CN102704960B - Mineral efficient energy-saving emulsification liquid feeding unit - Google Patents
Mineral efficient energy-saving emulsification liquid feeding unit Download PDFInfo
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Abstract
The invention discloses a mineral efficient energy-saving emulsification liquid feeding unit, which comprises a main liquid feeding module, an automatic liquid distribution module, an electric control module, a spare liquid feeding module, a recovery module and a working face. The mineral efficient energy-saving emulsification liquid feeding unit has the following functions of intensive liquid feed, emulsified liquid recovery and reuse, far-end guarding, automatic control, constant-pressure liquid feed, fixed-time liquid feed, automatic liquid distribution, perfect protection and mutual switch of a main pump and a spare pump. According to the mineral efficient energy-saving emulsification liquid feeding unit disclosed by the invention, long-distance transportation of ultrahigh pressure emulsification liquid is realized to satisfy the liquid use requirement of old mines and remote mining areas, and the installing volume of a unit is effectively lowered; and because of the adoption of a module-type integration assembling form, the unit has the advantages of small size, short liquid flowing path, small pressure loss, small occupied site area, easiness in installing and tidy and attractive machine room. The control system can be accessed into the industrial Ethernet of a mine by an Ethernet so as to realize the information share of an emulsification pump monitoring subsystem and an automated monitoring system of a whole mine, thereby providing stronger compatibility and expansibility.
Description
Technical field
The present invention relates to a kind of mining device, be specially the energy-saving emulsified feed flow unit of a kind of mining high efficiency.
Background technology
Colliery emulsification pumping station system be colliery generally use aim at the power source that comprehensive mining hydraulic bracket or hydraulic prop provide high-pressure emulsion.Pumping station layout is near down-hole coal-face, and each work plane arranges a pumping plant, and each pumping plant is installed two emulsification pumps (the using and the reserved), and the installed capacity of emulsification pump separate unit is tens to hundreds of kilowatt.The general mode of operation continuously that adopts of pumping plant, every every day power consumption be that hundreds of is during to a few megawatt, for coal master wants consumer.
Along with appearance and the enforcement of a series of energy-saving and emission-reduction policies of country and measure, coal mining enterprise payes attention to planned supply and use of electric power and using electricity wisely further, more and more focuses on using novel energy-conserving technology and equipment.2003, I according to south China small-size coal mine down-hole adopt hydraulic coupling low (being generally 15MPa following) for hydraulic prop supported face, the feature such as fluid volume is few, emulsion does not reclaim, from reducing maintenance and the using electricity wisely of equipment, designed the scheme of setting up ground central fluid supply, Bing Hunan Province has set up in the Bai Shanping of white sand mineral bureau colliery domestic first ground central fluid supply pumping plant.Pumping plant is located near the surface plant well head of ground, has been equipped with frequency conversion automatic control system, has realized ground central fluid supply.Adopt ground central fluid supply mode improving service life of equipment and reducing the aspects such as power consumption and received good effect, in Hunan, most middle and small scale coal mines were widely applied in recent years.Colliery emulsification pumping plant moves to ground from down-hole, by distributing liquid-supplying system, changes central liquid supply system into, itself is the technical important breakthrough of colliery feed flow, is also the change in theory.This mode, except saving in a large number electric energy, save equipment investment and maintenance cost, has also been created condition for Safety of Coal Mine Production, should vigorously promote the use.But, because this technology is before this still in the elementary step, also exist key technical problem in the majority not to be resolved, therefore having restricted it further develops, particularly it is restricted aspect range of application, only can adopt the small-sized work plane of hydraulic prop supporting to use, to fully-mechanized mining working or take that to combine the colliery of adopting as main inapplicable.Its concrete problem existing has:
The one, unresolved fully-mechanized mining working low pressure emulsion reclaims multiplying question, and this take and combine the colliery of adopting as main for the current overwhelming majority of China, and particularly big-and-middle-sized colliery is inapplicable.
The 2nd, the remote problem of carrying of unresolved high-pressure emulsion.Coal mine fully-mechanized mining hydraulic support requires liquid supply pressure to reach MPa more than 30, and most of collieries feed flow is apart from reaching thousands of rice, realize reliable delivery, and the key technologies such as the compressive resistance of its pipeline, leakage on the way and the pressure loss need to solve.
The 3rd, the hybrid coal winning technology of unresolved employing (be mine not only existed to combine adopt but also have a conventional face) mine, when each work plane need be different with pressure, and shares a liquid-supplying system feed flow difficult problem.
The 4th, the problem that unresolved liquid supply pressure is stable.Unstable because of liquid supply pressure, cause the setting load of pillar non-constant, cause potential safety hazard.Although existing central liquid supply system has carried out variable frequency control, only depend on and regulate the rotating speed of emulsification pump motor to carry out pressure adjusting, in actual use, pressure follow is undesirable, often causes larger pressure oscillation, and electric motor starting is frequent, unfavorable to equipment operation.
The 5th, the flow rate calculation problem of liquid for unresolved Multi-working-surface, often causes selected device capacity superfluous.Adopt after central fluid supply, although its installed capacity has significantly and reduces than distributing feed flow, because emulsification pump flow rate calculation be there is no to unified design formulas, the installed capacity of selected emulsification pump is often bigger than normal, has the phenomenon of low load with strong power.
The 6th, it is whole that equipment does not become, and each parts distributing is installed.The parts such as the emulsification pump in existing emulsification pumping plant, emulsification tank, liquid-adding device, control valve all adopt traditional distributing mounting means, and floor space is large, and in machine room, stringing is many, line loss is large, apparatus arrangement is mixed and disorderly, is not easy to centralized Control, and affects machine room and carry out production strictly in line with rules and regulations.
