1 process and main equipment
(1) Process: The semi-water gas self-desulfurization is electrostatically defocused, the pressure after the buffer is 720kPa, and the compressor is first compressed to 0.22MPa; after being cooled by the first-stage cooling separator, the oil and water are separated and then enter the second-stage compression to 0.70. MPa; after cooling by two-stage cooling separator, the oil-water separation enters the third-stage compression to 1.5MPa; after the three-stage cooling separator is sent to the conversion process, the converted gas continues to enter the carbon-carbon process for decarburization, and then enters the four-stage compression to 4.5. MPa; After cooling by four-stage cooling separator, the oil and water are separated and then enter the five-stage compression to 12.0MPa; after being cooled by the five-stage cooling separator, the oil and water are separated and sent to the refining system to make qualified refined gas; and then compressed to six.031 by six stages. 4MPa, after six-stage cooling separator cooling, oil and water separation and sent to the synthesis system. Each oil-water separator oil is recovered into the oil collecting tank, and the gas taken out by the helium is recovered to the compressor inlet buffer tank.
(2) The main technical parameters of MH-92/314 hydrogen nitrogen compressor are as follows:
Volume flow rate (first-stage suction state): 92m 3 /min; first-stage suction state pressure (absolute pressure): 0.1235MPa; first-stage suction state temperature: 35; final exhaust pressure (absolute pressure): 31.5MPa; stroke: 280mm Spindle speed: 428r/min; motor power: 1585kW; cooling water consumption: 170t/h; lubricating oil consumption (cylinder, packing): 2.4kg/h.
(3) The main equipment model specifications are as follows:
Hydrogen nitrogen compressor: MH-92/314; primary water cooler: SL6-50-00F=52.4m 2; secondary water cooler: SL10-50-00F=55.0m 2; three-stage water cooler: SL25A-45- 00F=55.0m 2; four-stage water cooler F= 22.05m 2; five-stage water cooler F=18.10 m 2; six-stage water cooler F=17.27 m 2; oil collecting tank V=5.50m 3 .
2 Technical transformation and production situation
Surface layout, improved compressor piping and equipment location for easy access and maintenance. The cooling system is a one-, two-, and three-stage vertical water cooler in the room, and the outdoor four-, five-, and six-stage circulating water jacketed water coolers are reduced in this way compared with the original spray-type water coolers of our factory. The floor space of the cooler, the water consumption of the cooling water and the influence of the water mist of the spray water cooler on the production operation environment are avoided, and the oil of the compressor system is recovered in the outdoor oil collecting tank. Since the grid was put into production, it has been successfully driven, the operation is balanced, the production is stable, and the yield has reached the nameplate index. Compared with the original L3.3-17/320 compressor of our factory, it has obvious superiority. Its main features are strong process versatility, reasonable structure, high output rate, reduced internal leakage and convenient maintenance and management. During the construction process, our factory corrects the coaxiality of the deflection of the rotor's own weight according to the actual situation, re-adjusts the level of the motor, slightly increases the horizontal level of the fuselage, forms the outer end face height, and the state of the motor end face is low. Reduce the impact on the installation. In the test run, it was found that the motor rotor moved 3mm to the north, and the center position of the magnetic field between the stator and the rotor was inconsistent with the position of the motor journal and the center of the bearing bush. After obtaining the opinions of the electric department, the stator was shifted to the south by 3mm. Because the machine and our factory The existing M8, H8, M12 are different, the balance section is eliminated in one column per cylinder, the pressure difference between the two ends of the high pressure stage is significantly reduced, not only the gas leakage condition is obviously improved, the wear of the piston ring and the cylinder liner is also reduced, and the service life of the compressor is prolonged. .
Comparison of production capacity: The production capacity of our factory MH compressor before use is about 33,000 t/a, that is, the production capacity of three L3.3-17/320 compressors is about 0.7 million t/a, and one H8 is about 0.5 million t/ a, 1 M8 is about 0.5 million t/a, 2 sets of M12 is about 15,000 t/a. The production capacity after adding 3 sets of MH-92/314 compressors is 31.3=3.9 (10,000 t/a).
3 Discussion on several issues
The three MH compressors are in good condition in our factory, which is easy to operate and convenient for maintenance. Regarding how to correctly select the equipment, fit the existing process, and scientific management is worth studying, we will discuss the following technical issues of the MH compressor of our factory.
