Zhejiang Zhangzhou Juhua Sulfuric Acid Plant is the first batch of key sulfuric acid production enterprises designed, manufactured and installed in China. It is the largest sulfuric acid production plant in Zhejiang Province.
In the process of sulfuric acid production, the water-cooled plate needs to be cooled. The cooling water circulation pump is an important equipment in the sulfuric acid production process. In the past, the cooling water circulation pump did not adjust the speed, and the outlet valve was used to control the water flow and the pipe network pressure due to the equipment. The selection is based on the maximum load condition. In the actual operation, the equipment has a large margin. The flow and pressure of the cooling water are adjusted by the cooling water circulation pump and the regulating valve on the inlet communication pipe to cause the motor. The operation efficiency is low, resulting in waste of electric energy. In order to reduce the production cost, after deciding, it is decided to use the Fengguang JD-BP37 high-voltage inverter to carry out the variable frequency speed regulation and energy-saving transformation of the cooling water circulation pump to solve the problem of energy waste. The working principle of the cooling water circulation pump is shown in Figure 1. Three circulating pumps are installed separately.
2. The relevant parameters of the user's cooling water circulation pump and supporting motor are:
Pump model: 500S-35 single-stage double-suction centrifugal pump;
Flow rate: 561L∕S Speed: 970r/min
Head: 35m
Motor power: 280KW
Voltage: 6000V
Current: 35.2A
Speed: 985r/min
3, new scenery JD-BP37 high voltage inverter
3.1 JD-BP37 high voltage inverter
JD-BP37 high-voltage frequency converter adopts the latest IGBT as the main control device, fully digital, color LCD touch screen control, high-quality inverter with high reliability, easy operation and high performance. After years of research and development, the products have been widely used in metallurgy, petroleum, chemical, electric power, cement, water supply and drainage, pharmaceutical, paper, sewage treatment and other industries. It is no accident to be a boutique.
The high-voltage inverter of wind and light adopts several low-voltage inverter power units connected in series to realize direct high-voltage output. The 6kv high-voltage inverter used in the transformer has 18 sets of edge windings, which are divided into 6 power units, three phases and 18 phases. The unit is 36-pulse rectified, and the harmonic components at the input end meet the national standard. The high-voltage inverter system structure is shown in Figure 2. The main circuit of the unit circuit is shown in Figure 3. The bypass branch uses a thyristor module.
3.2 JD-BP37 high voltage frequency converter main technical performance
3.2.1 High-high voltage source inverter, direct 6KV input, direct 6KV output, no need for any output transformer or filter, suitable for ordinary high-voltage motor, no damage to motor and cable insulation.
3.2.2 The input power factor is high, the current harmonics are small, and no power factor compensation or harmonic suppression device is required.
3.2.3 Modular design of unit circuit, easy maintenance and good interchangeability.
3.2.4 The high voltage main circuit and the controller are connected by fiber, strong and weak electrical isolation, safe and reliable.
3.2.5 Complete fault detection, accurate fault protection and accurate positioning display and alarm.
3.2.6 Built-in PLC to adapt to the changing needs of the site.
3.2.7 The control power supply and the high voltage power are independent of each other. No high voltage can detect the output of the inverter, which is convenient for on-site commissioning and training of operators and easy for maintenance.
3.2.8 The power unit has high reliability after 24 hours of high temperature aging and 150% load test.
3.2.9 Chinese Windows operation interface, color LCD touch screen operation.
3.2.10 Can receive and output multiple industrial standard signals.
3.2.11 Printable output run report.
4, control principle and electrical equipment transformation circuit diagram
The inverter controls the 3# circulation pump, and the 2# and 1# circulation pumps are opened. Now take the cooling water main pipe pressure as a given amount, adjust the circulating pump speed according to the mother pipe pressure required by the process, the pressure signal is taken from the main network, and the target pressure value is set at 0.24Mpa.
