Efficient air compressor station building system

Abstract

The utility model relates to the technical field of industrial compressed air systems, in particular to an efficient air compressor station building system. Comprising a high-pressure compressed air pipe network, a low-pressure compressed air pipe network and an electric control valve connecting the high-pressure compressed air pipe network and the low-pressure compressed air pipe network, the high-pressure compressed air pipe network directly supplies power to a high-pressure air terminal through a high-pressure air storage tank, and the low-pressure compressed air pipe network supplies power to a low-pressure air terminal through a low-pressure air And the electric control valve is also electrically connected with a DCS (Distributed Control System) centralized controller. The traditional pressure reduction throttling loss is reduced through a high-pressure and low-pressure compressed air pipe network partial pressure supply terminal. The combination of the high-voltage variable-frequency screw machine and the centrifugal machine is adopted, different load intervals are covered, and no-load energy consumption is reduced. 90-100 DEG C waste heat generated by operation of the air compressor is recycled through the closed cooling circulation system, and the water inlet temperature of the boiler is increased to 60 DEG C through the plate heat exchanger to replace part of fuel consumption.

Description

TECHNICAL FIELD

[0001] The utility model relates to industrial compressed air system technical field, concretely relates to a kind of high-efficiency air compressor station system. BACKGROUND

[0002] Compressed air system is one of the most important infrastructure in modern industrial plant, widely used in production process, equipment driving and automation control etc. However, traditional air compression station system has significant defects in dealing with multi-pressure demand, dynamic gas consumption fluctuation and energy comprehensive utilization. Take rubber tire manufacturing industry as an example, different processes in its production process have great difference in compressed air pressure demand: vulcanization, mixing etc. process needs 0.45MPa low-pressure compressed air, while calendering, molding etc. process needs stable supply of 0.8MPa high-pressure compressed air, and gas consumption fluctuates sharply (for example, calendering machine instantaneous gas consumption can reach 3 times of average value). Traditional system generally has the following problems:

[0003] Traditional air compression station mostly uses single type compressor (such as only configuring fixed-frequency screw machine), which is difficult to flexibly match different pressure demand. In low load working condition, compressor efficiency decreases greatly, resulting in increased operation cost.

[0004] To meet low-pressure gas demand, traditional scheme usually reduces pressure of high-pressure air to low-pressure pipe network through pressure reducing valve, which causes a lot of throttling loss in this process.

[0005] Cooling heat generated in air compressor operation is usually directly discharged to environment, without effective recycling, resulting in waste of heat energy resources and additional cooling system energy consumption.

[0006] Traditional system is prone to unstable gas supply pressure when facing sharp gas consumption fluctuation, resulting in production equipment shutdown or efficiency reduction. INVENTION CONTENTS

[0007] The utility model provides a kind of high-efficiency air compressor station system, its purpose is to improve the operation efficiency of air compression station as a whole by the way of configuring modular air compressor unit, multi-stage pressure gas supply unit, waste heat recovery, realizes compressed air system energy saving.

[0008] To achieve the above purpose, the technical scheme of the utility model is as follows:

[0009] A kind of high-efficiency air compressor station system, comprising:

[0010] High-pressure compressed air pipe network, low-pressure compressed air pipe network and electric regulating valve connecting the two, the high-pressure compressed air pipe network directly supplies high-pressure gas terminal through high-pressure air tank, the low-pressure compressed air pipe network supplies low-pressure gas terminal through low-pressure air tank;The electric regulating valve is also electrically connected with DCS centralized controller.

[0011] The electric regulating valve is controlled by a DCS centralized controller according to the signal of the low-pressure pressure sensor, so that the high-pressure pipe network dynamically supplies air to the low-pressure pipe network.

[0012] Further, the high-pressure compressed air pipe network comprises at least two high-pressure variable-frequency screw air compressors and one high-pressure centrifugal air compressor.

[0013] Further, the high-pressure compressed air pipe network comprises at least one low-pressure variable-frequency screw air compressor.

[0014] Further, the low-pressure variable-frequency screw air compressor and the high-pressure variable-frequency screw air compressor are connected in series with a front-stage two-stage oil removal filter, a compressed heat regenerative adsorption dryer and a rear-stage precision filter.

