Technical Means To Save Electricity And Reduce Consumption In Cotton Spinning Enterprises

In the direct production cost of cotton spinning enterprises, electricity cost is the second major cost factor after the cost of raw materials. China's electricity tariff is higher than that of many other countries in the world. The cotton spinning industry as a small profit industry, the cost pressure is constantly increasing. How to achieve electricity saving and consumption reduction through effective technological progress and lean management is an important issue facing cotton spinning enterprises.

For cotton spinning enterprises, the power consumption measurement and assessment indicators can be divided into the following items.

1) comprehensive electricity consumption. Refers to the sum of all kinds of electricity consumed by the enterprise during the reporting period. The unit is kW. H. In the process of production, due to different functions of production division, different types of electricity consumption will be generated, such as electricity consumption for each process, basic production and auxiliary production.

2) the product is comparable to the unit output and comprehensive electricity consumption. Refers to the enterprise in the statistical reporting period, in accordance with the prescribed calculation method, the cotton yarn production process, each variety, each specification output is revised respectively, converted to cotton yarn standard production, respectively, the product is comparable to the unit output comprehensive electricity consumption. The unit is kW. H. Because the yarn output is related to many factors such as production variety, twist factor, line density and coiling process, it is necessary to fold into a certain standard product, and then convert into standard consumption of electricity, so as to compare the power consumption level of different enterprises and different products.

3) power consumption per machine. Refers to the power consumption of a unit or unit of a unit during the reporting period, which is kW. H. It reflects the power consumption of different processes and equipments.

Technical means to save electricity and reduce consumption in Enterprises

Using advanced technology

The main engine of cotton spinning equipment adopts new transmission system, new driving technology, mechatronics technology and new lighting system of factory. It has good effect on saving electricity and reducing consumption.

1) a new type of transmission system is mainly used for synchronous belt drive, instead of traditional belt drive, gear drive and chain drive. Synchronous tooth belt drive realizes the transmission and movement of belt and belt wheel, which can eliminate the asynchronous phenomenon of the original traditional transmission form, and has no relative sliding between the belt wheel and the belt pulley, the transmission ratio is accurate, the transmission is stable, no gap and slip difference, and it is beneficial to power consumption, noise and product quality.

2) new drive technologies include AC servo drive, rare-earth permanent magnet synchronous motor drive, digital servo AC motor, brushless converter motor drive, DC bus control technology, etc., which can increase power, reduce power consumption and achieve better power saving effect.

3) mechatronics technology mainly combines mechanical and electrical integration, further combining the two functions, simplifying the organization and reducing power consumption. For example, the frequency conversion technology used in textile main engine, air conditioning fan and water pump can adjust the load speed to meet the load changes by adjusting the power supply frequency of the load, so that the original constant torque load can be adjusted through the frequency converter to adjust the spinning process and speed, so as to increase the output and improve the efficiency, and achieve the purpose of saving electricity.

4) water cooling technology for multi machine motors is adopted to reduce the heat of the motor, improve the electromagnetic load of the motor, improve the load capacity and efficiency, and reduce the power consumption. The water-cooled motor is aimed at the variable frequency speed regulation of the new spinning frame. The advanced electromagnetic calculation and special insulation system make it more suitable for inverter power supply system. The motor speed regulation is balanced, smooth, and the range of FM is wide. The cooling water is used to take away the heat generated when the motor is running, so that the cooling temperature of the motor can be reduced from about 80 degrees to 40 degrees, so as to improve the load capacity and efficiency. At the same time, the heat generated by the heat dissipation part of the motor is directly transferred from the cooling water system to the workshop building, and no longer enters the air-conditioning system. The heat dissipation of the motor is reduced, the heat of the workshop is reduced and the temperature is reduced, which is also beneficial for controlling the air supply volume of the workshop and reducing the energy consumption of the air conditioning fan.

5) in the lighting system, the traditional ballast type fluorescent lamp illumination, the power factor and the luminous efficiency are low. The new energy saving lamp adopts new electronic ballasts, which improves the power factor, generates less heat and electricity consumption, and improves the utilization rate of electric energy. It is beneficial to the efficiency of the power grid transmission, prolonging the life of the lamp tube, matching with the efficient reflective system, improving the brightness of the luminous efficiency, and obviously saving electricity. LED and other light source technology have changed the luminous principle and structure of the traditional lamp tube. It has the characteristics of low calorific value and high photoelectric conversion. With the decreasing cost, its industrial application prospect is also very broad.

6) spinning process is the largest power consumption process in cotton spinning production and operation, and spinning power load accounts for 50% of the whole spinning project. Therefore, the influence of spinning frame and equipment on power consumption is very important. For spindles, increasing spindles has become a trend. At present, the latest international long vehicle has reached 1824 spindles, and the long strip car has become an important choice for cotton textile enterprises to increase labor productivity and reduce employment. The long and short cars have no obvious advantage in calculating the absolute power consumption. However, due to the increase of labor productivity and efficiency, the cost per unit of output has a certain advantage over the short vehicle. It is also a technological progress measure to solve the shortage of labor force in labor intensive traditional cotton spinning industry.

