With the continuous development of wheat flour production enterprises in recent years, the competition of products in the market is more fierce. Affected by regional transportation costs, the profits of various production enterprises have been affected to varying degrees, and many small and medium-sized wheat flour processing enterprises in mainland provinces are more obvious, and some even have no choice but to close the factory directly. Electricity cost is the wheat flour production enterprises in addition to the raw materials of the first major expenditure. At this stage, the flour milling process continues to develop and improve, the manufacturing level of grain machinery equipment continues to improve, the power equipment in the flour processing process is more and more, the power consumption is higher and higher, and the electricity price has risen again and again, and the impact of power consumption on the economic benefits of flour enterprises is becoming more and more obvious. Therefore, energy saving and consumption reduction have become an important basis for measuring the management quality, production arrangement and technical level of flour processing enterprises. Doing a good job of scientific production scheduling, planning and maintenance, technological transformation, comprehensive supporting facilities and the use of green energy can effectively reduce the unit energy consumption of production enterprises, improve the economic efficiency of the food industry and achieve green energy conversion, so as to meet the requirements of the state to solve the emission reduction.
Measures to reduce power consumption in flour processing process
The power consumption in flour processing process can be reduced from the aspects of flour processing technology, equipment, adopting new technology and strengthening management.
Scientific production scheduling, according to the territorial power consumption policy fully combined with the peak and valley level, market sales demand and other factors for real-time production scheduling. Such as daily maintenance, planned technical reform, sales off-season and other special times, you can make full use of the peak period to carry out, the valley period to maintain contact with production. Optimized milling process to ensure the flow balance in the production process. Balance the material quality and flow of each system. When the material of each grinding system is not balanced, it is easy to cause too much or too little grinding material of the mill, and the grinding effect is poor. When the material is not balanced, some silo screen surface in the tall flat screen is often blocked, which seriously restricts the output; Some silo screening surface materials are easy to dry, affecting the quality of flour .
According to the performance of the equipment, make planned maintenance and spot inspection and replacement of the wearing parts of the equipment, and scientific and reasonable collocation of raw grains can help improve production efficiency and reduce energy consumption. For example, when there is more hard wheat in the raw grain, the mill load is heavier, the power consumption is significantly increased, and the pink of the flour is difficult to ensure. According to the market demand, the reasonable proportion of soft and hard wheat can not only reduce the power consumption of tons of powder, but also ensure the quality of flour.
Optimize the automatic control procedure of the process flow, set reasonable start-stop process and start-stop interval time; Minimize the idle power of the device and minimize unnecessary manual starting and stopping of the device. The automatic control system shortens the startup time of the equipment, reduces the failure rate during the startup of the equipment, and when the key equipment fails, due to the chain reaction of the control program, other related equipment can be stopped in time. The effect of using automatic control system is obvious in saving electricity.
Adopt scientific and reasonable start-stop control mode. For example, the high pressure fan, air compressor and Roots blower in the material pneumatic conveying system are regulated by frequency conversion, so that the high pressure fan can work in the best state according to the actual needs of the process. In the past, the high-pressure fan of the pneumatic conveying system of the flour mill was driven by a constant speed AC motor, and the air volume was adjusted by the damper, that is to say, the air volume was adjusted by changing the resistance characteristics of the pipeline, which was bound to cause a waste of electric energy. If the frequency conversion speed regulation technology is used to adjust the speed of the motor instead of the damper to adjust the air volume, the purpose of saving electric energy can be achieved. Because the input power of the load is proportional to the cube of the speed, and the flow of the load is proportional to the speed . If the flow rate is reduced by frequency conversion speed regulation, the input power of the asynchronous motor decreases according to the cubic law. The adoption of variable frequency speed regulation for high pressure fan can not only meet the technological needs, but also save energy to the maximum extent.
Each project design planning to scientific evaluation and selection, the selection of new energy-saving motor, eliminate high energy consumption of the old motor. For example, Y series motor is the best energy-saving motor in China and has been widely used in the powder industry . Compared with the JO2 old motor, it has the advantages of high efficiency, good starting performance, small size and light weight. In addition, the area where the three-proof motor is selected should select the corresponding type of equipment.
According to the process requirements, choose a reasonable motor. If necessary, the corresponding allocation coefficient can be enlarged or reduced appropriately; So that the power of each motor is matched with the mechanical equipment driven by it, and the phenomenon of “big horse cart” and “small horse cart” is reduced as much as possible, so that the motor can play the best effect.
Comprehensively improve the comprehensive skills and conservation awareness of all employees, and do a good job in enterprise power consumption and energy conservation management. Continuously strengthen the special skills training of employees, and widely carry out energy saving and consumption reduction education within the enterprise, so that each employee realizes the importance of energy saving and consumption reduction and consciously saves energy and consumption reduction. Adopt the index management of power consumption to form a good energy saving atmosphere. Formulate scientific and reasonable operating procedures, strive to achieve the operation level of all personnel close to or relatively stable, reduce frequent large adjustments and operations, and reduce equipment idling time. Try to avoid the waste of electrical energy caused by idling equipment, such as the power consumption of the mill idling is 90% of the full load operation. Equipment idling mainly includes the no-load operation of each equipment in the pulverizing process before feeding, and the idling of pulverizing equipment caused by maintenance machines and cleaning clogging. Therefore, after the equipment is started, the material should be fed in time, and the material should be prevented from being cut off and too little during the processing. If the fault is rectified for more than 10 minutes, you need to shut down some or all of the devices.