[0015] Further, the high-pressure centrifugal air compressor is connected in series with a compressed heat regenerative adsorption dryer and a rear-stage precision filter.

[0016] Further, the waste heat recovery device comprises a closed cooling circulation system and a plate heat exchanger, the closed cooling circulation system is driven by a cooling water pump to flow through a built-in cooler of the air compressor and the plate heat exchanger, recovers heat energy generated during the operation of the air compressor and is transmitted to a boiler water supply system.

[0017] The utility model discloses reached the beneficial effects are:

[0018] Through the high and low pressure compressed air pipe network pressure supply terminal, reduce the traditional pressure reducing throttle loss. Adopt the combination of high pressure variable frequency screw machine + centrifugal machine, cover different load interval, reduce the no-load energy consumption. Through the closed cooling circulation system recovery air compressor operation 90-100 DEG C waste heat, via plate heat exchanger, improve the boiler inlet water temperature to 60 DEG C, replace part fuel consumption.

[0019] Through the DCS centralized controller control electric regulating valve from high pressure pipe network dynamic air supply, solve the problem of pressure instability caused by the sharp fluctuation of gas consumption.

[0020] The high-pressure pipe network is provided with a plurality of variable-frequency screw machines and a standby centrifugal machine, so that reliable air supply under peak demand is ensured, and air supply interruption caused by equipment overload is avoided.

[0021] The air compressor unit is connected in series with a front-stage two-stage oil removal filter, an adsorption dryer and a rear-stage precision filter, so that the compressed air quality is guaranteed, and the service life of terminal gas equipment is prolonged. BRIEF DESCRIPTION OF DRAWINGS

[0022] In order to more clearly illustrate the technical solutions of the embodiments of the present application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiments or prior art description, obviously, the drawings described in the following are only some of the embodiments of the present application, and for those skilled in the art, other drawings can also be obtained according to the structures shown in the drawings without creative labor.

[0023] Figure 1 Process flow chart of the application of the high-efficiency air compressor station house system;

[0024] In the figure, 1, low-pressure screw air compressor; 2, first high-pressure screw air compressor; 3, second high-pressure screw air compressor; 4, high-pressure centrifugal air compressor; 5, first preposed two-stage oil removal filter; 6, second preposed two-stage oil removal filter; 7, third preposed two-stage oil removal filter; 8, first compressed heat regenerative adsorption dryer; 9, second compressed heat regenerative adsorption dryer; 10, third compressed heat regenerative adsorption dryer; 11, fourth compressed heat regenerative adsorption dryer; 12, first postposed precision filter; 13, second postposed precision filter; 14, third postposed precision filter; 15, fourth postposed precision filter; 16, low-pressure air storage tank; 17, high-pressure air storage tank; 18, low-pressure pressure sensor; 19, electric regulating valve; 20, high-pressure pressure sensor; 21, DCS centralized controller; 22, boiler softening water tank; 23, boiler feed water pump; 24, plate heat exchanger; 25, cooling water pump.

[0025] The implementation, functional features and advantages of the present application will be further described with reference to the embodiments in combination with the drawings. DETAILED DESCRIPTION

[0026] The technical solutions in the embodiments of the present application will be described clearly and completely in combination with the drawings in the embodiments of the present application, obviously, the described embodiments are only some of the embodiments of the present application, but not all the embodiments. Based on the embodiments in the present application, all the other embodiments obtained by those skilled in the art without creative labor are within the protection scope of the present application.

[0027] It should be noted that if the embodiments of the present application involve directional indications (such as up, down, left, right, front, back, …), the directional indications are only used to explain the relative position relationship, movement condition and the like between the components in a certain specific posture (as shown in the drawings), if the specific posture changes, the directional indications also change accordingly.

[0028] Furthermore, if the embodiments of this utility model involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, features defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, if the word "and / or" appears throughout the text, it means including three parallel solutions; for example, "A and / or B" includes solution A, solution B, or a solution that simultaneously satisfies A and B. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this utility model.

