Application Of Intelligent Optimization Energy Saving System In Textile Mill

In textile enterprises, electricity charges occupy a large proportion in production costs. Enterprises can save electricity expenses, reduce production costs and improve market competitiveness through intensive management of power.

In addition, power monitoring can also improve the power supply capability of the power grid and reduce the operation and maintenance costs of the equipment.

At present, some energy saving measures have been adopted in the textile mill, but the power management work is still very weak, and the space for power saving is still very large, for example, the pformer is not running economically, the power consumption of peak load is not in place, and the loss of power supply lines is large.

Through the monitoring and meticulous management of electricity, the energy saving benefits can not be ignored.

Current situation of power management in textile mills

In the weaving plant, the two factories are far apart, and the meter reading is usually far away from the factory. The meter reading is time-consuming and laborious, and there is time difference between the meter reading before and after the meter reading, which affects the accuracy of the data: the main production links such as carding, drawing, combing, spinning and other main parts in the spinning workshop, there are no systematic management of the electrical equipment and operation status in almost every link. The equipment is switched on by hand, and the equipment is switched on by the staff on duty. It is impossible to make rational use of electricity, scientific electricity and economic electricity. A textile company in Hubei has 100 thousand spindles of spinning equipment and 700 looms of various types, with 15 thousand tons of annual spinning and 40 million meters of weaving. The company has two factories, one spinning mill and one.

Enterprise energy management

The system monitors and analyzes the main energy points of the plant, builds an enterprise energy management center platform, runs intelligent optimization energy saving system software on the platform, monitors the real time energy consumption of the enterprise, monitors the operation status of the key electrical equipment, analyzes the historical energy data, finds out the energy management problems, and finds out the energy saving space.

Optimal operation of 1= air compressor

Air compressor stations have different power requirements under different start-up conditions. Air compressor operation is carried out in combination mode according to the gas consumption. After the implementation of the system, the data analysis of the combined operation of the air compressor shows that when the 6# air compressor is stopped (75kW), the overall energy consumption of the air compressor is the smallest. When the 4# air compressor (75kW) is stopped, the overall energy consumption is the largest. From the system air compressor load analysis report, it is found that the factory regularly stops 4# air compressors, and the 6# air compressor is stopped to save 32 degrees per hour than the 4 air compressors. The electricity is 24 hours per day, 330 days per year, 0.7 yuan / degree electricity price, and the annual air compressor is 177 thousand yuan. The air compressor belongs to the large energy users in the textile mill. The air compressor system of the textile mill is centralized gas supply, and the energy consumption of the whole air compressor system accounts for 28%-30% of the total energy consumption of the whole plant.

2= peak load shifting

In addition to spinning and weaving machines running 24 hours a day, other parts of the textile mill do not operate at full capacity. The factory now operates three shifts each day, 8 hours per shift. After the system is put into operation, we find that the flowers, carding and drawing work are 8 hours, but the actual working hours are only 5 hours. The three classes work in 15 hours, so the 24 hours per day can remove 6 hours of peak electricity, and the rest time is enough for these sections.

Through the system, it is found that the flower cleaning process is shut down in the morning every day, and there is a boot operation at peak power stage in the evening. Energy consumption can be saved by peak shifting electricity.

The peak to peak power consumption will be shifted to electricity consumption during the valley period. The total consumption of electricity will be 210 hours per day, and the total consumption of electricity will be 210 degrees per day. According to the annual operation of 330 days, the electricity consumption will be saved by about 52 thousand yuan. Similarly, the situation of carding is also the same. There is also the situation that the peak power is switched on, and the energy consumption can be achieved by shifting the peak power. Under the condition of keeping the total time of the original opening and stopping, the peak shifting time is removed, the peak hours are selected to move to the valley period for 2 hours, the peak electricity is pferred to the normal period 1 hours, the carding is 3 hours per hour, the peak hour is broken, and the average power consumption is 88 degrees per hour.

3= line loss and energy saving

The spinning workshop of the textile mill is powered by 2 1600kVA pformers of the same type. After the use of the system, the same pformer is found. The difference between the total power consumption of the high and low voltage side is very large every day, and there is still a 300 degree gap after excluding the pformer's own consumption.

The system promptly sent out reminders, and the on-site personnel found that the problem was discovered because the electricity load in the earlier stage was smaller, the bus busbar met the carrying capacity, increased the equipment at the later stage, increased the load, and the bus exhaust fever was serious and the loss was large. Taking measures to increase a bus bar in each phase, the loss was obviously reduced. After handling the bus lap surface, the daily high and low voltage power gap was restored to normal value. Based on this, it was estimated that the annual electricity price could be saved by 69 thousand. If no system was used, the problems could not be found in time, and the waste would always exist.

4= air conditioning management energy saving

Through the alarm function of the system, we find that under the condition of low ambient temperature, some of the air conditioners are still running at high speed. The high and low speed of the air-conditioner is mainly used by the textile workers to adjust the temperature and humidity of the workshop, and the control of temperature and humidity has a great influence on the quality of the products.

At present, the textile mill adopts artificial adjustment of air conditioning facilities. There are problems in real-time and accuracy. After the use of the system, the alarm and energy consumption statistics function of the system enables operators to control the air-conditioning energy consumption and control the temperature and humidity of the workshop at a glance.

The air conditioner has a power difference of 10kW between the high speed gear and the low speed gear. The system reminds 5 air conditioners that there are problems. According to the one year air conditioning operation at low speed for 4 months, 24 hours per day, the average electricity price is calculated at 0.7 yuan / degree, which can save 100 thousand yuan on electricity charges.

Concluding remarks

After adopting the intelligent optimization energy saving system software, the textile mill makes timely analysis and diagnosis report based on the system software, adjusts the production time in time, strengthens equipment management, and rectify the power supply line during maintenance. Through these measures, the system can achieve energy saving efficiency of about 455 thousand yuan per year.

In addition, intelligent optimization energy saving system can also realize remote monitoring, bring high efficiency management mechanism to enterprises. By setting up remote access, it can achieve system platform access between the head office and its branches. The production status, statements and equipment of the branch company are clear and clear at the same time.

While achieving remote management, it also improves office efficiency and improves management efficiency.