With the development of petrochemical plants to large scale, high-power compressors are commonly used in production plants with compression process requirements. Since the production load tends to vary within a certain range, the power of the compressor has a certain margin relative to the production load under normal conditions, and may occur in a relatively large amount of time or a period of time. In this case, the traditional adjustment method is to return excess compressed gas to the compressor inlet through the bypass. This adjustment method greatly wastes the productivity of the compressor, and consumes more electric energy and cooling water. After extensive market research and technological innovation, Gaoqiao Petrochemical Company's refining business unit applied HOERBIGER's Hydrocom technology to improve the gas volume adjustment mode of a single machine, that is, the application of the pipe network to combine similar compressors into a fleet for improvement. The useless power of the compressor is reduced, and a good energy saving effect is achieved. 1 Hydrol technology hydrocracking unit used in the hydrocracking new hydrogen compressor unit C. Originally designed with three reciprocating new hydrogen compressors K3101A/B/C (see Table 1 for technical parameters), normal production According to the compressor hardware (AB unit is the American Dresser-rand imported unit, C unit is the domestic unit), one of the AB units is fully loaded, and the C unit is adjusted according to the production load. The actual load is The fluctuation of the rated load is between 40% and 75%, and the excess capacity is large. It is adjusted by the common bypass adjustment method. The surplus hydrogen after three-stage compression is throttled by the bypass control valve, and then cooled by the water cooler and returned to the first-stage inlet tank of the unit, thereby realizing the flow regulation, and thus reciprocating. The adjustment 84 mechatronics 12010.12 method wastes a lot of electric energy and consumes more circulating water, which is very unreasonable. Table 1 Hydrocracking unit technical parameter table Equipment specifications Models All levels of suction / discharge pressure (MPa) flow m3 / h motor power (kw) continued Table 1.1 technical transformation program principle installed on the C machine HOERBIGER gas volume stepless The adjustment system Hydrocom uses electromechanical integration technology to control the closing time of the intake valve with a set of intelligent electro-hydraulic actuators, so that the compressor only compresses the required amount of gas, so that the surplus gas flows back into the initial stage of the compression stroke. In the air cavity, more useless work is saved, thereby achieving the purpose of energy saving. After the system is put into use, the return bypass will be completely shut down, and the compressor's work process will be as good as it is. ABCDA is the original design process. After the technology is improved, the work process becomes into -BCFEA. In the CF stage, the surplus gas is returned to the intake cavity by the Hydrocom system. The compressor only returns little work. From the figure, we can see that the area covered by CDEF is the work of saving. 1.2 Reconstruction and implementation In March 2009, the temporary parking opportunity was utilized by the device. After three days, the investment was 3 million yuan, and the Hydrocom system configured as shown in Table 2 was installed. The system principle is as shown. Table 2 Hydrocom system parameter table interface central command, compressor Hydrocom system field control center intelligent actuator is provided by HU hydraulic power, CIU real-time control, realize steam valve as needed to close the hydraulic station hydraulic power system top dead center sensor transfer piston The position service unit in the cylinder is based on the analysis and diagnosis platform of the production platform. The PID controller in the DCS control system outputs a standard current signal of 4-20 mA according to the compressor's three-stage exhaust pressure and the interstage signal. The CR is sent to the DCS. The electrical signal is converted into the control signal of the first, second and third stage actuators. In this modification, the Hydrocom system principle is added according to the Hydrocom control requirements in the I/A control system of the original device F0XB0R0. After the effect detection system is put into operation, the compressor current data of the 130t/h production load under normal conditions of the hydrocracking unit is collected. At this time, the C load fluctuates around 70%, and the data is shown in Table 3. 2010.121 Mechatronics Ming Table 3 Compressor Current Data Date A Machine Current (A) c Machine Current (A) Date A Machine Current (A) C Machine Current (A) Average From the collected data, after using the Hydrocom system, The current drops by an average of 100A, a decrease of about 40%. The compressor current drop data is basically within this range for more than a year. Energy-saving effect ==1. = 3.74 million yuan / year It can be seen that the energy-saving effect is very obvious. At the same time, the stepless adjustment of the 0-100% load of the compressor is realized, which reduces the labor intensity of the crew and makes the operation adjustment of the device more stable. Therefore, the technical transformation work was very successful. 2 set up 8.0MPa new hydrogen pipe network, the compressor is improved from single control to the group control in the original design, the operation five-zone production unit 3 million tons of diesel hydrogenation unit, 800,000 tons of gasoline and diesel hydrogenation unit, 1 million tons of wax oil The hydrogenation unit has two new hydrogen compressors. The compressor data is shown in Table 4. The operation mode is one open and one standby. In actual operation, the new hydrogen compressor of each unit has a certain margin. The return amount to meet the production requirements, energy consumption is huge (especially diesel hydrogenation), there is a large potential for energy saving. Table 4 Compressor data list Device name Compressor type, quantity export displacement m3/h Normal hydrogen consumption m3/h 1 million tons of wax oil hydrogenation 800,000 tons of gasoline and diesel hydrogenation 1 set of 3 million tons of diesel hydrogenation total consumption Hydrogen quantity 2.1 Technical transformation scheme Principle effect detection Three sets of devices are geographically close, and the new hydrogen system pressure is 7.2 MPa. After technical demonstration, six new hydrogen compressors of three sets of devices are combined into a fleet control, and six compressor outlets are connected. The new hydrogen pipe network is 8.0 MPa, and the pressure of the diesel hydrogenation system is used as the control value of the pipe network pressure, and the DCS of the original device is used for control. The DCS adjusts the return amount of the diesel hydrogenation compressor according to the system pressure. After the control scheme is changed, only one diesel hydrogenation hydrogen compressor and one of the other two new hydrogen compressors can be operated to meet the total production demand of 44,000 m3/h. 2.2 The scheme implements a new hydrogen pipe network of 8.0 MPa, uses the original diesel hydrogenation DCS to control the pressure, deactivates the return control of the other two sets of compressors, and closes the final return circuit. After the fleet management, the wax oil hydrocompressor was basically stopped. The energy saved is 1117kW/h, and the economic benefit is=1117kW/hx8000h/yx05 yuan/kW=446.8 million yuan/year. 3 Conclusions Two energy-saving improvement projects have been very successful. After the project is put into operation, the device runs smoothly and has the value of promotion and use. However, Hydrocom's investment cost is high, which restricts the promotion and use of the technology. In the latter retrofit solution, the compressor still has a certain amount of return, but the ratio of recovery value to equipment investment limits the application of the technology. Compressor group management is a good innovation, and it is based on a higher level of energy saving methods in production facilities. The original design of the production equipment, there are many energy-saving potentials to be dug, waiting for our technicians to better master advanced science and technology, play a subjective initiative, and carry out technological improvement and innovation. 86 Mechatronics 2010.12 Metal Deep Drawing,Metal Drawers,Deep Drawing Metal,Coustom Metal Deep Drawing Nanpi Jian Tong Hardware Manufacturing Co., Ltd. , https://www.sheetmetals.nl
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