Energy-saving and consumption-reducing treatment method of air separation air inlet system

Abstract

The invention discloses an energy-saving and consumption-reducing treatment method for an air separation air inlet system, and relates to the technical field of aerodynamics and fluid mechanical engineering. The collected data comprises particle size distribution and percentage data of dust particles in air inlet of the air separation air inlet system, air compressor treatment amount data and air inlet temperature, humidity and salt content data; and step 2, calculating a filtering level meeting system requirements based on the collected data. According to the energy-saving and consumption-reducing treatment method of the air separation air inlet system, personalized customization of a filtering scheme is achieved through refined data collection and analysis, the capturing efficiency of the system on fine particulate matter is effectively improved, the dust accumulation phenomenon of air compressor blades is reduced, then the air flow viscous resistance and the air compressor energy consumption are reduced, and the air separation efficiency is improved. Selection of filtering grades is optimized, the overall energy efficiency of the air separation air inlet system is remarkably improved, and the purposes of saving energy and reducing consumption are achieved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of aerodynamics and fluid machinery engineering, in particular to an energy-saving and consumption-reducing processing method for an air separation intake system. BACKGROUND

[0002] In the operation process of an air separation system, an intake filter is a key component for ensuring stable and efficient operation of the system. Its core function is to filter dust particles in the air entering the compressor to prevent the particles from adhering to the surface of the compressor blades, thereby protecting the blades from wear and corrosion and maintaining the normal working efficiency and service life of the compressor. Currently, the filtering grades of mainstream intake filters in the industry are mostly concentrated in the F7 to F9 range. According to the EN779:2012 standard, taking the widely used F9 grade filter as an example, its final resistance is set to 450 Pa, the filtration efficiency for particles with a size of 0.4 microns can exceed 70%, and the average filtration efficiency is higher than 95%, which can meet the basic filtration needs of the air separation system. However, as the industry's requirements for energy-saving and consumption-reducing indicators of air separation equipment continue to increase, the performance optimization space of existing filtration systems is gradually highlighted.

[0003] The existing air separation intake filtration technology still has certain improvement directions in actual application: on the one hand, the existing filtration scheme is mostly based on general standards for selection and configuration, and cannot fully combine individualized working condition parameters such as dust particle size distribution, dust concentration, and actual air handling capacity of the air compressor for customized design, resulting in difficulty in achieving precise balance between filtration efficiency and intake resistance in some scenarios, which may cause insufficient filtration level affecting blade protection, or excessive filtration level increasing intake resistance; on the other hand, the EN779:2012 standard does not make explicit requirements for the filtration efficiency of MPPS (i.e. the most difficult to filter particles, with a particle size usually concentrated in the range of 0.1-0.3 microns), so the interception ability of existing filters for such small particles is limited, and long-term operation may cause dust accumulation on the compressor blades, increasing airflow viscous resistance and indirectly leading to increased energy consumption of the compressor. In addition, the existing technology lacks systematic simulation analysis and optimization of the flow field distribution of the intake system, and the matching degree of the installation layout of the filter and the airflow flow demand is insufficient. Meanwhile, in the system modification process, the weight load of the added filter components and the strength of the original pipeline structure are not fully checked, and auxiliary functions such as intake desalination, water removal, and temperature regulation are not fully integrated, making it difficult to fully adapt to the efficient operation needs of the air separation system in complex environments. In view of this, we propose an energy-saving and consumption-reducing processing method for an air separation intake system. SUMMARY

[0004] To solve the above technical problems, an energy-saving and consumption-reducing processing method of an air separation intake system is provided, which solves the problems of the above-mentioned general standard selection, lack of customized design combined with on-site working conditions, difficulty in balancing filtration efficiency and intake resistance, and lack of flow field simulation optimization.