5, high-voltage inverter power-saving situation introduction
The equipment renovation project was completed in January 2005. The high-voltage inverter was successfully tested once, and the operation was normal. The frequency was running at around 40 Hz, which guaranteed the normal temperature of the circulating water. Its power saving related data is:
5.1. Power frequency operation data is:
May 27th 14:30 Operating frequency 50Hz Input current 23.8A Input voltage 6KV
May 27th 21:35 Operating frequency 50Hz Input current 26.4A Input voltage 6KV
May 28th 08:00 Running frequency 50Hz Input current 25.2A Input voltage 6KV
May 28th 21:00 Running frequency 50Hz Input current 24.8A Input voltage 6KV
May 29th 06:25 Operating frequency 50Hz Input current 24.1A Input voltage 6KV
Power frequency average running current 24.86A Power factor COSΦ1 = 0.85
5.2. Frequency conversion operation data
May 27th 11:00 Running frequency 41:55Hz Input current 13.0A Input voltage 6KV
May 27th 12:00 Operating frequency 41:55Hz Input current 13.1A Input voltage 6KV
May 27th 13:00 Operating frequency 41:55Hz Input current 13.0A Input voltage 6KV
May 27th 14:00 Running frequency 41:55Hz Input current 13.2A Input voltage 6KV
The average operating current of the inverter is 13.07A, and the power factor is COSΦ2 =0.98.
Save electricity every year:
(I × COS Φ 1-I × COS Φ 2 ) × Ua × 1.732 × 24 hours × 350 days = 718,000 degrees
Annual electricity consumption savings: annual electricity savings × 0.5 yuan / kWh = 359,000 yuan
The power saving rate reaches 40% when the inverter is running.
When the frequency of the equipment reaches 35Hz, the water pressure of the process can be reached. In the spring, winter and autumn, the equipment can run at 35Hz, and the power saving rate can reach 50%. According to the current 41Hz operation calculation, the annual energy saving can be 710,000. Degree, saving electricity costs of 359,000 yuan, the cost recovery period is 1.8 years.
6, the conclusion
The application of Fengguang high-voltage frequency converter in the cooling water circulation pump of Juhua Co., Ltd. sulfuric acid plant can make the cooling water circulation pump adjust the cooling water flow with the change of load to save energy, and protect the soft start of the circulation pump. Pumps and motors reduce the maintenance cost of the pump body and motor, improve the operating conditions of the cooling water circulation pump, and reduce the production cost of the enterprise. Today, high-voltage inverter technology is becoming more and more mature. It is believed that domestic high-voltage inverters will have better performance in various industries.
Zhejiang Yijia Energy Saving Equipment Co., Ltd., the undertaker of this project, is a professional energy saving service provider. Through the installation, commissioning and operation of the 280KW/6000V high-voltage inverter, it also reflects the high professional quality and technical level of Yijia Energy-saving Equipment Company in the energy-saving industry.
In the process of sulfuric acid production, the water-cooled plate needs to be cooled. The cooling water circulation pump is an important equipment in the sulfuric acid production process. In the past, the cooling water circulation pump did not adjust the speed, and the outlet valve was used to control the water flow and the pipe network pressure due to the equipment. The selection is based on the maximum load condition. In the actual operation, the equipment has a large margin. The flow and pressure of the cooling water are adjusted by the cooling water circulation pump and the regulating valve on the inlet communication pipe to cause the motor. The operation efficiency is low, resulting in waste of electric energy. In order to reduce the production cost, after deciding, it is decided to use the Fengguang JD-BP37 high-voltage inverter to carry out the variable frequency speed regulation and energy-saving transformation of the cooling water circulation pump to solve the problem of energy waste. The working principle of the cooling water circulation pump is shown in Figure 1. Three circulating pumps are installed separately.
2. The relevant parameters of the user's cooling water circulation pump and supporting motor are:
Pump model: 500S-35 single-stage double-suction centrifugal pump;
Flow rate: 561L∕S Speed: 970r/min
Head: 35m
Motor power: 280KW
Voltage: 6000V
Current: 35.2A
Speed: 985r/min
3, new scenery JD-BP37 high voltage inverter
3.1 JD-BP37 high voltage inverter
JD-BP37 high-voltage frequency converter adopts the latest IGBT as the main control device, fully digital, color LCD touch screen control, high-quality inverter with high reliability, easy operation and high performance. After years of research and development, the products have been widely used in metallurgy, petroleum, chemical, electric power, cement, water supply and drainage, pharmaceutical, paper, sewage treatment and other industries. It is no accident to be a boutique.
The high-voltage inverter of wind and light adopts several low-voltage inverter power units connected in series to realize direct high-voltage output. The 6kv high-voltage inverter used in the transformer has 18 sets of edge windings, which are divided into 6 power units, three phases and 18 phases. The unit is 36-pulse rectified, and the harmonic components at the input end meet the national standard. The high-voltage inverter system structure is shown in Figure 2. The main circuit of the unit circuit is shown in Figure 3. The bypass branch uses a thyristor module.