The 7th, equipment adopts traditional manually on duty, manual manipulation mode, needs support staff many, is unfavorable for mine Automation Construction, and easily causes equipment operating error.
The 8th, unresolved automatic liquid matching problem.Adopt artificial dosing mode, dosing quality can not be guaranteed, and time-consuming, is not easy to management.
Summary of the invention
Technical problem solved by the invention is to provide a kind of mining high efficiency energy-saving emulsified feed flow unit, the present invention is directed to the problem and the defect that in above-mentioned background technology, exist, from solving all collieries (particularly implementing to combine the colliery of adopting) central fluid supply problem, it is starting point, on the basis of studying for many years and testing, key breakthrough super-pressure, length needs the technical barriers such as pressure of different brackets apart from emulsion conveying technology and different operating face, from theory and practice, explore basic law and the fluid volume computational methods of liquid for the Multi-working-surface of colliery, optimize liquid-supplying system emulsification pump, high pressure feed pipe, energy storage equipment, the selection designing method of the critical pieces such as emulsification tank, aim at colliery and develop a kind of energy-efficient emulsification feed flow unit.This unit is installed on ground, is applicable to adopt for combining, high-grade conventional mining, big gun is adopted and mix the ground central fluid supply in all kinds of collieries such as coal mining.Unit is different according to installed capacity, is divided into super-huge, large-scale, medium-sized and small-sized four kinds of specifications, is applicable to respectively the colliery of various scales.
Technical problem solved by the invention realizes by the following technical solutions:
The energy-saving emulsified feed flow unit of mining high efficiency, comprises main feed flow module, automatic liquid matching module, electric control module and work plane;
Shown in main feed flow module comprise that high pressure divides gate valve, high pressure total gate valve, accumulator, main emulsifying pump, liquid inlet control valve, strainer, safety valve, emulsion box, woven hose, the liquid feeding end of described main emulsifying pump connects strainer by liquid inlet control valve, strainer arranges in emulsion box, the outlet end of main emulsifying pump, high pressure divide gate valve, accumulator, high pressure total gate valve to be connected successively with woven hose, and described woven hose is connected with the feed flow pipe network being laid on work plane;
Described automatic liquid matching module comprises water-delivery pump, outlet water control valve, oil-feed control valve, oil transfer pump, emulsion tank, feed cistern;
Described electric control module comprises host computer, switch board, power cabinet, frequency converter, pressure sensor, liquid level sensor, concentration sensor, described host computer connects the input of switch board by Ethernet, the input of switch board is Bonding pressure sensor, liquid level sensor and concentration sensor also, the output of switch board connects water-delivery pump, oil transfer pump, main emulsifying pump, frequency converter, and described frequency converter connects main emulsifying pump; Described host computer is Industrial Personal Computer (IPC).
In described switch board, be provided with PLC, described PLC adopts PID computing.
The present invention also comprises standby feed flow module, described standby feed flow module comprises that standby emulsification pump, high pressure divide gate valve, liquid inlet control valve, strainer, safety valve, described standby emulsification pump connects respectively output and the frequency converter of switch board, the liquid feeding end of standby emulsification pump connects strainer by liquid inlet control valve, strainer arranges in emulsion box, and the outlet end of standby emulsification pump, high pressure divide gate valve, pressure sensor and high pressure total gate valve to be connected successively.
The present invention also comprises recycling module, and described recycling module comprises oil return pond, returns liquid force (forcing) pump, liquid back pipe, and described oil return pond is connected with the feed flow pipe network being laid on work plane, and described oil return pond, time liquid force (forcing) pump, liquid back pipe are connected successively with emulsion box.
Compared with prior art, the present invention has following beneficial effect:
(1) central fluid supply function.Realize each coal-face of full mine and other shared liquid-supplying systems in use liquid place, by ground unit central fluid supply.
(2) emulsion reclaims multiplexing function.Realization is reclaimed and is recycled combining to adopt with the low pressure emulsion of cantilever support work plane.
(3) far-end is on duty, automatic control function.After host computer or switch board " key starts ", unit just enters the auto-controll operation state of acquiescence, has " far-end " and " on the spot " two kinds of monitor modes.
(4) constant-pressure liquid supply function.By attached with frequency converters, coordinate the PID constant voltage closed-loop adjustment function of PLC, liquid-supplying system pressure is carried out regulating from motion tracking, guarantee that " feed flow as required " and liquid supply pressure are constant.
(5) the long distance that realizes super-pressure emulsion is carried, and meets the needs of liquid for old mine and outlying exploiting field.More than pumping plant can reach 5000m for distal-most end work plane distance.
(6) effectively reduce the installed capacity of unit.By optimizing unit, configure, utilize the proportionality action of large system feed flow, and by adopting frequency conversion and unvarying pressure control and installing the measures such as large capacity accumulator fluid infusion additional, significantly reduce the installed capacity of emulsification pump.With respect to existing distributing liquid-supplying system, the installed capacity of emulsification pump reduces more than 80%, significantly reduces power consumption.
(7) timing feed flow function.By setting the clock of PLC controller, realize timing automatic startup-shutdown.
(8) automatic liquid matching function.The one, guarantee that emulsion box has appropriate liquid measure; The 2nd, keep emulsion to have suitable oil, water than (being that concentration meets the requirements).
(9) possesses perfect defencive function.Wherein the prerequisite protection of hydraulic system has feed flow overpressure protection, low pressure operation overtime protection, emulsion box liquid level superelevation and ultralow protection etc.; The prerequisite protection of electric part has major loop overcurrent protection, under-voltage and single phasing protection, earth leakage protective, motor overtemperature prote etc.When there is above fault, unit hard stop self-locking and warning, only press reset button and carry out after " reset ", can restarting systems.