[0005] To achieve the above purposes, the technical scheme adopted by the present application is:

[0006] An energy-saving and consumption-reducing processing method of an air separation intake system, comprising the following steps:

[0007] Step one, data collection, including: particle size distribution and percentage data of dust particles in the air separation intake system intake, air compressor processing air volume data, and intake temperature, humidity and salt content data;

[0008] Step two, based on the collected data, calculate the filtration grade that meets the system requirements, and then calculate the intake resistance and compressor energy consumption under different filtration grades to obtain energy-saving effect data of each filtration grade and evaluate it, select the one with the best energy-saving effect as the preliminary filtration scheme, and perform structure calculation based on the preliminary filtration scheme to ensure that the weight of the new components meets the system load requirements;

[0009] Step three, according to the preliminary filtration scheme, perform flow field simulation to verify the intake resistance and flow field distribution of the system, and optimize and adjust the filtration scheme according to the simulation results.

[0010] Preferably, in step one, the particle size distribution and percentage data of dust particles are obtained by a dust detection device located at the intake port;

[0011] The air compressor processing air volume data is obtained by air volume detection instruments arranged at the inlet and outlet pipelines of the air compressor;

[0012] The intake temperature, humidity and salt content data are obtained by sensors arranged at the intake port and key positions of the pipeline.

[0013] Preferably, in step two, based on the particle size distribution data of dust particles and the air compressor processing air volume, the candidate filtration grade is determined by comparing the filtration standard;

[0014] For each candidate filtration grade, the intake resistance and total energy consumption value of the compressor under this grade are calculated according to its resistance characteristics and filtration efficiency.

[0015] Preferably, when calculating the total energy consumption value, the resistance change of the filter element caused by dust accumulation during the entire service life is comprehensively considered, and the average inlet resistance is calculated as the energy consumption calculation basis.

[0016] Preferably, in step two, the total energy consumption values of each candidate filter level are compared with the annual comprehensive operation cost based on the preset reference filter level energy consumption, and a comprehensive evaluation is performed to select the preliminary filter scheme.

[0017] The structure calculation includes checking the load distribution influence of the added components and the original pipeline structure strength.

[0018] Preferably, in step three, a fluid dynamics simulation model is established based on the structure of the air separation inlet system, boundary conditions are set according to the data collected in step one, and simulation is performed to obtain the flow field distribution and inlet resistance data inside the system.

[0019] Preferably, the flow field simulation includes evaluation of the uniformity of airflow distribution on the filter element surface, and the installation structure or arrangement of the filter element is optimized according to the evaluation results.

[0020] Preferably, the optimization and adjustment of the filter scheme according to the simulation results include:

[0021] If the local flow velocity is too high or there is a dead zone of airflow, the flow field distribution is optimized by adjusting the arrangement of the filter element or adding a flow guide device;

[0022] If the inlet resistance is too high, the effective filter area of the filter element is increased or the distance between the multi-stage filter elements is adjusted to reduce the resistance.

[0023] Preferably, it further includes:

[0024] Based on the collected inlet salt content and humidity data, if the values exceed the preset threshold of the system, corresponding salt removal devices and water removal devices are added in the filter system;

[0025] After adding the devices, structure calculation and energy consumption evaluation are performed again.

[0026] Preferably, it further includes:

[0027] Based on the collected inlet temperature data, if the annual average temperature exceeds the optimal operating temperature range of the compressor, corresponding inlet heating devices or cooling devices are added in the filter system;

[0028] After adding the devices, flow field simulation is performed again and the comprehensive energy saving effect is calculated.

[0029] Compared with the prior art, the beneficial effects of the present application are:

[0030] The energy-saving and consumption-reducing method for air separation intake systems proposed in this invention achieves personalized customization of filtration schemes through refined data acquisition and analysis. This effectively improves the system's capture efficiency of fine particulate matter, reduces dust accumulation on compressor blades, and consequently reduces airflow viscous resistance and compressor energy consumption. It also optimizes the selection of filtration grades, avoiding increased energy consumption due to inappropriate filtration levels. Furthermore, it uses flow field simulation technology to finely control the filter layout, ensuring smooth airflow and further reducing intake resistance. By comprehensively considering multiple factors such as desalination, water removal, and intake temperature regulation, it enhances the system's adaptability to complex environments. The introduction of structural calculations ensures the safe and stable operation of the system during the modification process, significantly improving the overall energy efficiency of the air separation intake system and achieving the goal of energy saving and consumption reduction. Attached Figure Description

[0031] Figure 1 This is a diagram illustrating the method steps of the present invention. Detailed Implementation

[0032] The following description is intended to disclose the invention and enable those skilled in the art to implement it. The preferred embodiments described below are merely examples, and other obvious variations will occur to those skilled in the art.