Compressor water cooling system, at present, our factory is a circulating cooling water system. There are short-term use of the first, second and third-stage water coolers during the use. Especially in the summer high temperature season, the water consumption of the coolers of all levels must be balanced. The main reason is caused by the quality of the gas and the quality of the cooling water, causing the water cooler to be blocked, the cleaning cycle not meeting the requirements, the maintenance cost increasing and the parking loss increasing. Improving the mass of the pre-process gas can improve the heat exchange effect of the water cooler and reduce the blockage of the tubes caused by the entrainment of impurities by the gas. To this end, the first and second water cooler specifications proposed improvement: design pressure, first and second water coolers are changed to 1.0MPa, shell and tube bundle specifications and assembly dimensions are the same with the original primary water cooler (SL6-50- 00) The same; the baffle spacing is changed to improve the heat transfer effect. The cooling water is made of circulating water, and it is found that there is sediment in the circulating water, and the oil draining pipe is added at the upper water main pipe to discharge the sediment and the oil (as shown). The deposition of sediment in the circulating water will affect the heat transfer effect of the first, second and third stage water coolers. It is necessary to strengthen the management of circulating water, regularly clean up, increase the sewage treatment or sedimentation tank device to improve the water quality and heat transfer effect. Increase the pumping capacity of the compressor. During the operation, the gas temperature at the outlet of the five-stage water-cooled jacketed tube was high, which seriously affected the production of refining and other processes. It was decided not to exchange the piping, but a pair of inlet and outlet pipes were added to the piping, and the gas outlet temperature was 55. It is reduced to about 38, so that the problem of insufficient heat exchange area of ​​the outdoor water jacketed pipe is improved without increasing the water consumption.
Operation valve frame and pipeline installation and treatment, in order to facilitate the operation, reduce the workload of workers, according to the flow situation of our factory has done the following treatment: at each level of the outlet set the circuit valve (101106 valve), and the total back connection, easy to ease the parking Uniformly adjust the safe alternate operation of the load and valve. The system shut-off valve uses a double valve, one is normally open and one is used for system operation, which is convenient for changing the valve in case of non-system parking. The random check valve was cancelled because the one-way check valve used when the sound was loud, and the sealing effect was not good after a period of use. After the installation, the pipeline was complicated and the maintenance difficulty was increased. For the phenomenon of large pipe vibration, it is advisable to take reinforcement measures at appropriate positions to improve the vibration of pipes and equipment.
Pipes, fittings, buffers and water coolers account for a large proportion of the compressor's auxiliary de-energizers and meters. They should be friendly and negotiated with suppliers in the case of their respective processes. Our factory design life from synthetic high reliability main wearing parts for half a year, practically up to one year or longer and easy to maintain. No matter more than 2 people can complete the cylinder, filling or changing, we can complete our most and most Users with a wide range of production characteristics are recommended to you, from which you can find similar references as a reference. At the same time, we have a series of positive and negative experiences and lessons that have emerged since the technology of canceling the balance segment.
If you are operating on the heart, what kind of doctor do you choose? The modification of the compressor is a cautious and large-scale process feature and installation capability. The following corrections have been made: no supply of pipes, valves, fittings, and self-redesign Repurchase materials to make the best use of them and avoid waste. The 46-stage water cooler uses a self-designed jacketed water cooler to improve the operation and production environment and save water resources.
Strengthening lubrication management, according to the practice of our factory, it is not worth the effort to return the oil scraped from the scraper back into the fuel tank. This part of the oil is treated separately.
The secondary piston ring of the compressor has a larger clearance between the inner and the ends of the cylinder because the clearance between the inner two piston rings is larger than the stroke of the compressor (S=280). It is recommended to increase the chamfer before installation and adjust the clearance during installation. Fix the working area of ​​the piston in the original position to avoid the knocking phenomenon caused by the piston ring.
Regarding how to extend the service life of the first, second and third stage vertical water coolers, after a period of observation, we noticed that the gas pipe wall of a water cooler generally does not scale. We believe that the reason is that the impurities entrained in the inlet gas are not easy to form a scale layer, and in the latter two stages, the compressed gas is dry and adheres to the pipe wall, and is not easy to flow and deposit. The gas purification device in the previous process should be improved to improve the gas. Quality, improve heat transfer efficiency of the heat exchanger.
4 economic benefits
Compared with the original 3 L-machines and M8, H8, and 2 M12, the MH-92/314 compressor has a 3% increase in output and a significant drop in consumption.
It can be seen that after the MH compressor is put into operation, the fuel consumption is greatly reduced, the consumption of ammonia oil is reduced from 1.09kg to 0.58kg, and the compressor oil is reduced by 90,000 yuan per year; the electricity consumption per ton of ammonia is reduced from 961kWh to 911kWh, which can be saved every year. The electricity is about 1.02 million yuan; since the MH-92/314 compressor has eliminated the balance section in one column, the pressure difference between the two ends of the high pressure stage is obviously reduced, the internal leakage is reduced, and the process index is also improved. The CO2 volume fraction in the shift gas is from the original. The 27% increase to about 28.2%, correspondingly reduce the material consumption before and after; the cooling water adopts closed-circuit circulation, which can reduce water resource usage fees and sewage charges by about 800,000 yuan per year; due to strong process versatility, reasonable structure and convenient maintenance and management, The equipment maintenance fee can be reduced by 120,000 yuan per year. Compared with the original compressor, it can reduce the energy consumption and other expenses of about 2.1 million yuan per year. Its operation not only creates conditions for our factory to expand production, but also improves management level and labor efficiency. From the actual operation of the machine, it has achieved the design requirements and energy saving, and achieved obvious economic benefits.
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