电能控制十条金规.ppt

电能控制十条金规10GoldenRulesforPowerMastery,DPCApril2009,2,10能耗控制黄金箴言GoldenRulesforPowerCostReduction,OptimiseBallMillPower优化球磨机电耗MinimiseFalseAir减少漏风ManageEquipmentIdling设备空转的管理VerticalMillPowerOptimisation立磨优化EfficientGasHandling气体效能掌控PowerMonitoring功率监测ProductionManagement生产管理MasteringQualityImpactonPowerConsumption质量控制对效率的影响MillFeedSizeControl控制入磨物料粒度MinimiseCompressedAir最小化压缩空气的消耗,3,RULE1:OptimiseBallMills球磨优化,Howdoesyourmillmeasureup?你的工厂如何进行测量？Canyoutickalltheboxes?你能对所有方框的问题打对号码吗？,4,Checkinstruments&Tunecontrolloops检查仪表并对控制回路进行调节Feedproportions喂料均匀FeedvselevatorkW喂料vs提升机功率Airflowcontrol气体流量控制Milloutlettemperature磨机出料口温度控制Producttemperature产品温度Electricalear,Minimisefalseair减少漏风,BallMillPowerOptimisation球磨功率优化(1)OperationActions运行,Removescrapmedia去除费介质&clinkernibs和熟料渣块,保持磨机喂料的稳定性Millfeedrateuniformity,Separatorefficiency选粉机功率circulatingloadtest循环负荷试验,Fineadditionstoseparatoravoidadditiontomill向旋风筒加细添加料-避免向磨机内加,CheckFeed检查喂料Size粒径Moisture湿度Temperature温度Grindability易磨性,Minimisefalseair减少漏风,助磨机优化Grindingaidoptimisation,Followelevatorpower-maintaincirculatingload跟踪提升机功率保持循环负荷,优化袋收尘清理功能Optimisebagfiltercleaning,Optimisebagfiltercleaning优化滤袋提高滤袋清洁度,Measure&maintainseparatorairflow测控并保持选粉机气体流量,Measure&maintainmillairflow测量并保持磨机风量,避免过粉磨Avoidovergrinding代表样品，产品细度控制频率、执行控制卡片representativesample,productfinenesscontrolfrequency&implementcontrolcard,减少产品数量和保持相似性Minimisenumberproducts&aimtokeepsimilar,KPIs关键技术指标Productionratetph台时产量MilldrivepowerandkWh/tweekly磨机驱动功率和kWh/t-每周PowerIndicatorFinishMill水泥磨功率指示器,减少漏风Minimisefalseair(heatedmill),Settargetballchargelevel&makeregulartopups设定充球量目标并进行定期的检查，使料位和球位在同一个水平面上,5,BallMillPowerOptimisation(2)Inspectandmaintainatplannedstoppagesatleastmonthly&useopportunitystops球磨机功率优化（2）检查并每月至少进行一次计划停机或者利用停磨的机会进行维修,Checkballfillingratio&topuptotargetmaintainlevel检查球的填充率，物料与级配是否保持在同一个平面上MaintainaveragemillkW+/-30保持磨机平均功率,Linercondition&wear衬板情况和磨损,Chargecondition,Diaphragmventgrids隔仓板的通风篦,Diaphragmslotcondition&blockage隔仓板篦缝状况和堵塞情况,C1Stepheight40mmC1阶梯高度,Heightabovecharge高于级配,Wornoutliners磨损的衬板,Contaminatedcharge,Slotspeenedover受到敲击的篦缝,Slotsblocked篦缝堵塞,Ventgridareatoosmall通风篦区域太小,Checkaxialgrindingprofile检查轴向粉磨状况,Checklinersandballscoating检查衬板和抱球情况,Checkbuildup检查堆料,Separatorbuildups&wearespeciallyairseals,6,BallMillPowerOptimisation(3)Support球磨机功率优化,CementPortalGrindingDomain水泥门户网-粉磨类Procedures程序Howtomanageballchargelevel如何管理充球量Howtooptimiseaballcharge如何优化级配Howtodoamillroutinestopinspection如何进行磨机常规停机检查Howtodoamillcrashstopinspection如何进行磨机急停检查Howtoremovescrapfromaballmillcircuit如何从球磨系统中去掉废渣Howtocheckairflowthroughthemill如何检查磨机的分量Howtomanagelinerwearinaballmill如何进行球磨内的衬板磨损管理Howtoconductaballmillaudit如何进行球磨审计KnowledgeDocuments知识文件Procedurefortheauditofballmillcircuits球磨系统审计程序GuideBallmilloptimisation-PostSevillamodule5指导-球磨优化-PostSecilla模块5VademecumGrinding粉磨TechnicalCentreProcessTeam技术中心粉磨团队,7,RULE2:MinimiseFalseAir减少漏风,Isyourplantwinningthebattle?