[0033] Reference Figure 1 As shown, an energy-saving and consumption-reducing method for an air separation intake system includes the following steps:

[0034] Step 1: Data collection, mainly including: particle size distribution and percentage data of dust particles in the air intake of the air separation system, air compressor processing volume data, and intake temperature, humidity, and salinity data.

[0035] Step 2: Calculate the required filtration level based on the collected data. Then, calculate the intake resistance and compressor energy consumption under different filtration levels to obtain the energy-saving effect data of each filtration level and conduct a comprehensive evaluation. Select the one with the best energy-saving effect as the preliminary filtration scheme. Then, carry out structural calculations based on the scheme to ensure that the weight of the new components meets the system requirements.

[0036] Step 3: Perform flow field simulation based on the preliminary filtration scheme to verify the system's intake resistance and flow field distribution, and optimize and adjust the filtration scheme based on the simulation results.

[0037] In the data collection of step one, the specific operation is as follows: for the particle size distribution and percentage data of dust particles in the air inlet of the air separation inlet system, a dust detection device should be used for on-site testing at the air inlet of the air inlet system. The device needs to be calibrated before testing. The testing process should cover all types of operating conditions of the system. Through the device, dust samples at different time periods are collected, and particle size analysis is carried out on the samples. The number and mass of particles in each particle size interval are counted to obtain the particle size distribution and percentage data. For the air compressor processing air volume data, air volume detection instruments that meet industry measurement standards are used. Detection points are set at the inlet and outlet pipelines of the air compressor to monitor and record the gas flow under the operating load. Combined with the operating parameters of the air compressor, the actual processing air volume is calculated. For the inlet temperature, humidity and salt content data, temperature and humidity sensors and salt content detectors should be used to arrange monitoring points at the air inlet and key positions of the pipeline to collect and record the corresponding data. The temperature and humidity data are recorded once an hour, and the salt content data are collected once a day.

[0038] When obtaining the air compressor processing air volume data, dynamic collection needs to be combined with the change of system operating load: during the normal operation of the air separation system, three typical load conditions are selected, and 24 hours of air volume data are continuously collected under each condition; ultrasonic flow meters are used during collection, and they are installed on the straight pipe section of the air compressor outlet. During the collection process, the instantaneous flow rate is recorded every 15 minutes, and the corresponding air compressor speed, outlet pressure and inlet temperature parameters are recorded at the same time; after the collection is completed, the instantaneous flow rate data under each condition is statistically analyzed, the average processing air volume of each condition is calculated, and the weighted average processing air volume of the air compressor is further calculated according to the proportion of the running time of different conditions of the air separation system.

[0039] In step two, the method for calculating the required filtration level based on the collected data is as follows: first, sort the collected dust particle size distribution data, count the proportion of MPPS particles with a particle size of 0.1-0.3 microns and other key particle size intervals, and combine the air compressor processing air volume data to determine the actual intake scale of the system; then, refer to the EN779:2012 filtration standard to extract the technical parameters of filter cartridges of different filtration levels, including the filtration efficiency of particles of different sizes and the final resistance; match the field dust data with the standard parameters to select candidate filtration levels that can effectively filter the main particle sizes in the field and the final resistance will not exceed the system's bearing range due to too high a filtration level. When calculating the intake resistance and compressor energy consumption under different filtration levels, according to the resistance characteristic curve of each candidate filtration level filter cartridge, combined with the air compressor processing air volume, the intake resistance value corresponding to the actual intake volume under the filtration level is determined; then, according to the performance curve of the air compressor, the shaft power change of the air compressor under the intake resistance is found, and the basic energy consumption value caused by the intake resistance is calculated; at the same time, according to the filtration efficiency of the candidate filtration level, the dust amount entering the compressor is estimated, combined with the adhesion law of dust on the blade, the additional energy consumption caused by the increase of viscous resistance is calculated, and finally the total energy consumption value under each candidate filtration level is obtained.