(10) the mutual handoff functionality of main pump and stand by pump.When process pump breaks down, switch to stand by pump operation, guarantee continuous liquid supply, do not affect mine normal production.
(11) unit adopts modular integrative assembly form, and volume is little, and fluid flow path is short, the pressure loss is little, and occupied ground area is little, is easy to install, and machine room is neat and artistic.
(12) control system can access the dry net of mine industry ether by Ethernet, realizes emulsification pump Monitor And Control Subsystem and the Automatic monitoring systems information sharing of mine entirely, has stronger compatibility and autgmentability.
Accompanying drawing explanation
Fig. 1 is the principle sketch of the energy-saving emulsified feed flow unit of mining high efficiency of the present invention.
Fig. 2 is PID control principle drawing of the present invention.
In figure: 1 work plane, 2 oil return ponds, 3 times liquid force (forcing) pumps, 4 host computers, 5 switch boards, 6 power cabinets, 7 frequency converters, 8 water-delivery pumps, 9 outlet water control valves, 10 oil-feed control valves, 11 oil transfer pumps, 12 standby emulsification pumps, 13 high pressure divide gate valve, 14 pressure sensors, 15 high pressure total gate valves, 16 accumulators, 17 main emulsifying pumps, 18 liquid inlet control valve, 19 liquid level sensors, 20 concentration sensors, 21 safety valves, 22 emulsion box, 23 emulsion tanks, 24 feed cisterns, 25 liquid back pipes, 26 woven hoses.
The specific embodiment
In order to make technological means of the present invention, creation characteristic, workflow, using method reach object and effect is easy to understand, below further set forth the present invention.
As shown in Figure 1, the energy-saving emulsified feed flow unit of mining high efficiency, comprises main feed flow module, automatic liquid matching module, electric control module, standby feed flow module, recycling module and work plane 1.
Shown in main feed flow module comprise that high pressure divides gate valve 13, high pressure total gate valve 15, accumulator 16, main emulsifying pump 17, liquid inlet control valve 18, strainer, safety valve 21, emulsion box 22, woven hose 26, the liquid feeding end of described main emulsifying pump 17 connects strainer by liquid inlet control valve 18, strainer arranges in emulsion box 22, the outlet end of main emulsifying pump 17, high pressure divide gate valve 13, accumulator 16, high pressure total gate valve 15 and woven hose 26 to be connected successively, and described woven hose 26 is connected with the feed flow pipe network being laid on work plane 1.
Described automatic liquid matching module comprises water-delivery pump 8, outlet water control valve 9, oil-feed control valve 10, oil transfer pump 11, emulsion tank 23, feed cistern 24, and described water-delivery pump 8 provides water source for emulsion box 22, and described oil transfer pump 11 provides oil sources for emulsion box 22.
Described electric control module comprises host computer 4, switch board 5, power cabinet 6, frequency converter 7, pressure sensor 14, liquid level sensor 19, concentration sensor 20, described host computer 4 connects the input of switch board 5 by Ethernet, the input of switch board 5 is Bonding pressure sensor 14, liquid level sensor 19 and concentration sensor 20 also, the output of switch board 5 connects water-delivery pump 8, oil transfer pump 11, main emulsifying pump 17, frequency converter 7, described frequency converter 7 connects main emulsifying pumps 17, and described power cabinet 6 provides providing capability for system.
Described standby feed flow module comprises that standby emulsification pump 12, high pressure divide gate valve 13, liquid inlet control valve 18, strainer, safety valve 21, described standby emulsification pump 12 connects respectively output and the frequency converter 7 of switch board 5, the liquid feeding end of standby emulsification pump 12 connects strainer by liquid inlet control valve 18, strainer arranges in emulsion box 22, and the outlet end of standby emulsification pump 12, high pressure divide gate valve 13, pressure sensor 14 and high pressure total gate valve 15 to be connected successively.
Described recycling module comprises oil return pond 2, returns liquid force (forcing) pump 3, liquid back pipe 25, and described oil return pond 2 is connected with the feed flow pipe network being laid on work plane 1, and described oil return pond 2, time liquid force (forcing) pump 3, liquid back pipe 25 are connected successively with emulsion box 22.
Feed flow unit is installed near grass surface plant auxiliary shaft mouth, and each mine only need be installed a set of.Two emulsification pumps are installed, a-worker-a-backup on unit.Unit, by " unmanned " design, adopts frequency conversion automatically to control, and at centralized monitoring mine center, host computer is set, and realizes the remote monitoring to unit.The operation of equipment can adopt " on the spot " and " long-range " two kinds of modes, as long as carry out just entering after " key start " the automatic operational mode of acquiescence.
From ground feed flow machine room, to down-hole, each lays feed flow pipe network and liquid back pipe net with liquid work plane.Lay by laying (monomer supported face does not need to establish liquid back pipe) with path on liquid feeding pipeline and liquid back pipe road.Liquid feeding pipeline is delivered to each work plane by the high-pressure emulsion of ground feed flow unit output, for force piece liquid.The low pressure emulsion that support is flowed out on liquid back pipe road is led and is back to ground emulsification tank, forms emulsion closed cycle and uses system.When the pit mining degree of depth (hang down high) is no more than 200m, can adopt the mode of directly returning liquid to return liquid, directly utilize that force piece hydraulic cylinder high and low pressure lateral pressure is poor is pressed into liquid back pipe by low pressure emulsion, through liquid back pipe, directly lead back ground emulsion box.When well depth is vertical high over 200m, adopt the mode of directly returning liquid will cause support liquid-supplying system " back pressure " too high, action to support brings interference, even cause the support can not regular event, liquid auxiliary pressure device should be set back at the bottom of the auxiliary shaft of mine, the liquid that returns of each fully mechanized coal face is concentrated and drained into ground emulsion box after force (forcing) pump pressurization.