Strengthen equipment maintenance, improve equipment integrity rate. Regular maintenance of the equipment and the adjustment and replacement of wearing parts to ensure the smooth operation of the equipment and good process performance to the maximum extent. Strengthen the spot inspection in the daily production process, so that the fault can be effectively solved in the bud, and prevent the long-term operation of the equipment with disease. The power saving work is closely related to the operation, maintenance and repair quality of the power supply system and the good rate of mechanical equipment. Ensure the integrity rate and reliability of the equipment in the pulverizing process, and prohibit the equipment to work with disease, resulting in downtime accidents.
Strengthen management to ensure equipment process effect and product quality. In order to achieve good powder and low power consumption, in addition to the adjustment of process equipment, there should be operation and management in line with the requirements of process equipment, and key parts of the production process, such as water dispensers, stone removal machines, grinding, screening, etc., should be focused on management, and strictly abide by the operating procedures.
Measures to reduce power loss
In flour mills, reducing power loss is mainly to reduce the power loss of the distribution system . Reasonable reactive power compensation to improve the power factor, which is a powerful measure to reduce line loss. In the power system, because the change of the user’s power factor directly affects the ratio change of the system’s active power and reactive power, if the user’s power factor is too low, the power factor of the grid will decrease. This not only reduces the output of the generation and power supply equipment, resulting in fluctuations in the grid voltage, but also increases the long-distance transmission of reactive power and the loss of active power in the line, but also increases the user’s electricity expenses, such as serious lack of compensation once verified will face a huge penalty issued by the power supply department. Therefore, enterprises must be equipped with perfect, scientific and reasonable compensation equipment and facilities to reduce reactive power consumption.
Using copper conductor instead of aluminum conductor has better energy saving effect. Since the resistivity of the copper conductor is 57.7% of the resistivity of the aluminum conductor, the loss rate can be reduced by 42.3% from the power calculation, which is a very practical measure. Otherwise, in order to achieve the same level of loss as the copper conductor, it is necessary to expand the cross-section of the aluminum conductor by about 1 times, so the initial investment and later maintenance costs are unreasonable.
Choose energy-saving transformer. With the development of related technologies, energy-saving transformers have reached a better level in terms of quality. At present, it has developed to more than S9 series products; At the same time, wraparound core and amorphous core transformers began to appear. The no-load loss of amorphous core transformer [7] is only 25% to 30% of the S9 series, which can play a great role in further reducing the loss in the transmission process.
Set up a perfect centralized power room cooling system to ensure that the power room ventilation, dry, not high temperature, can effectively improve the service life of electrical equipment, efficiency and eliminate high temperature safety hazards. At the same time, plan the development of the special cable, electrical appliances, facilities maintenance plan, timely replacement or maintenance of related electrical equipment and facilities, to ensure that electrical facilities are in good working condition. In order to reduce the loss of transmission and leakage, the low-voltage distribution line should be reformed and updated to expand the current level of the conductor and improve the insulation level.
Measures to reduce the electricity consumption of office and workshop lighting
The lighting power in the office area is controlled by acousto-optic device to realize automatic lighting control. The lighting power supply system in the production area is implemented at a fixed time, the workshop lighting replaces high-energy incandescent lamps with high-efficiency energy-saving fluorescent lamps, the selection of electronic rectifiers, and the phase-out of iron core rectifiers with large energy consumption. It is forbidden to use high-power electrical equipment such as electric stove and electric kettle. These measures can play a significant role in lighting energy saving work.
Application of green and low-carbon energy
Fully combined with the national energy policy, actively respond to the national call of “carbon peak carbon neutrality”, the new park and new plant from the project start synchronous planning and design, the old plant combined with the actual situation to scientifically use the top floor area of the good lighting performance of the plant and the warehouse, especially the new project, from the initial research, project, plant construction integration, synchronous supporting construction of complete photovoltaic projects. Scientific arrangement and use; Maximum efforts to achieve the use of photovoltaic power generation during the peak period of electricity prices. Thus to achieve the purpose of energy saving, consumption reduction, quality improvement and efficiency.
Construction and application of energy storage facilities
At present, many large and medium-sized cities in China have implemented the peak and valley electricity price policy, and each enterprise scientifically schedules production according to its actual situation and shifts peak electricity consumption. At the same time, with the continuous development and progress of energy storage supporting facilities, enterprises can combine local policies and regional advantages, adopt different forms of cooperation or independent construction of superior performance of energy storage facilities, charge and store energy in the low period of electricity, and release energy between the peak of electricity, so as to maximize the cost of electricity, so as to achieve a good virtuous cycle of using valley peak. Provide support for the operation of enterprises.
Post time: Dec-21-2024