[0040] Further, the detailed method for obtaining and evaluating the energy-saving effect data of each filtration level is as follows: first, determine the evaluation benchmark, and take the energy consumption of the existing industry commonly used F9 level filter under the same air compressor processing air volume as the benchmark energy consumption value; compare the total energy consumption value of each candidate filtration level with the benchmark energy consumption value, and calculate the energy consumption reduction rate of each candidate level; at the same time, the use cost of the filter cartridge also needs to be considered, including the procurement cost, replacement cycle and replacement and maintenance cost, so as to calculate the annual comprehensive cost under each candidate filtration level; then, a comprehensive evaluation system is established, and the energy consumption reduction rate and the annual comprehensive cost are taken as the indexes to score each candidate filtration level, wherein the weight of the energy consumption reduction rate accounts for 60%, and the weight of the annual comprehensive cost accounts for 40%, and the filtration level with the optimal comprehensive performance is selected as the preliminary filtration scheme according to the total score. In terms of structural calculation, the weight, size and installation method of the new components in the preliminary scheme need to be determined, and the material, cross-sectional size and bearing limit parameters of the bearing components of the original structure of the air separation intake system are extracted according to the design drawings; through structural mechanics calculation, the influence of the installation of the new components on the load distribution of the bearing components is analyzed, and it is verified whether the weight is within the bearing limit range; at the same time, it is checked whether the installation of the new components will affect the structural strength of the original intake pipeline, to ensure that the structure of the modified system meets the safety operation standard.

[0041] In calculating the intake resistance under different filter levels, the influence of filter core service period on resistance also needs to be considered: first, obtain the resistance-dust capacity curve of each candidate filter level filter core; then, according to the dust particle concentration data collected in step one, calculate the amount of dust entering the filter core per unit time, and determine the replacement period in combination with the rated dust capacity of the filter core; divide multiple time nodes within the replacement period, and calculate the filter core resistance value corresponding to each time node; according to the annual operation time of the air separation system, in combination with the resistance value of each time node and the proportion of the running time of the node, the average intake resistance of the filter core within a replacement period is calculated; finally, the average intake resistance is taken as the basis for calculating the energy consumption of the compressor.

[0042] The detailed method of carrying out flow field simulation in step three is as follows: first, build a simulation model, according to the actual structure of the air separation intake system, use a three-dimensional modeling software to establish a 1:1 scale geometric model, the model needs to accurately restore the diameter, length, elbow angle of the pipeline, the internal cavity size of the filter and the arrangement mode of the filter core; then set the simulation parameters, based on the principle of computational fluid dynamics, set the inlet boundary condition as the flow rate corresponding to the air compressor processing air volume, the inlet temperature and humidity collected in step one, and set the outlet boundary condition as the actual working pressure of the compressor inlet; the boundary conditions of the filter core are set according to the technical parameters of the filter core in the preliminary filtration scheme, including permeability and resistance coefficient; next, carry out mesh division, use unstructured mesh to discretize the model, implement mesh densification on the areas inside the filter, pipeline elbows and areas where vortex is easy to occur, to ensure that the mesh quality meets the calculation accuracy requirements; finally, run the simulation software to simulate the flow process of air in the intake system, the simulation time should cover 3 complete air flow circulation periods to obtain the flow field distribution data and the overall intake resistance value inside the system.