For meeting the mine of various scales, use, feed flow unit is divided into four kinds of specifications by the size of installed capacity, i.e. super-huge (power is more than 200KW), large-scale (power is more than 125KW), medium-sized (power is more than 55KW), small-sized (power is more than 15KW).Wherein super-huge unit is applicable to the mine of annual production 500～1000 tons, large-scale unit is applicable to the mine of annual production 200～500 tons, medium-sized unit is applicable to produce per year the mine of 30～200 tons, minicomputer is applicable to produce per year 300,000 tons of following mines, specifically should be according to mine working face after the condition such as how many and support model calculates, selection standard type.
The control of emulsification pump adopts advanced at present frequency conversion automatically to control and remote control technology, the high sensibility pressure transducer arranging in coupled system, realization to emulsification pump frequency conversion automatically control, make unit energy according to the number conveying liquid of down-hole fluid volume, and keep hydraulic coupling constant.Unit arranges automatic liquid matching unit, adopt current state-of-the-art high-resolution concentration of emulsion used sensor, realize the online detection of concentration of emulsion used and automatically regulate, guarantee that emulsion box has enough emulsification liquid measures, by correct water, oil ratio, carry out dosing simultaneously, guarantee that concentration is suitable.The major electrical equipment component such as PLC controller, relay, contactor, transmitter are installed in switch board, the devices such as touch-screen, control button, changeover switch are housed on its panel.PLC adopts the FX of Mitsubishi more widely of application at present
2Nseries of products, systems soft ware adopts Mitsubishi's professional version to write main program.Host computer adopts Industrial Personal Computer (IPC), and in host computer and switch board, PLC communication adopts Ethernet and optical cable transmission technology, adopts winCC to write host computer configuration interface.On switch board, touch-screen is as on-the-spot man-machine interface, for operating, setting and the supervision to unit operation situation of parameter.Video system is separately set, for the intuitive monitoring to situations such as machine room, equipment.
one, each function realizes principle and method for designing
(1) central fluid supply function
At ground surface plant, establish central fluid supply pumping plant, feed flow unit is installed in standing, two emulsification pumps are installed on unit, a job, one is standby.Emulsification pump becomes emulsion pressurization in emulsification tank into high-pressure emulsion to delivered downhole.In down-hole, lay main liquid feeding pipeline and branch line, high-pressure emulsion is delivered to each work plane, as the hydraulic power of support apparatus.For guaranteeing the requirement of the required hydraulic coupling of different operating face and flow, mainly take following technology and measure:
1. in order to meet each different requirements to emulsion pressure size with liquid place, the outlet pressure of unit should be according to setting by down-hole required maximum hydraulic pressure power work plane, other can, by the mode of one way pressure-reducing valve is set on each branch line, be adjusted to its required force value by pressure with liquid place.
According to pascal's principle, the setting pressure of feed flow machine set outlet is calculated as follows:
P=F/(2Лr
2)+Δp
In formula:
P-pumping plant outlet setting pressure (Mpa);
The setting load (N) of F-support single upright column supporting roof is required hydraulic coupling maximum functional face support single upright column setting load here;
R-fully mechanized mining supporter column cylinder body radius (mm);
The pressure loss (MPa) when Δ p-emulsion flows in pipe network, relevant with caliber and flow velocity.What carry due to liquid-supplying system is super-pressure emulsion, and flow is little, and by contrast, the pressure loss of the pipe network of flowing through is very little, negligible during calculating.
2. in order to meet the required traffic requirement of each a plurality of work planes operation simultaneously, be unlikely to again to make the installed capacity of unit superfluous, mainly take two technical measures of following technology:
The one, according to liquid registration rule for each work plane gap, the liquid supply rate of reasonable computation unit.The flow of unit calculates by following formula:
Q＝K
1K
2（Q
1＋Q
2+… Q
n）
＝K
1K
2(2×V×3.14×d
1 2 /4+2×V×3.14×d
2 2/4+…2×V×3.14×d
n 2/4)
In formula:
The flow of Q-emulsification pump (l/min);
K
1-Cai face overlap coefficient is got 1,2 and is adopted face and get 0.7,3 and adopt face and get 0.6,4 and adopt face and get 0.5 when adopting face for 1 ..., but N while adopting face value be not less than 0.4;
K
2-accumulator fluid infusion coefficient, according to the number of added accumulator, desirable 1～0.5, accumulator volume is larger, gets the small value;
Q
1, Q
2... Q
n-be respectively required emulsion flow (l/min) while respectively adopting face setting prop;
V-setting prop speed (mm/s);
D
1, d
2... d
n-be respectively and respectively adopt face bracket upright post cylinder diameter (mm).
