end. The principle of heat recovery of Ingersoll Rand oil-free screw air compressor is shown in the figure.
Ingersoll Rand oil-free screw air compressor heat recovery products can heat recovery of any brand of oil-free screw air compressor of 90kW-300kW, the water temperature can reach above 60 °C, and the recovery efficiency is over 80%.
Shanghai Precision Composite Copper Tube Co., Ltd. has two Ingersoll Rand ML250 oil-free screw air compressors for nitrogen production. The company needs to use 45-60 °C hot water in the production process, and the original electric heating (90kW) method to solve the demand.
After heat calculation, heat recovery of an oil-free screw air compressor is sufficient to meet the heat demand of the process. After the transformation, the electric heating was completely deactivated, the annual electricity cost was 498,000 yuan, and the investment return period was 18 months.
In addition, the company received a government energy incentive of 200,000 yuan.
2 Centrifugal air compressor heat recovery system 2.1 Heat recovery principle The heart air compressor is generally used in the case of stable atmospheric and gas demand. Its working principle is that gas enters centrifugal air pressure. Shanghai energy-saving technology and products Ingersoll Lan oil-free screw air compressor heat recovery principle diagram network centrifugal air compressor heat recovery flow chart machine impeller, under the action of the impeller blades, while the impeller rotates at high speed, while rotating centrifugal force to the impeller The flow is discharged, and the pressure and kinetic energy of the impeller are increased. After the gas enters the diffuser, the kinetic energy is further converted into pressure energy, and the gas flows through the curve and the reflux device to the next impeller. Compressed so that the gas pressure meets the requirements required by the process.
The heat recovery of the centrifugal air compressor is full-stage heat recovery, that is, heat recovery is performed for each stage of compression heat. Centrifugal air compressor heat recovery, taking into account the three requirements of the reliability, running performance and heat recovery efficiency of centrifugal air compressor, Ingersoll Rand designed a special heat recovery system for centrifugal air compressor, compressor cooling System, heat transfer system (slide design). Therefore, the main contents of heat recovery of centrifugal air compressors include compressor modification, heat exchange system and heat transfer system.
It is a flow chart of a two-stage compressed centrifugal air compressor heat recovery system. For the two-stage centrifugal centrifugal air compressor, the first stage and the second stage are equipped with high-efficiency heat exchangers. The high-efficiency heat exchanger is a heat recovery device designed for centrifugal air compressors, which is the heat of the centrifuge. The core component of the recycling works by heat exchange of the compressed air and circulating water of each stage, and recovers the heat of compression while effectively reducing the exhaust gas temperature.
Under the premise of ensuring continuous and stable operation of the centrifugal air compressor throughout the day, Ingersoll Rand can effectively recover 90% of the compressor input power, producing 90. (: high-grade heat source water to meet the back-end pair The demand of different temperature heat sources; at the same time ensure the pressure drop loss is controlled by the air compressor. The original built-in cooling system is modified by this device, and the heat recovery heat recovery system is adopted to achieve the following heat recovery target: to ensure system stability For operation, the heat exchange system should use demineralized water to reduce fouling.
For the customer's hot end, it should be designed according to the actual load ratio of the site and the application temperature requirements. According to the structure, it is generally divided into two types: straight-through heat transfer or cyclic heating; according to the control mode, it can be divided into fixed temperature control, constant temperature difference control and constant flow control.
Shanghai energy-saving and energy-saving technologies and products 2.2 Centrifugal air compressor heat recovery control system Centrifugal air compressor heat recovery control system can mainly achieve the following functions: (1) In/out water temperature and pressure local instrument monitoring; (4) In / Outlet water temperature, pressure PLC remote monitoring and abnormal alarm; (5) Unit time energy saving statistics and unit time cost saving statistics.
2.3 Project Cases A pharmaceutical company in Shanxi, China National Pharmaceutical Group, has 5 Ingersoll Rand 5C centrifugal air compressors with a stand-alone power of 3,500 kW.
The five 5C air compressors are now heat-recovered. The on-site measured circulating heat power is 11.5Gcal/h, which is equivalent to the heat power of 13372kW. The recovery efficiency is up to 95%, the outlet temperature is 90.1 °C (influent water is 23 °C), and the water flow rate 220m3 / h, equivalent to 166,000 Va of steam, recoverable value of about 17.96 million yuan / a. 3 Conclusion With the development of production, the amount of compressed air is increasing, the use of compressed air waste heat is also increasingly valued. Ingersoll Rand believes that in the recovery of air compressor compression heat, the normal operation of the air compressor must be guaranteed, which is a prerequisite for heat recovery of the air compressor.
The energy saving potential of air compressor heat recovery is huge. The heat energy recovery of air compressors is a necessary means to improve the energy utilization level of compressed air systems and improve customer productivity.
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