7) solar energy is used in the production and logistics of cotton spinning enterprises, such as using solar energy to heat water, generate electricity, and lighting. With the continuous development of solar energy application technology, more energy conservation will be made for enterprises.

8) in the design of the new plant, the energy saving effect should be taken into consideration in the plant building design, so as to effectively reduce the heat conduction and radiation heat of the building. In the design of textile factory buildings, the factory building should be designed as a smaller wall shape as far as possible, so as to reduce the energy loss caused by heat conduction of the wall. By improving the thermal insulation performance of the enclosure structure, improving the energy efficiency ratio of the air conditioning system, and effectively improving the efficiency of energy utilization. For example, the auxiliary room is designed at the periphery of the main workshop, changing the structural form of the single wall of the main workshop directly contacting with the outside air, so that the attached room can form a certain heat barrier and reduce the energy loss caused by the wall and floor.

Attention should be paid to the construction of factory windows. In summer, sunlight should be reduced directly to the workshop through windows. Control window to wall area ratio, minimize window area and quantity. In strengthening the management of energy conservation in plant buildings, it is necessary to improve the airtight performance of doors and windows of workshop buildings, reduce the free exchange of air and outdoor air in the workshop, and reduce energy consumption. Many enterprises in winter cold season, in the main channel hanging curtain, prevent dry and cold air into the workshop, reduce workshop heat loss, is also a practical way. The roof should be well insulated to prevent energy loss and prevent roof condensation in winter. The surface color of the workshop should be beneficial to reduce heat absorption in summer.

9) energy consumption of air conditioning and dust removal system in cotton spinning enterprises accounts for more than 20% of production energy consumption. The design and selection of advanced and reasonable air conditioning dedusting system and unit is the focus of saving electricity and reducing consumption. In the factory design of the air conditioning and dust removal scheme, frequency conversion control technology should be adopted for fans and pumps, so as to effectively reduce the energy consumption under the condition of insufficient load. Reasonable design and layout of air conditioning and dust removal system to send exhaust pipe and size. In the dust removal system, reduce the number of irregular pipes, such as elbow, three way and variable diameter, to ensure the reasonable flow speed and pressure of the fluid, reduce resistance loss, and ensure smooth flow and transmission efficiency. Energy saving fans and energy saving systems such as energy-saving axial flow fans, new airfoil blower and efficient spray fans are selected. The new composite insulation wind pipe has been gradually applied. Compared with galvanized iron air pipe and FRP duct, it has been improving in terms of improving heat insulation performance, reducing air leakage, improving conveying efficiency and environmental protection performance. The potential of energy saving nozzles and efficient water retaining boards for electricity saving and water saving is also being constantly used.

Air conditioning automatic control system is the direction of technological progress of cotton spinning enterprises. Adopting frequency conversion speed control, sensor detection and computer technology to realize automatic real-time control of spinning production air conditioning air volume, spray quantity and mixing air ratio, which is conducive to reducing energy waste, enabling accurate control of temperature and humidity in production workshop, achieving stability of product quality, reducing fluctuation of quality and energy consumption caused by human factors, reducing work intensity and workload of air conditioners, and achieving energy saving, downsizing, stable production, informatization and networking.

10) the safety and energy saving operation of the distribution room is mainly to increase the power factor and reduce the line loss. The installation of harmonic control and reactive power compensation devices can reduce reactive current, improve power factor and effectively improve the power quality of power grid. While saving energy, it is also beneficial to improve the reliability of power system and the stability of mechanical equipment. Reasonable selection of energy saving transformer and reasonable distribution line length to control the power supply radius, increase the cross sectional area of conductors, adopt the smaller conductor of resistivity and reduce the number of contacts to reduce resistance are all measures to reduce the line loss. At the same time, the motor with high efficiency and matching load is selected.

Strengthening technological transformation

It is a more practical choice for cotton spinning enterprises to adopt some technical transformation measures to save energy and reduce consumption and stabilize product quality.

1) the air conditioning fan, water pump and some old equipment mainframe are transformed by frequency conversion technology. According to the load demand, the load power frequency is regulated, and the power saving effect is achieved with reasonable load speed.

2) through the transformation of the air conditioning blower, the return air fan and the ground suction fan, the new energy-saving impeller is used to improve the air volume, reduce the running power, improve the efficiency and save the electricity consumption by optimizing the parameters of the impeller material, blade shape and quality.

3) spinning frame is the main power consumption model in spinning equipment, and its winding part is also the focus of energy consumption of spinning frame. Reducing the diameter of the spindle can effectively improve the transmission of mechanical power and reduce power consumption. The spindle diameter of 17 mm~19 mm is also beneficial to increase spindle speed and increase yield per unit area. The development and application of the new high speed and high performance spindle will improve the friction mode of the billet structure, bearing, spindle and spindle, which will be beneficial to speed up the spinning and reduce the power consumption of unit yarn.

4) the energy saving spinning suction fan is improved on the basis of the structure, form and power of the traditional spinning suction fan, which reduces the power of the motor and reduces the power consumption of the spinning device.

5) the energy saving spindle belt is improved in the aspects of friction factor stability, quality, size and joints. It has an advantage in improving spinning efficiency and reducing power consumption.