[0029] I. Implementation Examples of Modular Air Compressor Units

[0030] like Figure 1 As shown, the low-pressure air supply unit is equipped with a low-pressure variable frequency screw air compressor with an outlet pressure of 0.45MPa, connected in series with the first pre-stage two-stage oil removal filter 5, the first compression heat regeneration adsorption dryer 8, and the first post-stage precision filter 12. The air is supplied to the low-pressure terminals such as the vulcanizing machine and the internal mixer through the low-pressure air storage tank 16, covering 70%-100% of the load.

[0031] like Figure 1 As shown, the high-pressure air supply unit is equipped with two 0.8MPa high-pressure variable frequency screw air compressors and one high-pressure centrifugal air compressor 4, which are connected in series with a pre-stage two-stage oil removal filter and a compression heat regeneration adsorption dryer, respectively. The high-pressure air storage tank 17 covers 20%-90% load (variable frequency screw compressor) and 90%-100% (centrifugal compressor); specifically, the first high-pressure screw air compressor 2 is connected in series with the second pre-stage two-stage oil removal filter 6, the second compression heat regeneration adsorption dryer 9, the second post-stage precision filter 13, and the high-pressure air storage tank 17; the second high-pressure screw air compressor 3 is connected in series with the third pre-stage two-stage oil removal filter 7, the third compression heat regeneration adsorption dryer 10, the third post-stage precision filter 14, and the high-pressure air storage tank 17; the high-pressure centrifugal air compressor 4 is connected in series with the fourth compression heat regeneration adsorption dryer 11, the fourth post-stage precision filter 15, and the high-pressure air storage tank 17.

[0032] The air compressor includes a low-pressure screw air compressor 1, a high-pressure variable-frequency screw air compressor, and a high-pressure centrifugal air compressor 4. The high-pressure variable-frequency screw air compressor includes a first high-pressure screw air compressor 2 and a second high-pressure screw air compressor 3. The front-stage secondary oil removal filter includes a first front-stage secondary oil removal filter 5, a second front-stage secondary oil removal filter 6, and a third front-stage secondary oil removal filter 7. The compressed heat regenerative adsorption dryer includes a first compressed heat regenerative adsorption dryer 8, a second compressed heat regenerative adsorption dryer 9, a third compressed heat regenerative adsorption dryer 10, and a fourth compressed heat regenerative adsorption dryer 11. The rear-stage precision filter includes a first rear-stage precision filter 12, a second rear-stage precision filter 13, a third rear-stage precision filter 14, and a fourth rear-stage precision filter 15.

[0033] In the low-load stage in the early production stage, only the high-pressure variable-frequency screw air compressor is started.

[0034] In the capacity improvement stage, when the load of the high-pressure variable-frequency screw air compressor reaches 100%, the low-pressure air compressor is started.

[0035] In the capacity peak stage, if the low-pressure variable-frequency screw air compressor, the first high-pressure screw air compressor 2, and the second high-pressure screw air compressor 3 are all fully loaded, the low-pressure variable-frequency screw air compressor, the first high-pressure screw air compressor 2, and the second high-pressure screw air compressor 3 are closed, the high-pressure centrifugal air compressor 4 is started, and the electric regulating valve is used to directly supply gas from the high-pressure pipe network to the low-pressure terminal.

[0036] The electric regulating valve is further electrically connected with a DCS centralized controller 21. The electric regulating valve is controlled by the DCS centralized controller 21 according to the signal of the low-pressure pressure sensor 18, so as to realize dynamic gas supplementing from the high-pressure pipe network to the low-pressure pipe network. When the load of the low-pressure pipe network is high, the high-pressure pipe network supplements gas through the electric regulating valve (the gas supplementing pressure error is controlled within ±0.02 MPa).

[0037] II. Embodiment of multi-stage gas supply unit

[0038] 1. Step-by-step gas supply design

[0039] High-pressure pipe network (0.8 MPa): directly supply high-pressure terminal (such as calender, etc.).

[0040] Low-pressure pipe network (0.45 MPa): supply low-pressure terminal.

[0041] A DCS control electric regulating valve is arranged between the two networks, and real-time pressure regulating and gas supplementing are realized according to the signal of the low-pressure pressure sensor 18.

[0042] 2. Dynamic gas supplementing control

[0043] When the low pressure pipe network pressure is lower than a set threshold (for example, 0.43 MPa), the DCS centralized controller 21 starts the electric regulating valve to supplement air to the low pressure pipe network with a stability precision of 0.45 MPa.