3.2 JD-BP37 high voltage frequency converter main technical performance
3.2.1 High-high voltage source inverter, direct 6KV input, direct 6KV output, no need for any output transformer or filter, suitable for ordinary high-voltage motor, no damage to motor and cable insulation.
3.2.2 The input power factor is high, the current harmonics are small, and no power factor compensation or harmonic suppression device is required.
3.2.3 Modular design of unit circuit, easy maintenance and good interchangeability.
3.2.4 The high voltage main circuit and the controller are connected by fiber, strong and weak electrical isolation, safe and reliable.
3.2.5 Complete fault detection, accurate fault protection and accurate positioning display and alarm.
3.2.6 Built-in PLC to adapt to the changing needs of the site.
3.2.7 The control power supply and the high voltage power are independent of each other. No high voltage can detect the output of the inverter, which is convenient for on-site commissioning and training of operators and easy for maintenance.
3.2.8 The power unit has high reliability after 24 hours of high temperature aging and 150% load test.
3.2.9 Chinese Windows operation interface, color LCD touch screen operation.
3.2.10 Can receive and output multiple industrial standard signals.
3.2.11 Printable output run report.
4, control principle and electrical equipment transformation circuit diagram
The inverter controls the 3# circulation pump, and the 2# and 1# circulation pumps are opened. Now take the cooling water main pipe pressure as a given amount, adjust the circulating pump speed according to the mother pipe pressure required by the process, the pressure signal is taken from the main network, and the target pressure value is set at 0.24Mpa.
5, high-voltage inverter power-saving situation introduction
The equipment renovation project was completed in January 2005. The high-voltage inverter was successfully tested once, and the operation was normal. The frequency was running at around 40 Hz, which guaranteed the normal temperature of the circulating water. Its power saving related data is:
5.1. Power frequency operation data is:
May 27th 14:30 Operating frequency 50Hz Input current 23.8A Input voltage 6KV
May 27th 21:35 Operating frequency 50Hz Input current 26.4A Input voltage 6KV
May 28th 08:00 Running frequency 50Hz Input current 25.2A Input voltage 6KV
May 28th 21:00 Running frequency 50Hz Input current 24.8A Input voltage 6KV
May 29th 06:25 Operating frequency 50Hz Input current 24.1A Input voltage 6KV
Power frequency average running current 24.86A Power factor COSΦ1 = 0.85
5.2. Frequency conversion operation data
May 27th 11:00 Running frequency 41:55Hz Input current 13.0A Input voltage 6KV
May 27th 12:00 Operating frequency 41:55Hz Input current 13.1A Input voltage 6KV
May 27th 13:00 Operating frequency 41:55Hz Input current 13.0A Input voltage 6KV
May 27th 14:00 Running frequency 41:55Hz Input current 13.2A Input voltage 6KV
The average operating current of the inverter is 13.07A, and the power factor is COSΦ2 =0.98.
Save electricity every year:
(I × COS Φ 1-I × COS Φ 2 ) × Ua × 1.732 × 24 hours × 350 days = 718,000 degrees
Annual electricity consumption savings: annual electricity savings × 0.5 yuan / kWh = 359,000 yuan
The power saving rate reaches 40% when the inverter is running.
When the frequency of the equipment reaches 35Hz, the water pressure of the process can be reached. In the spring, winter and autumn, the equipment can run at 35Hz, and the power saving rate can reach 50%. According to the current 41Hz operation calculation, the annual energy saving can be 710,000. Degree, saving electricity costs of 359,000 yuan, the cost recovery period is 1.8 years.
6, the conclusion
The application of Fengguang high-voltage frequency converter in the cooling water circulation pump of Juhua Co., Ltd. sulfuric acid plant can make the cooling water circulation pump adjust the cooling water flow with the change of load to save energy, and protect the soft start of the circulation pump. Pumps and motors reduce the maintenance cost of the pump body and motor, improve the operating conditions of the cooling water circulation pump, and reduce the production cost of the enterprise. Today, high-voltage inverter technology is becoming more and more mature. It is believed that domestic high-voltage inverters will have better performance in various industries.
Zhejiang Yijia Energy Saving Equipment Co., Ltd., the undertaker of this project, is a professional energy saving service provider. Through the installation, commissioning and operation of the 280KW/6000V high-voltage inverter, it also reflects the high professional quality and technical level of Yijia Energy-saving Equipment Company in the energy-saving industry.
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