Energy-saving transformation of printing and dyeing equipment
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Printing and dyeing enterprises consume a large amount of heat energy and electricity during the production process. In order to save energy and reduce consumption, production enterprises have taken measures to carry out energy-saving technological transformation. The “Frontline Communication” column in this issue summarizes the experiences of some enterprises in energy conservation and emission reduction, hoping to inspire readers.
Method 1: Modify the heating source of the shaping machine
Save 3.8924 million yuan/year
The heat setting machine is one of the main equipment in the printing and dyeing industry. In order to save energy, we have modified the heating source of the heat setting machine and replaced the steam heating and electric heating of the whole machine with thermal oil heating. The heat transfer medium of the original steam boiler is water. The boiler heats the water into steam and enters the radiator. After heat dissipation, it becomes waste steam or condensed water and is discharged. This heat transfer method has a large heat loss. The heat transfer medium of the hot oil furnace is a kind of heat transfer oil with special properties. After heating, its temperature can be as high as 280℃~290℃ without vaporization. After the high-temperature oil enters the radiator through the pipeline for heat dissipation, it is not discharged out of the furnace like steam. Instead, the thermal oil is forced to be pumped back into the oil furnace through a circulation pump to continue heating, and then introduced into the radiator for heat dissipation. This closed-circuit heat transfer method not only has little heat loss, but also has high economic benefits. The hot oil furnace also has low-pressure and high-temperature working characteristics, and can obtain an operating temperature of more than 280°C at a low pressure of less than 0.1MPa. Moreover, at such a high temperature, the working pressure is only equivalent to 1/1 of the pressure required for saturated steam to reach the same temperature. 68, which can greatly reduce the pressure level of heat-consuming equipment, so the radiator on the original machine can be used with slight modifications.
Through the transformation, it not only saves electricity, steam and water significantly, but also reduces production costs, alleviates the electricity shortage, and achieves good energy-saving benefits. Comparative calculations before and after the transformation show that the use of oil boilers can save 7997.86 tons of standard coal and 3.8924 million yuan in costs one year. ■Shanghai Hengxin Chemical Co., Ltd. Ji Bingkui
Method 2: Wastewater waste heat recovery
Save steam cost 550,000 yuan/year
Printing and dyeing factories consume a large amount of heat energy and electricity during their production processes, especially the large amount of heat energy. The heat energy consumption used in cleaning, bleaching, coloring and other processes accounts for about 10% of the heat energy used in the entire process. 70%. During the coloring process, about 8% to 10% of the heat provided by steam is lost through equipment heat dissipation, 20% of the heat is taken away by the process cooling water, and the remaining heat is discharged through waste water. At the same time, the incoming water needs to be heated with steam during the coloring process. Therefore, if the heat in the waste water can be recovered and the incoming water is preheated, the steam consumption can be reduced. On the other hand, the discharged wastewater is sent to the sewage treatment plant for treatment. Since the temperature of the discharged colored wastewater is relatively high (the average temperature is above 50°C), it has a greater impact on the quality of the wastewater treatment, especially in the biochemical treatment process. The water temperature will cause the death of biochemical bacteria, thus affecting the effectiveness of wastewater treatment and severely affecting the discharge of wastewater into compliance with standards or the reuse of reclaimed water.
In view of the high temperature of wastewater and low temperature of process water in printing and dyeing plants, the heat in the wastewater can be transferred to the process water through heat exchange in the heat exchanger to achieve the purpose of saving energy and improving production efficiency. The heat extraction efficiency is calculated as 80%, then the heat recovery = specific heat of water × wastewater flow rate × heat extraction efficiency × (wastewater inlet temperature – wastewater outlet temperature). Taking the annual recycling of 100,000 tons of wastewater as an example, the annual steam consumption can be reduced by 3,043 tons, which is equivalent to 347 tons of standard coal. Calculated at 180 yuan per ton of steam, the steam cost saved can reach 550,000 yuan per year. ■Ningbo Huayan Energy Saving, Environmental Protection and Safety Design Research Co., Ltd. He Yuanfang
Method 3: Apply sewage conversion equipment
Reduce wastewater discharge
At present, membrane separate treatment and reuse technology has become the development direction of advanced treatment of printing and dyeing wastewater. The current technical difficulty is how to extend the membrane life both economically and reliably. The “early pretreatment + comprehensive monitoring of each membrane stage” solution adopted by the 2,000-ton printing and dyeing wastewater resource recycling equipment has the advantages of system reliability and low cost, and can effectively cope with the complex and changing composition of my country’s printing and dyeing wastewater.
The operation and monitoring of the printing and dyeing wastewater resource treatment system consists of the central controller PLC, sensing and testing instruments, various execution components (high-pressure pumps, metering pumps, mixers, electric valves, etc.) and human-machine interfaces (touch screens). The system has manual and automatic operation modes to choose from, and has a chain protection function and an audible alarm indication function, which can provide system protection and alarm actions under abnormal conditions.
The 2,000-ton printing and dyeing wastewater resource recycling equipment uses printing and dyeing wastewater as a resource for regeneration and recycling. It can not only reduce the total discharge of printing and dyeing wastewater and COD, control water environmental pollution, but also save fresh water, alleviate water shortages, and It can reduce water costs for enterprises, improve production capacity, and contribute to the sustainable development of the printing and dyeing industry. The complete set of equipment also has the advantages of small floor space, low investment, and low operating cost. ■Chinese Academy of Military Sciences NingboBranch Wang Yaojun
AAAKY, 7II56U65
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