[0044] III. Embodiment of waste heat recovery device

[0045] 1. Closed cooling circulation system

[0046] The heat conducting medium adopts ethylene glycol and water in a ratio of 50:50, and the boiling point is raised to 108℃ to prevent high-temperature boiling.

[0047] During operation, the 32℃ refrigerant flows through the air compressor built-in cooler (absorbing 90-100℃ waste heat) through the cooling water pump 2525, and is heated to 60℃. After being cooled to 32℃ by the plate heat exchanger 24, it is circulated.

[0048] 2. Heat energy utilization

[0049] The air compressor internal cooling pipeline (temperature 90-100℃) is pushed by the cooling water pump 25 to heat the 32℃ cooling liquid to 60° through the air compressor built-in cooler, and is cooled to 32℃ through the plate heat exchanger 24 to return to the cooling water pump 2525 inlet, so as to make the air compressor cooling system circulate. At the same time, the 32℃ softened water from the boiler softened water tank 22 enters the plate heat exchanger 24 to be heated to 60℃ and enters the boiler water supply system, so as to improve the water inlet temperature of the boiler, save the boiler fuel consumption, and replace about 5% of the fuel.

[0050] During the initial production stage of the factory, since the demand for compressed air is small, a high-pressure screw air compressor is started. As the production capacity of the factory increases, when the load of the high-pressure screw air compressor reaches 100%, a low-pressure screw air compressor is started. When the production capacity of the factory continues to increase, and the load of the high-pressure screw air compressor and the low-pressure screw air compressor both reach 100%, a high-pressure centrifugal air compressor 4 is started, and the three screw air compressors are closed. At the same time, the electric regulating valve is opened, and the low-pressure compressed air terminal is supplied with air by the high-pressure compressed air pipeline. Since the variable-frequency screw air compressor has high variable load performance under small flow conditions, and the centrifugal air compressor has high operating efficiency under large flow conditions, through the DCS control system, the variable-frequency and start-stop control is realized, so as to reduce the idle rate of the screw air compressor and the centrifugal air compressor in their respective low-efficiency zones, thereby achieving the energy-saving effect.

[0051] The above only describes optional embodiments of the present application, and does not limit the patent range of the present application. Any equivalent structural transformation made by using the content of the present application specification and drawings, or direct / indirect application in other related technical fields is included in the patent protection range of the present application.

Claims

1. A high-efficiency air compressor station system, characterized in that, include: A high-pressure compressed air pipeline network, a low-pressure compressed air pipeline network, and an electric regulating valve connecting the two; the high-pressure compressed air pipeline network supplies high-pressure air to the high-pressure air-consuming terminal directly through a high-pressure air storage tank (17), and the low-pressure compressed air pipeline network supplies low-pressure air to the low-pressure air-consuming terminal through a low-pressure air storage tank (16); the electric regulating valve is electrically connected to a DCS centralized controller (21).

2. The high-efficiency air compressor station system according to claim 1, characterized in that, The high-pressure compressed air pipeline network includes at least two high-pressure variable frequency screw air compressors and one high-pressure centrifugal air compressor (4).

3. The high-efficiency air compressor station system according to claim 2, characterized in that, The high-pressure compressed air pipeline network includes at least one low-pressure variable frequency screw air compressor.

4. The high-efficiency air compressor station system according to claim 3, characterized in that, The low-pressure variable frequency screw air compressor and the high-pressure variable frequency screw air compressor are connected in series with a pre-stage two-stage oil removal filter, a compression heat regeneration adsorption dryer, and a post-stage precision filter.

5. The high-efficiency air compressor station system according to claim 2, characterized in that, The high-pressure centrifugal air compressor (4) is connected in series with a compression heat regeneration adsorption dryer and a post-precision filter.

6. The high-efficiency air compressor station system according to claim 1, characterized in that, It also includes a waste heat recovery device, which uses a cooling water pump (25) to drive the flow through the air compressor’s built-in cooler and plate heat exchanger (24) to recover the heat generated by the air compressor’s operation and deliver it to the boiler feedwater system.

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