The production status of 11 sets of screw-type ammonia compressors, normally open 3 4 sets (previously opened 6 7 sets, through continuous technical transformation and optimization of production, the number of start-ups is slowly reduced), the total refrigeration capacity is 20. 9 25. 08 GJ. Due to the influence of water quality, the oil cooler is extremely easy to scale, which seriously affects the cooling effect, and has many problems such as high oil temperature, high oil consumption, large fuel consumption, and poor separation effect. In order to improve the cooling effect, the scale of the oil cooler must be stopped frequently during production, and the amount of cooling water is increased, but the oil temperature is still 60 65 for a long time, and the oil temperature of the ammonia compressor in summer is as high as 70, and the outlet temperature reaches 90. 100, often burn shaft seals, bearings and rotors, increase maintenance costs and workload, affecting normal production. It is estimated that: 1 ammonia compressor with a cooling capacity of 8.37 GJ is filled with oil, and it is necessary to stop replenishing the lubricating oil for one week of continuous operation, at least 480 kg for one time; one ammonia with a cooling capacity of 4. 18 GJ The compressor is full of oil, and it must be stopped once every 2 weeks of continuous operation, supplementing 360 kg of lubricating oil; 1 set of ammonia compressor with a cooling capacity of 2.09 GJ is filled with oil, and it must be stopped once every 4 weeks of continuous operation. , supplemented with lubricating oil 180 kg. According to the company's production load, the general situation usually open 3 ammonia compressors, 2 sets of 8. 37 GJ, 1 set of 4. 18 GJ, then the average monthly lubricating oil consumption is 4. 56 ,t Not only is it expensive, but it is also very passive due to frequent parking and reversing. 2 technical transformation process In order to solve the problem of ammonia compressor oil cooling system, the company has taken three measures: 1 increase the heat exchanger area of ​​the oil cooler; 2 set the outer cooling of the oil cooler; 3 increase the flushing of the oil cooler, but the effect Not very satisfactory. To this end, the company set up a technical reform team, and repeatedly inspected the same industry, combined with the analysis of production status, and finally decided to change the ammonia compressor oil cooling system from water-cooled to ammonia-cooled, and earlier to 4. 18 The GJ ammonia compressor oil cooling system was retrofitted. It can be seen that the liquid ammonia enters the liquid ammonia buffer tank from the outlet of the gas ammonia cooler, enters the main pipe through a certain position difference, and then enters each oil cooler of the ammonia compressor separately, and evaporates into a gas ammonia by heat exchange with the lubricating oil, and compresses with ammonia. The compressed air ammonia is mixed into the cooler. The principle of the process is to use the cold amount of ammonia in the recovery liquid, cool the lubricating oil with higher temperature in the oil cooler, evaporate the liquid ammonia into the gas to remove the heat, and then cool the ammonia to liquid ammonia recycling. 3 transformation effect The technical reform work began in June 2005 and was completed and put into use in September 2005. The effect is very obvious: 1 the oil temperature is generally only about 30 40, the outlet temperature is only 50 60; 2 the exhaust pressure is reduced by 0. 2 0 3 MPa, only 1. 0 1. 2 M Pa, the load of the subsequent condenser is greatly reduced; 3 reduces the consumption of circulating water desalinated water and electricity; 4 reduces the amount of small ammonia tank venting, fully recovers the liquid Ammonia; 5 improves the separation of lubricating oil. On the basis of the success of the previous technical reform, the company implemented ammonia-cooled technical transformation on the ammonia compressor oil cooling system with a cooling capacity of 8.37 GJ in October and December 2005 respectively, so that the ammonia compressor lubricating oil was consumed. Greatly reduced, ensuring long-term stable operation of equipment and devices. 4 economic benefits (1) From normal use in July 2005 to February 2006, the total operating time is 8 months, the total consumption of lubricating oil is 24.56, and the average fuel consumption per month is 3.07, t compared with the technical reform. The previous monthly average fuel consumption of 4.56 t can save the refrigeration oil in the year: ( 4. 56- 3. 07) 12 = 17. 88 ( t). According to the price of frozen oil in the existing market of 5,000 yuan / t, the annual savings can be: 17. 88 5 000 = 8.94 million. (2) After the technical reform, the circulating water can be completely eliminated. The previous three ice oil coolers consume 100 m 3 /h of water, and the circulating water cost is 0.30 yuan / m 3, which is saved by 330 working days per year. The cost is: 100 24 330 0. 30= 23.76 million yuan (3) After the technical transformation, the ammonia compressor outlet pressure drops and the operating current also drops. 8. 37 GJ ammonia compressor current is reduced by 5 A, 4. 18 GJ ammonia compressor current is reduced by 3 A.8. 37 GJ ammonia compressor voltage design value is 10 000 V, 4. 18 GJ ammonia compressor The voltage is 6 000 V, 330 operating days per year, the power factor is 0.9, and the annual power saving is: 5 10 000 3 0. 9 330 2 24= 123. 46,000 kW h 3 6 000 3 0. 330 24= 22. 220,000 kW h 22. 22+ 123. 46= 145. 680,000 kW h according to the current electricity price of 0.30 yuan / kW h, the annual cost savings: 145. 68 0. 30 = 43.70 million yuan. The above three items can create economic benefits for the company every year: 8. 94+ 43. 70+ 23. 76= 76.40 million. In addition, since the gas ammonia cooled by the oil cooler returns to the ice machine outlet gas cooler, the load of the subsequent cooler may be increased, but the ammonia is cooled, the consumption is small, and the oil temperature is lowered, and the outlet gas is ammonia. After the temperature is lowered, the influence of the subsequent cooler is compared. The latter factor is larger than the former, so the amount of the outlet gas cooler to remove the brine is also reduced. Moreover, due to the long operating cycle, the amount of parking and maintenance is reduced, the maintenance cost is reduced, the pressure is reduced, and the air pressure is reduced. This also reduces environmental pollution and safety accidents, and also receives certain social benefits.
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1 situation before technical reform