(2) emulsion reclaims multiplexing function
To having to combine, adopt or cantilever support work plane and mine, must design special emulsion return liquid system, the low pressure emulsion of work plane is reclaimed and recycled.Return liquid system is mainly comprised of liquid back pipe road and time liquid auxiliary pressure device.The low pressure emulsion that support apparatus flows out in lifting column process is directed at ground emulsion box through return liquid system, recycles.When pit mining vertical depth is no more than 200m, can take directly to return liquid mode, while utilizing support action, the high and low pressure reduction of hydraulic cylinder is pressed into liquid back pipe by low pressure emulsion, by liquid back pipe, directly leads back ground emulsification tank; When pit mining vertical depth surpasses 200m, if still adopt the liquid mode of directly returning, return the larger back pressure that liquid forms liquid-supplying system, normal use to fully mechanized mining supporter has a great impact, liquid auxiliary pressure device must be set back at the bottom of mine auxiliary shaft, the low pressure emulsion of each work plane imports liquid return tank by liquid back pipe, then passes through auxiliary pump pressurized delivered to ground emulsification tank.Auxiliary pressurized pump is controlled by liquid return tank liquid-level switch, realizes automatic start-stop.
1. the setting of liquid back pipe.Liquid back pipe (comprising house steward and arm) is laid with path with feed pipe, selects seamless steel pipe, and it connects the snap joint of the mining K type of employing, and its caliber is not less than corresponding feed pipe.
2. the calculating of auxiliary pressurized pump discharge.Auxiliary pressurized pump discharge can be calculated according to fully-mechanized mining working advancing velocity and the liquid measure of returning of moving frame, and calculating formula is as follows:
q =kq
1/t
In formula:
Flow (the m of q-force (forcing) pump
3/ h);
The capacity redundancy of K-pump, gets 1.3;
Q
1-often move a required fluid volume (m of support
3);
T-often moves a support required time (h).
3. liquid return tank capacity determines.Support liquid is intermittence liquid, and its time liquid measure is little, and liquid return tank volume can design very littlely, but in order to make force (forcing) pump be unlikely to frequent starting, in down-hole, has in enough installing space situations, can suitably increase the capacity of liquid return tank.Generally fetching liquid pool capacity is 1m
3.Liquid return tank adopts general steel plate to be made into casing form.
(3) super-pressure emulsion length is apart from conveying function
In the liquid-supplying system of colliery, more than emulsion pressure reaches 30MPa conventionally, fed distance reaches thousands of rice.For assurance emulsion, carry reliably, must guarantee the compressive resistance of pipeline, and must prevent that pipeline from leaking and reducing as far as possible the pressure loss on the way, meanwhile, for adapting under the service condition of down-hole, the necessary dismounting of pipeline, convenient in carrying.Specifically take following technical measures:
1. Rational choice tubing
Because what carry in pipeline is highly pressurised liquid, collateral security reliability and safety and saving initial investment aspect are considered, from ground to each, use the main line in liquid place should adopt 16Mn steel high pressure seamless pipe.Pipeline in work plane, to install and move be main, should be selected high-pressure rubber pipe assembly.
2. optimize PIPE DIAMETER CALCULATION
Main line (seamless steel pipe) internal diameter is calculated as follows:
d=
In formula:
Q-supervisor's flow (L/min), should equal emulsification pump delivery and accumulator and discharge flow sum.The flow that accumulator discharges is generally got 0.5～1 times of emulsification pump delivery;
V
1the flow velocity (m/s) of-emulsion in pipeline, gets 3～5 m/s.
After having determined supervisor's diameter, get sebific duct internal diameter in the face of adopting and be 0.7～1 times of supervisor's internal diameter.
3. pipe thickness is calculated
Supervisor's (steel pipe) wall thickness is calculated as follows:
b=0.5 d [
－1]+a
In formula:
B-thickness of steel pipe (mm);
The internal diameter of d-steel pipe (mm);
σ-steel pipe allowable stress (Mpa), seamless steel pipe is got 163 Mpa;
A-considers steel pipe foozle and in use corrosion and the thickness (cm) that increases, generally gets 0.1～0.2cm;
P
d-overpressure (Mpa).
4. union is selected
Consider the reliability that pipeline connects, Leakage prevention, and installation and removal is convenient, all selects the snap joint of high pressure KJ2 type to connect between tube and tube.Steel pipe and the snap joint of KJ2 type adopt welding manner (note: weld seam must good groove, weld strength must not lower than steel pipe itself).Adopt face inner high voltage rubber tube assembly itself with the snap joint of KJ2 type, do not need to select else joint.
According to above design, selected pipeline not only has enough compressive resistances, and its caliber little (steel pipe that general mine employing internal diameter is no more than 50mm is enough), connects reliably, and Meteorological is low, pipeline dismounting, convenient in carrying.
(4) equipment installed capacity miniaturized design
By optimizing the structure of unit and adopting the technology such as accumulator fluid infusion, installed capacity is significantly reduced, thereby reach significant power savings.Mainly take following concrete measure:
1. by traditional down-hole distributing liquid-supplying system, change ground central liquid supply system into, the capacity of emulsification pump is reduced to original part.Mainly required maximum stream flow is determined when meeting the operation of single force piece in the emulsification pump installed capacity of distributing liquid-supplying system, therefore selected emulsification pump capacity is large, the emulsification pump most of the time is in light load or no-load running state.Take, after central fluid supply mode, to take full advantage of the proportionality action of large system feed flow, can greatly improve the rate of load condensate of emulsification pump.As calculated, adopting its installed capacity of central fluid supply is only 1/2～1/4 (determine according to the number of coal face, the more minimizings of work plane number are more) of distributing installed capacity.
2. by installing the mode of accumulator additional, further reduce the installed capacity of emulsification pump.Accumulator has the effect to liquid-supplying system fluid infusion and systems stabilisation pressure.When each work plane fluid volume of down-hole is less or during without liquid, accumulator carries out accumulation of energy, when system fluid volume is greater than emulsification pump delivery, accumulator supplements emulsion to system.Like this, homogenizing the load of emulsification pump, further reduced emulsification pump installed capacity.