[0043] The specific content of adjusting and optimizing the filtration scheme according to the simulation results includes: analyzing the flow field distribution data, if there is a local area with too high flow rate inside the filter, which is easy to cause excessive local filtration load of the filter core, the arrangement mode of the filter core should be adjusted, the number of filter cores in this area should be increased or the distance between filter cores should be increased to disperse the airflow; if there is a dead zone of airflow in the pipeline, a flow guide plate should be installed on the inner wall of the pipeline corresponding to the dead zone, the angle and length of the flow guide plate should be determined according to the flow field simulation results. When analyzing the intake resistance data, if the simulation obtained intake resistance is higher than the maximum resistance value allowed by the system design, the structure parameters of the filter core should be adjusted on the premise of ensuring that the filtration efficiency does not decrease, such as increasing the effective filtration area of the filter core, to reduce the airflow resistance per unit area; if the preliminary scheme is multi-stage filtration, the distance between each stage of filter core should be adjusted to ensure smooth transition of airflow between stages. After optimization and adjustment, a new simulation model needs to be established and simulation needs to be run to verify whether the adjusted flow field distribution is uniform and whether the intake resistance meets the requirements.

[0044] The flow field simulation verification also needs to include the evaluation of the uniformity of the air flow distribution on the surface of the filter element: in the simulation model, a plurality of monitoring points are arranged on the windward surface of each filter element; after the simulation is completed, the air flow velocity data of each monitoring point is extracted, and the average value and the standard deviation of the flow rate of all monitoring points are calculated; the uniformity of the air flow distribution is evaluated by means of the ratio of the standard deviation to the average value, if the coefficient of variation is greater than 0.2, the installation structure of the filter element needs to be optimized, and the flow field simulation is performed again; this process is repeated until the coefficient of variation of the air flow distribution on the surface of the filter element is less than 0.2.

[0045] In addition, the salt content and humidity data collected in step one can also be combined to add a salt and water removal device in the air separation inlet system: first, analyze the collected inlet salt content data, if the monthly average salt content exceeds the upper limit of the air separation industry specified corrosion resistance of the compressor blade, install an adsorption type salt removal device at the front end of the filter; the adsorption material of the salt removal device should be ion exchange resin, and the filling amount is determined according to the inlet amount and salt content; the salt removal device should be provided with a differential pressure monitor, which will remind to replace the adsorption material when the resistance of the device exceeds the preset value. If the collected monthly average humidity of the inlet air exceeds the critical humidity value for preventing dew condensation on the filter element, install a cooling type water removal device at the front end of the filter; the cooling power of the water removal device is calculated according to the inlet amount, inlet temperature and humidity. After installing the salt and water removal device, the structural calculation needs to be performed again to verify whether the weight of the device meets the system bearing requirements, and the resistance parameters of the device are also included in the inlet resistance calculation to re-evaluate the energy consumption of the compressor.

[0046] The inlet air temperature data collected in step one can also be combined to add an inlet air heating or cooling device in the air separation inlet system: first, analyze the collected inlet air temperature data, if the annual average inlet air temperature is lower than the lower limit of the best operating temperature provided by the compressor manufacturer, install a steam heating type inlet air heating device at the rear end of the filter; the heating area of the heating device is calculated according to the difference between the inlet amount, inlet temperature and the best operating temperature, and a temperature control system should be set; if the annual average inlet air temperature is higher than the upper limit of the best operating temperature of the compressor, install a water-cooled inlet air cooling device at the front end of the filter; the heat exchange area of the cooling device is calculated according to the difference between the inlet amount, inlet temperature and the best operating temperature, and the temperature of the cooling water, and a flow control valve is set. After installing the heating or cooling device, the flow field simulation needs to be performed again to check the influence of the device on the system flow field distribution, and the operating energy consumption of the device is calculated and compared with the reduced energy consumption of the compressor due to the optimization of the inlet air temperature.

[0047] The above shows and describes the basic principles, main features and advantages of the present application. Those skilled in the art should understand that the present application is not limited to the above-mentioned embodiments, and the above-mentioned embodiments and descriptions in the specification are only the principles of the present application. Various changes and improvements can be made without departing from the spirit and scope of the present application, and these changes and improvements all fall within the scope of the claimed present application. The scope of protection of the present application is defined by the appended claims and their equivalents.