你的工厂在这个环节胜利了吗？,8,TypicalSourcesofFalseAir漏风来源,Missingbolts,FanSeals风机密封,Doors检查孔,Doors检查孔,FlapSeals翻板阀密封,KilnInletSeal窑头密封？,ClinkerChute熟料卸料槽,ExpansionJoints膨胀节,ClassifierSeal分级机密封,FeedingPoint喂料点,FeedingPoint喂料点,Doors检查孔,Doors检查孔,FanSeals风机密封,PokeHoles捅料孔,Flanges,TieRodSeals拉杆密封,KilnHoodSeals窑罩密封,FanSeals风机密封,Seals密封,Seals密封,Casingcracks壳体裂缝,Casingwear&corrosion壳体磨损和腐蚀,Isolation隔离阀dampers,ExpansionJoints膨胀节,Lookforgaps/cracks/missingbolts/missingpackingetc找出间隙、裂缝、丢失的螺栓、丢掉包装等Listenforwhistlingair听是否有呼啸的声音Lookfordustblowingoutduringstartup开机时查找漏灰的地方,9,ManageFalseAir漏风的管理,Prerequisite前提条件Teamwork团队工作Process工艺,MaintenanceandProduction维修和生产Actions行动Settargetfalseairlevels设定漏风标准TypicalValues标准值Preheater预热器5%Rawmill生料磨20-40%*Coalmill煤磨20-30%*Cementmills水泥磨30-50%*Coolerexhaust蓖冷机排风95%可靠性系数Annualincidentstops75%,19,EfficientGasHandling(3)Support气体处理测量（3）-支持,CementPortal水泥门户网Howtomeasurefanefficiencyofthemainfans如何测定主风机效率Howtoimprovefanefficiencybyinternalinspection如何通过风机内部的检查提高风机效率,TechnicalCentreProcess&MaintenanceTeams技术中心、工艺和维修团队Gashandlingtraining气体处理测量培训,20,RULE6:Powermonitoring功率检测,Youcanonlycontrolwhatyoucanmeasure!你仅能控制你能测量到的,21,PowerMonitoring(1)MeasurementRequirements功率监测（1）-测量要求,Installmetersforeachshop/area&mainmotors为每一个系统单元和主电机安装计量设备MeterslinkedtoPCS&IP21forbestcontrolofpower将计量设备连接到PCS和IP21，更好的控制效率Knowequipmentcoveredbyeachmeter清楚每一个计量器所覆盖范围Studyelectricaldistributionlinediagram学习电器接线图Shopsareofteninter-mixedduetoproximityofsub-stationsoradditionofequipment系统单元经常采用统一计量导致各子项系统或附属设备能耗无法分开CheckmeteraccuracyasnecessaryNeedportabletestingequipment必要时使用便携式测量设备检查计量设备的精确度Loadcurveprediction(dependingoncontract)负载曲线预报（根据约定）？,22,PowerMonitoring(2)TrackingConsumption功率检查（2）-能耗跟踪,Checkpowerconsumptionregularly(minimummonthly)规律性的检查功率消耗（每月至少一次）Breakdownbyshop,mainequipment,separateauxilaryequipment通过系统单元的细分，分离主副机Calculatespecificconsumptionpershop&contributiontoclinker&cement准确计算每一个系统单元的消耗，分配到熟料和水泥Analysetrendsofconsumption分析消耗趋势Checkshopspecificconsumptionforvariousconditions检查不同工况下系统单元的准确消耗Operationatnominalcapacitysetbaselineconsumption额定产量下的运转-设置基准消耗Operationindifferentmodespound,direct不同模式下的运转-例如混合粉末和分别粉末Differentproducts不同产品品种Operationatreducedcapacity减产时的运转Duringshopstartupandshutdown开机和停机期间Etc.等等Crosscheckconsumptionusingcalculationse.g.formills,fans,blowers&conveyors,etc.通过计算复核消耗，例如磨机、风机、鼓风机和输送设备Reconciletotalofconsumptionforallshopswithmonthlypowerbill通过月电耗表来合并？所有系统单元消耗,23,PowerMonitoring(3)Support功率监测（3）-支持,CementPortal水泥门户网Bestpracticepowertracking功率最佳实践的跟踪Bestpracticepowermeteringrequirements功率最佳实践的要求TechnicalCentreProcess&MaintenanceTeams技术中心工艺和维修团队,24,RULE7:Productionmanagement生产管理,Scheduleyourproductiontotakeadvantageoflowpricepower.