The volume calculations of accumulator is as follows:
1. by keeping liquid-supplying system pressure stability condition to calculate accumulator volume:
V
0＝
（1）
In formula:
V
0-accumulator volume (L);
Q
5-setting prop is closed flow in preceding pipeline (l/min) with fluid valve;
P
max-pumping plant outlet pressure fluctuation higher limit (Bar), gets P
maxfor setting pressure+5%;
P
min-pumping plant outlet minimum pressure value (Bar), gets-5% of setting pressure;
When t-adopts face setting prop, valve opening or shut-in time (s), get 0.5s;
L-produces the duct length (m) impacting.
2. by the maximum stream flow of carrying out fluid infusion to system, calculate accumulator volume:
When in down-hole, a plurality of work planes are used liquid simultaneously, requiring accumulator need be 0.5～1 times of emulsification pump discharge capacity to the maximum stream flow of liquid-supplying system fluid infusion.According to on-the-spot practical measurement, the comprehensive mining hydraulic bracket setting prop time is t, and accumulator in each setting prop activity duration domestic demand to the supplementary liquid measure of system is:
Q
，= Qt
Again according to Boyle's law, the gas of certain mass, when temperature remains unchanged, the product of its pressure p and volume V equals constant.The liquid measure discharging when bag type accumulator compressed nitrogen is reduced to 95% by setting pressure is 5% of accumulator nominal capacity, and accumulator volume is:
V
1=5 Q
，×10
－2 （2）
(2) two kinds of results that mode is calculated of comparison expression (1) and formula, get higher value.
3. accumulator operating pressure determines
Accumulator is arranged on feed flow unit, and its nominal pressure should equal the rated pressure of unit, and its actual the blowing pressure should be determined by 60～80% of machine set outlet setting pressure.
(5) constant-pressure liquid supply function
Conventionally, mining emulsification pump itself is provided with mechanical type pressing apparatus for adjusting force, but its reliability and pressure degree of regulation all do not reach desirable effect, and because of it, to control sensitivity low, often cause liquid-supplying system pressure to change greatly, can not guarantee the stable of force piece setting load.And, this voltage regulating mode, even if emulsification pump, under unloading situation, still operates in full-speed state, power consumption and mechanical shock and wearing and tearing are larger, cause equipment failure rate high, shorten application life.
For eliminating above-mentioned defect, mainly take following two measures:
The one, to unit, adopt frequency conversion automatically to control.In control system, PLC has PID regulatory function, take liquid supply pressure as control object, and emulsification pump running speed is controlled, and when down-hole fluid volume increases, improves the rotating speed of emulsification pump, otherwise, reduce its rotating speed, realize as required, constant-pressure liquid supply.
The PID constant pressure adjust principle of feed flow unit is shown in Fig. 2.The actual pressure value that control system records high sensibility pressure transducer and system pressure setting value compare, its difference is carried out computing by the PID adjuster of PLC by the adjusting rule of predetermining, draw conditioning signal, control output voltage and the frequency of frequency converter, thereby the rotating speed that changes emulsification pump is to keep constant hydraulic pressure in pipe network.
The 2nd, large capacity accumulator is set in liquid-supplying system, utilize the fluid infusion of accumulator and all pressure effects, guarantee that system pressure is constant.
(6) far-end is on duty, automatic control function
This function is mainly realized by the automatic control system of feed flow unit.Control system is mainly comprised of PLC switch board, peripheral various sensors and host computer.PLC switch board is arranged on machine room scene, and host computer is located at colliery centralized-control center.PLC and host computer are connected with Ethernet protocol, adopt Siemens's professional version to write main program and adopt winCC to write configuration interface, realize on the spot communication and control with far-end.
The various sensors such as field erected pressure, liquid level, concentration, electric current, voltage are delivered to PLC by the signal detecting, PLC carries out computing and processing according to the rule of predetermining to signal, its output signal realization control to various executing agencies on the one hand, transmit signals to host computer simultaneously, realize far-end and monitor.Operating personnel realize the control to site plant by being arranged on the host computer of mine centralized-control center.On the switch board at control system scene, be provided with touch-screen and various changeover switch and button, operating personnel can realize the setting to the local operation of unit and control parameter on touch-screen.
The control of unit is arranged to two kinds of modes of operation: the one, " automatically " mode, after starting by host computer or field control cabinet one key, equipment just enters the automatic control mode (all adopting under normal circumstances this kind of mode) of acquiescence; Another kind is " manually " mode, when automatic control system or frequency converter break down, unit can be converted to " manually " mode of operation.Manual mode is power frequency operation, and power savings is poor, during only as emergent start, uses.
(7) timing feed flow function
According to colliery rule on and off duty, set startup-shutdown period every day, the time clock feature of controlling design timing start-stop emulsification pump in software at PLC, realizes regularly startup-shutdown.In colliery, relieve the period, work plane does not need with liquid, emulsification pump autostop; In the work plane normal operation period, emulsification pump starts automatically.
(8) automatic liquid matching function
Automatic liquid mixing system is comprised of parts such as PLC controller, liquid level sensor, concentration sensing receiver, water-delivery pump, oil transfer pump, emulsion box.Liquid level sensor and concentration sensor are installed in emulsion box, realize the data acquisition to emulsification tank liquid level and strength of fluid, and signal are delivered to PLC controller and carry out calculation process.Water-delivery pump and oil transfer pump are set in system, for to emulsification tank supplementing water and oil emulsion.Water-delivery pump adopts constant displacement pump, and oil transfer pump adopts measuring pump, by setting flow and the running time of two pumps, realizes and adds in proportion clear water and oil emulsion.