Claims

1. An energy saving and consumption reducing processing method for an air separation intake system, characterized in that, The method comprises the following steps: Step one, data collection, including: particle size distribution and percentage data of dust particles in the air intake of the air separation intake system, air compressor processing air volume data, and intake temperature, humidity, and salt content data; Step two, based on the collected data, calculate the filtration level that meets the system requirements, then calculate the intake resistance and energy consumption of the air compressor under different filtration levels to obtain energy-saving effect data for each filtration level and evaluate it, select the optimal energy-saving effect as the preliminary filtration scheme, and perform structural calculation based on the preliminary filtration scheme to ensure that the weight of the new components meets the system load requirements; Step three, perform flow field simulation according to the preliminary filtration scheme, verify the intake resistance and flow field distribution of the system, and optimize the filtration scheme according to the simulation results.

2. The energy saving and consumption reducing treatment method of the air separation intake system according to claim 1, characterized in that, In step one, the particle size distribution and percentage data of dust particles are obtained by dust detection equipment located at the air inlet; The air compressor processing air volume data is obtained by air volume detection instruments arranged at the inlet and outlet pipes of the air compressor; The intake temperature, humidity, and salt content data are obtained by sensors arranged at the air inlet and key positions of the pipeline.

3. The energy saving and consumption reducing treatment method of the air separation intake system according to claim 1, characterized in that, In step two, based on the particle size distribution data of dust particles and the air compressor processing air volume, compare the filtration standards to determine the candidate filtration level; For each candidate filtration level, calculate the intake resistance and total energy consumption value of the air compressor under this level according to its resistance characteristics and filtration efficiency.

4. The energy saving and consumption reducing treatment method of the air separation intake system according to claim 3, characterized in that, When calculating the total energy consumption value, consider the resistance change of the filter element due to dust accumulation during the entire use cycle, and calculate the average intake resistance as the basis for energy consumption calculation.

5. The energy saving and consumption reducing treatment method of the air space intake system according to claim 1, characterized in that, In step two, take the energy consumption of the preset reference filtration level as the reference, compare the total energy consumption value and annual comprehensive operating cost of each candidate filtration level, and perform comprehensive evaluation to select the preliminary filtration scheme; The structural calculation includes checking the load distribution impact of the new components and the original pipeline structure strength.

6. The energy saving and consumption reducing treatment method of the air space intake system according to claim 1, characterized in that, In step three, establish a fluid dynamics simulation model based on the structure of the air separation intake system, set boundary conditions according to the data collected in step one, and run the simulation to obtain the flow field distribution and intake resistance data inside the system.

7. The energy saving and consumption reducing treatment method of the air space intake system according to claim 6, characterized in that, The flow field simulation includes evaluation of the uniformity of airflow distribution on the surface of the filter element, and optimization of the installation structure or arrangement of the filter element based on the evaluation results.

8. The energy saving and consumption reducing treatment method of the air space intake system according to claim 1, characterized in that, Optimizing the filtration scheme according to the simulation results includes: If local flow velocity is too high or there is a dead zone, adjust the arrangement of the filter element or add a flow guide device to optimize the flow field distribution; If the intake resistance is too high, increase the effective filtration area of the filter element or adjust the spacing between multiple filter elements to reduce the resistance.

9. The energy saving and consumption reducing treatment method of the air space intake system according to claim 1, characterized in that, Further including: Based on the collected intake salt content and humidity data, if the values exceed the system's preset threshold, corresponding desalination devices and water removal devices are added to the filtration system; After adding the devices, perform structural calculation and energy consumption evaluation again.

10. The energy saving and consumption reducing treatment method of the air space intake system according to claim 1, characterized in that, Further including: Based on the collected intake temperature data, if the annual average temperature exceeds the optimal operating temperature range of the air compressor, corresponding intake heating devices or cooling devices are added to the filtration system; After adding the devices, perform flow field simulation and calculate the comprehensive energy-saving effect.

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