用最低的功率成本制定生产计划,25,ProductionManagement生产管理,Detailedunderstandingofpowercontractclauses.详细理解供电合同条款Monitorelectricalloadforeachshop监控每一个系统单元的电力负荷Trackloadcurvetomaximiseequipmentoperation(especiallymills)duringcheappowerperiods在供电价格低的期间跟踪大型设备的负载曲线（特别是磨机）Preferencetooperatemoreefficientequipmente.g.rollerpressinsteadofballmill优先运行效率高的设备，比如辊压机取代球磨Avoidexceedingmaximumdemand避免查过最大需量Communicateloadsheddingscheduletoproduction&maintenanceteamsforplanning？Recordpeakandoffpeakproductionhours记录峰谷时段开机时间WorkcloselywiththeBUenergypurchasingmanager密切配合能源采供经理,26,ProductionManagement-SupportPortfolioManagement生产管理-支持部长管理,Exofminimumsupplyfortheregulationsupplier,Detailed2000loadcurvepersite(exhourlyloadcurve),Buythat,Usethat,Sellthat,Coordinatedportfoliomanagementforallplantswithinamarketregion,27,RULE8:Masteringqualityimpactonpowerconsumption质量控制对功率消耗的影响,Qualityparametershaveahugeimpactonpowerconsumption质量指标对功率消耗的巨大影响,28,RapidclinkercoolingAlite急速冷却熟料硅酸三钙30m,Stableburningconditions稳定的燃烧环境FLUI60,OptimumRawmix原料配料优化grindabilityminimisequartzcontent易磨性系数-石英含量,OptimumRawmealresidue原料细度优化200m2%90m:targetdesignedtogetgoodburnability为得到较好的易烧性,Oxidisingatmosphere空气中氧含量,ClinkerFree游离石灰Lime1-2%,Shortburningzone缩短烧成带,Fuelresidues燃料筛余+200m1%+90m=50%VM%,KFUI14,Minimisefreesilicaresidue降低游离氧化硅细度at45m(2.5%),29,MasteringQualityImpactonPower(2),Plantooptimiseclinkerreactivity对熟料煅烧的优化Minimiseincreaseofrawgrindingpower尽量降低生料粉磨电耗Ensureburnabilityingoodrange保证易烧性在合理的范围内Maximisesavingincementgrindingpower最大降低水泥粉磨电耗Ensuresaturationofalkalisbysulfate控制合理的硫碱比Operateatoptimumcementsulfate合理控制水泥三氧化硫含量ChallengeexistSO3levelusingstatisticalformula通过统计方法优化现有SO3含量Conducttrialstoconfirmoptimum通过实验确定合理范围Ensuregoodcontrolofproductsurfaceareaavoidover-grinding控制合理的水泥比表面积-避免过粉磨Considertouse/optimisegrindingaid考虑使用/优化水泥助磨剂Challengemarketing&salesregardingcementstrengthtargets,particularlyforrequeststoincrease?Developandimplementactionplans-WorkinconjunctionwithTCRawMix,Product&Processteams可执行的改进计划-联合技术中心原料配料，产品&工艺团队一起完成此项工作,30,MasteringQualityImpactonPower(3)Support,CementPortal水泥门户网10BasicFactsonclinker熟料的10个基本原则Rawmixdesign(BestPractice)原料配料设计（最佳实践）Silicarejectsinrawmiximpactonquality(BestPractice)不合格的硅土在原料配料中影响品质TYTPUniformityindicatorsTYTP一致性指标Burningpetcoke(BestPractice)燃烧Howtostart&optimiseaburner如何使用&优化燃烧器CombustionManual(PostSevilla)煅烧手册Sulfatingrules(BestPractice)硫酸盐原则（最佳实践）CommunicationbetweenManufacturing&Sales(BestPractice)制造&销售信息沟通TechnicalCentreRawMix,Product&ProcessTeams技术中心原料配料，产品&工艺团队,31,RULE9:Millfeedsizecontrol控制入磨物料粒度,Crushersaremoreefficientatcrushingthanmills-optimise&controlmillfeedsize破碎机破碎效力高于磨机优化&控制入磨物料,32,MillFeedSizeControl(1)控制入磨物料粒度（1）,Observemillfeedsizeonfeedbeltinregularinspectionroute在日常的巡检路线观察入磨物料粒度,Checkfeedsizegrading检查粒度分布,Checkcrusherbaskets/breakerplates,etc检查破碎机篦子、反击板等,Checkforwearofcrushingparts检查破碎零部件磨损,Checkconditionofscreens/grizzly检查筛子/格筛状况,Checksizeofincomingmaterials检查矿山物料粒度,VRMmaxfeedsizetypically70mm,bewareofexcessivefines原料立磨典型粒度70mm，防止粒度过细,Ballmillfeedsize球磨机物料粒度95%25mm,Checkhammerorientation检查锤头磨损倾向,33,Millfeedsizecontrol(2)Actions控制入磨物料粒度行动,Settargetmaximumfeedsize(alsoforVRMmaxfines%passing1mm)设定最大的物料粒度（同样包含原料立磨最高允许%几的物料小于1mmAgreecontractfeedsizewithsupplierofincomingmaterials同供应商确认入破碎机的物料粒度合同Define&implementinspectionplan(Production&maintenance)toinclude:定义&执行巡检计划包含（产品&维修)Millfeedsizeobservation(weekly)观察入磨物料粒度（每周）Crushers&screensinspection破碎机筛子巡检Incomingmaterialsfeedsize入破碎机物料粒度Occasionalsizegradingcheck(monthly,dependinguponcrusherwear)临时的物料粒度检查（每月，由破碎机磨损情况决定）Considerpossibilitytoproduceasmallercrusherproducttoreducepowerconsumption,buttakecaretoalsoconsider:考虑尽可能的生产小粒度物料以降低功率消耗，但必须考虑以下问题：Increasedcrusherwear破碎机磨损增加Reducedcrusherthroughput-Increasedoperatingtime减低破碎机产量增加破碎机开机时间Potentialforexcessivefines(lowleveldust&VRMvibration)过多的细粉（低水平的粉尘原料立磨振动）,34,Millfeedsizecontrol(3)Support控制入磨物料粒度（）支持,CementPortal水泥门户网BallmilloptimisationpostSevilla球磨机优化TechnicalAgendaStudyVRM原料立磨原理学习TechnicalCentreRawMix&ProcessTeams技术中心原料配料工艺团队,35,RULE10:Minimizecompressedair最小化压缩空气的消耗,Typicalcompressedairenergyefficiency10-15%-useitwisely压缩空气典型的能源效率10-15%-精明地利用它,36,MinimiseCompressedAir(1)Improvements最小化压缩空气的消耗（1）-改进,Replaceintakefilters更换进气滤芯,Optimisesystempressureavoidexcessivepressure优化系统压力-避免使用过高压力,Changeoutletfilterelementsregularly定期更换出口滤芯,Systematicleaksinspection,tagging&repair系统漏气巡检，标记&修理,Ultra-sonicleakdetection?发现超音速泄露？,Eliminateinappropriateusebyalternatemethods通过循环交替用气的方法代替不合理运用,Checkcondensatetraps检测空气被压缩时冷凝物,Checkbagfiltersforleakingdiaphragmvalves检查袋式除尘器隔膜阀/膜片阀泄露量,Switchoffcompressorswhennotinuse(idling25-30%power)不使用时关闭空压机（空压机空载时功率25-30%）,Automaticpressurecontrol自动压力控制,MonitorfilterP监测滤芯压差,Condensatetrapcontrolminimizeleakage冷凝物控制-降低压气泄漏,Monitorpressureatusagepoints监测使用压力,Controldryerusingmoisturesensor通过湿度传感器控制干燥器,Variablespeedcompressorforcontrol?可控压缩机速度,Removeunusedpipe-work拆除不使用的管道系统,Matchcompressorsizetodemand按标准值匹配型号,Checkifpipesizeissufficient检查管径是否足够,Matchairqualitytouse压气等级与使用要求相符,Examinepipe-worklayoutshortestdistancetopointofuse.检查管道系统布置图-管道至使用点最短路线Considerloopsystem考虑系统循环,Replaceelbowsbysweepingbends大弯曲半径弯头代替肘型弯头,Intakecoolairbest进气冷空气最佳,Wasteheatrecovery?余热重复利用？,37,MinimiseCompressedAir(2)-SpecificCases最小化压缩空气的消耗-特殊案例,Homogenisingcompressors均匀化空压机Checkeffectivenessofblending检查混合效率Considerconversionofhighenergytolowenergydesign考虑将高能耗转变为低能耗Pneumaticconveying气力输送设备Checkconveyingvelocity/pipesize/conveyingairvolume检查输送速度/管道直径/输送气量Numberofbends转弯点数量Pipelineroute管线长度B