6) to improve the spinning material of spinning frame, compared with the original roller, the quality reduction, roundness, dimensional stability, friction coefficient and other improvements can effectively reduce the transmission load of the spindle of spinning frame on the premise of reducing slippery and stabilizing twisting efficiency.

7) strengthen the configuration and management of spinning and blowing fans. When the two spinning machines are side by side, a set of suction and suction devices can be equipped. On the cycle of running time, the adjustment can be made according to the requirements of different product varieties. The improvement of the integrated box of blowing and suction air filter is beneficial to reduce the electricity consumption.

8) the lower tension frame of the spinning frame is improved to the bearing type, making the sliding friction become rolling friction, which has certain effect on improving the operation stability and power saving of the lower apron.

9) on the long spinning machine platform with cluster, some varieties can choose the right diameter steel collar, play the advantage of the automation of the cluster, resolve the contradiction between the reduction of the diameter of the steel collar diameter, the increase of the number of doffing and the increase of workload. On the basis of the optimization of the rolling, tension and broken ends, the machine head breakage rate and the yarn quality indicators are basically stable, the diameter of the collar is reduced, which is conducive to the improvement of spindle speed, thereby improving the output of the yarn. Although the spindle speed increased and output increased, the direct production electricity consumption increased synchronously. The power consumption per unit output of the spinning unit did not decrease, and had little effect on the direct production cost. However, the fixed cost of the enterprise was reduced by the increase of output and the total cost of the enterprise was reduced.

Implementation of process optimization

From the point of view of technology and economy, it is an important means to reduce the energy consumption per unit product by optimizing the design process parameters reasonably and giving full play to the equipment capability according to the characteristics and requirements of different varieties.

1) advanced processes, such as blowing and carding process, combing, self homogenization and blending technology, coarse and fine connection, fine connection, coarse and fine connection, have adopted electromechanical integration, advanced driving system, automation, continuous technology and other new technologies. They are advanced in improving product quality, effectively improving labor productivity and reducing unit production cost.

2) adopting reasonable and advanced process parameters to ensure the product's characteristics and quality, it will achieve certain results in reducing the electricity consumption. For example, the optimization of each process quantity, speed and drafting distribution will have an impact on effective supply, production capacity, efficiency and power consumption reduction. The technical parameters such as draft pressure, yarn twist and spindle tension are closely related to the electricity consumption.

3) the ten stage variable speed parameters of spinning spindle speed are closely related to product quality, breakage and power consumption. According to the requirements of product characteristics, the optimization of small yarn and large yarn segment is emphasized. On the basis of ensuring the quality and broken ends, the length of the middle section yarn is increased by increasing the length of the middle section, and the high speed output of the middle section is increased, so as to reduce the unit output and the electricity consumption.

Management system guarantee

1) strengthen the construction of energy conservation management system and form an enterprise energy conservation management system. In accordance with the state's energy conservation law, we should strengthen the awareness of energy conservation and awareness of responsibility at all levels. Clear the Department responsible for energy conservation management.

2) to strengthen the construction of energy measurement and statistics and analysis system, formulate the evaluation system of energy consumption targets at all levels, and closely link with the performance appraisal at all levels, so as to implement the responsibilities at different levels.

3) the refinement of management system. On the basis of strengthening the awareness and measures of energy saving for all staff, some key energy-saving management measures must be highly valued. For example, according to the production of peak shifting production in different periods of power peak, valley and Ping, and making effective use of the characteristics of the gap production plan of some processes in cotton spinning enterprises, we should arrange every process plan, start-up and production capacity reasonably, reduce the peak electricity and reduce the cost of electricity consumption effectively. Through lean management, we can effectively improve equipment operation rate, production efficiency, product production rate, one-time pass rate of products, reduce empty spindle, broken ends, defective products, malfunction and rework. Attention should be paid to the effect of lubrication, wear and accuracy on energy consumption in equipment maintenance. In view of the characteristics of equipment and product characteristics of every enterprise, the maintenance and repair system of traditional equipment should be reformed, and the maintenance mode of products with the responsibility of product quality, personnel structure and energy consumption control should be established. Strengthen daily management and seasonal transformation of air-conditioning management and measures. We should strengthen the management of the "dripping leakage" phenomenon in the daily operation of enterprises, and effectively control all kinds of waste phenomena such as leakage, leakage, leakage and oil leakage in the operation of enterprises.

4) strengthen technical training and improve professional skills and quality. While doing a good job of basic management, we should strengthen energy knowledge training and basic management training for equipment maintenance personnel, operation operators, air conditioning and air compressor professional personnel at all levels, and strengthen personnel training on the use, maintenance and management of main engine, auxiliary equipment, special equipment, special equipment, new technology and new technology, so as to achieve good safety, quality and energy saving operation effect.

To sum up, energy conservation and emission reduction, improving energy efficiency and building a conservation minded society are important strategies for national economic and social development. For cotton spinning enterprises, it is necessary to enhance competitiveness, survival and development. Adopting advanced technology and lean management is an effective way to save energy and reduce costs for enterprises.