(1) automatic liquid-feeding.Utilize liquid level sensor to set 3 liquid levels at emulsification tank, i.e. " minimum liquid level ", " adding liquid level " and " position of rest ".In pond, liquid level is down to setting while " adding liquid level ", and PLC controls water-delivery pump and oil transfer pump simultaneously to liquid feeding in pond.When liquid level rises to " position of rest " of setting, water-delivery pump and oil transfer pump stop liquid feeding.When liquid level is down to " minimum liquid level ", illustrate that serious leakage has occurred liquid-supplying system or fault has appearred in liquid feeding system, control system stops emulsification pump operation, and sends alarm signal.
(2) adjusting of concentration of emulsion used.Concentration of emulsion used is set as to 3%～5% scope in accordance with regulations.The actual concentrations detecting when control system is lower than 3% time, and PLC controls oil transfer pump isolated operation, and Xiang Chizhong adds oil emulsion, and concentration is 3% to stop when above in addition always.When the actual concentrations detecting is higher than 5% time, PLC controls water-delivery pump add separately clear water in pond, when concentration is 3% in addition always, stops.
(9) perfect defencive function
Control system mainly realizes following protection:
1. the low liquid level protection of emulsification tank
When in pond, liquid level is down to setting " minimum liquid level ", (be generally set as than " adding liquid level " low 100～200mm); being considered as that the serious leakage of liquid-supplying system or automatic liquid-feeding system occur can not automatic liquid-feeding fault; control system is carried out safeguard protection immediately; frequency converter stops output; emulsification is out of service, and shows failure cause.Only have more than liquid level returns to " minimum liquid level ", and after safety return circuit is resetted, can restart emulsification pump.
2. the serious leakage protection of liquid-supplying system
When the continuous oepration at full load of emulsification pump (take frequency converter output frequency be decision condition for 50Hz) surpasses setting-up time; and liquid-supplying system pressure does not reach setting value yet; be considered as the serious leakage of liquid-supplying system, control system is carried out safeguard protection immediately, and shows failure cause.After only having safety return circuit being resetted, can restart emulsification pump.
3. the overload of motor and short-circuit protection
Current transformer on main circuit power supply is sent to current transducer by the three-phase current recording, and is converted to standard signal is delivered to PLC by current transducer.When motor generation overload or short trouble, PLC compares actual current value and setting value, and when its any phase actual current is greater than setting value, control system is carried out safeguard protection immediately, and shows failure cause.
4. voltage protection
Voltage protection mainly comprises ultra-voltage, under-voltage, the protection such as single-phase.Three-phase voltage transmitter is that standard signal is sent to PLC controller by the voltage transitions of power supply major loop; PLC compares the actual voltage value recording and setting range (get rated voltage 90～110%); when any phase actual voltage value exceeds setting value; control system is carried out safeguard protection, and shows failure cause.
5. motor overtemperature prote
Set temperature sensor on motor housing, and transmit signals to PLC controller, PLC compares actual temperature value and setting value (being generally set as 70 ℃), when reaching setting value, carries out safeguard protection, and shows failure cause.
6. frequency converter failure protection
Frequency converter itself is provided with fairly perfect protection, and when it breaks down, its signal is sent to PLC controller, and controller stops frequency converter operation immediately, and shows failure cause.
(10) live video function for monitoring
Video system is set separately.Video system display screen is located at colliery centralized Control machine room (together with host computer).In significant points such as pump house, every emulsification pump and emulsification liquid pools, camera is installed, operating personnel can carry out intuitive monitoring to machine room panorama and equipment operation condition.
(11) soft start and soft stop function
Utilize frequency converter originally in the characteristic starting and stopped process medium frequency progressively raises or reduces, realize soft start and the soft stop of emulsification pump.When emulsification pump starts, frequency converter frequency is progressively increased to power frequency by zero, and motor speed is also corresponding progressively to raise; When stopping emulsification pump, frequency converter output frequency is progressively down to zero, and the rotating speed of motor is also progressively down to zero.The soft start of emulsification pump and soft stop process have been avoided electric and mechanical shock, have reduced energy consumption.
two, main innovate point
The development of this unit has mainly realized following innovation:
(1) theory innovation
Proposed " feed flow large system equalization theoretical ", and derived " unbalanced by liquid flow system flow design formulas ".
Feed flow unit is intermittence liquid principle based on each face timbering under coal mine, has proposed " feed flow large system equalization theoretical ", and has derived " unbalanced with liquid flow system flow theoretical calculation formula " (calculating formula sees above and states).This calculating formula is applicable to the designing and calculating of colliery central liquid supply system flow and emulsification pump installed capacity, sets up central liquid supply system established theoretical foundation for colliery.Use the central liquid supply system of this formula design to meet objective reality, the installed capacity of equipment significantly reduces.
Coal face supporting operation is intermittence liquid, large by the randomness of liquid, " one side one system " the distributing liquid-supplying system adopting before this, when lectotype selection, the installed capacity of emulsification pump is determined according to meeting maximum flow and the pressure during with liquid of work plane operation, therefore, often there is the phenomenon of " low load with strong power " in selected device, in use the overwhelming majority time, in underloading or no-load running state, has been wasted electric energy to equipment, mechanical wear is large, and equipment purchasing expense is high.This project has proposed " the large system equalization of feed flow is theoretical ", and utilizes the balanced principle of large system feed flow to draw " unbalanced with liquid flow system flow theoretical calculation formula ", has solved the computational problem of central liquid supply system installed capacity.
Algorithm thinking: regard central fluid supply pipe network as an airtight pressure vessel.Emulsion decrement under high pressure depends on its modulus of elasticity, although emulsion has very little compression ratio, its volume is larger, and pressure is higher, and the volume of release is more, stronger to the ftercompction ability of system.When work plane is used liquid, system is not depended merely on emulsification pump delivery to supplementing of fluid volume and to guarantee, but expands and discharge and the coefficient result of emulsification pump feed flow and accumulator fluid infusion at system emulsion.Like this, system pressure excursion reduces.According to this principle, liquid-supplying system is larger, pressure is higher, and the self-adjusting ability of emulsion pressure is stronger, and liquid-supplying system pressure is more stable.Therefore, central system system has good pressure equalizing, with respect to distributing liquid-supplying system, can significantly reduce the installed capacity of emulsification pump, and system pressure stability improves.
(2) application innovation
1. accumulator is applied to liquid-supplying system fluid infusion, and derives accumulator fluid replacement formula
Conventionally, accumulator mainly works to reduce compression shock in hydraulic system.This project is used for accumulator system is carried out to fluid infusion, and derives the design formulas of hydraulic accumulator amount infused, has expanded the purposes of accumulator, utilizes accumulator liquid replenishing function simultaneously, significantly reduces the installed capacity of emulsification pump.
Accumulator fluid infusion basic principle is: when each work plane fluid volume of down-hole is less or during without liquid, accumulator carries out accumulation of energy; When system fluid volume is greater than emulsification pump delivery, accumulator supplements emulsion to system.According to Boyle's law, the gas of certain mass, when temperature remains unchanged, the product of its pressure p and volume V equals constant.Bag type accumulator compressed nitrogen is reduced to 95%(liquid-supplying system pressure allowable fluctuation range by setting pressure) time the liquid measure that discharges be 5% of accumulator nominal capacity, accumulator volume is V
1=5 Q
,* 10
-2.When having determined the amount infused Q of system
,time, just can calculate accumulator volume.
2. with ground central fluid supply form, replace original down-hole distributing feed flow form
This unit is installed on ground machine room, with an equipment, concentrate to down-hole feed flow, realized the change of " with replacement down-hole, ground " and " many with a generation " Function and forms, function and the range of application of equipment have been expanded, improved functional performance, reduced the initial investment of equipment and the maintenance cost in use procedure, the installed capacity of equipment reduces greatly, and power saving rate is high.
The basic principle realizing:
Near the surface plant well head of ground, central fluid supply machine room is set, a feed flow unit is installed in machine room, two emulsification pumps are installed, a-worker-a-backup on unit.Emulsification pump becomes emulsion pressurization in emulsification tank into high-pressure emulsion, with constant pressure to delivered downhole.In down-hole, lay main liquid feeding pipeline and branch line, high-pressure emulsion is delivered to each work plane, as the hydraulic power of support.Like this, the distributing feed flow that has replaced the former installation of mining face under mine with central fluid supply form.
3. frequency conversion automatic control technology is applied to feed flow unit
The original emulsion power pack in colliery is because be arranged on mining face under mine, and environment for use is poor, is subject to the restriction of the condition such as explosion-proof simultaneously, all adopts simple manual control mode.This unit is arranged on ground, for the condition of having created is controlled in the automation of equipment.This project adopts frequency conversion and automated control technology to control unit, realize remote-controlled operation and the monitoring of constant-pressure liquid supply and equipment, not only improved feed flow quality, significantly reduced power consumption simultaneously, save machine room duty personnel, improved coal production automatization level.
The basic principle realizing:
Unit arranges frequency conversion automatic control system, and control system is mainly comprised of frequency converter, PLC controller, peripheral various sensors and host computer.Frequency converter is for the control to emulsification pump motor speed.The control system that the PLC controller of take is core is controlled the operation of unit and automatic liquid matching.Host computer is located at colliery centralized-control center.PLC and host computer are connected with Ethernet protocol, control software and adopt Siemens's professional version to write main program and adopt winCC to write configuration interface, form on the spot and remote communication and control.Control system mainly realizes the controls such as automatic startup-shutdown, constant voltage, automatic liquid matching and various protections to unit.
The various sensors such as field erected pressure, liquid level, concentration, electric current, voltage are delivered to PLC by the signal of detection, PLC carries out computing and processing according to the rule of predetermining to signal, its output signal realization control to various executing agencies on the one hand, transmit signals to host computer simultaneously, realize far-end and monitor.The host computer and the on-the-spot PLC that are arranged on mine centralized-control center adopt ethernet communication agreement to be connected, and operating personnel realize the control to site plant by host computer.Be arranged on and on on-the-spot switch board, be provided with touch-screen and various changeover switch and button, on touch-screen, can realize to the various operations of equipment with to the setting of each control parameter and fault inquiry etc., by changeover switch and button, can realize the execute-in-place to equipment.
The major effect of obtaining:
(1) " feed flow as required " and " constant-pressure liquid supply " have been realized.When work plane fluid volume is little or during without liquid, emulsification pump is in the slow-speed of revolution or stopped status; When down-hole fluid volume increases, the corresponding raising of emulsification pump rotating speed; When system fluid volume surpasses emulsification pump delivery, accumulator carries out fluid infusion to system.Like this, just remained the constant of liquid supply pressure.(2) saved emulsification pump duty personnel.Adopt after central fluid supply and automatic control, down-hole operator has been reduced in colliery, has saved cost of labor, has improved personnel's safety insurance degree.(3) improve mine automation degree, by rationally setting the start/stop time of emulsification pump, accomplished to keep away peak with regard to paddy electricity consumption simultaneously.
(3) technological innovation
1. successfully solve fully-mechanized mining working low pressure emulsion and reclaimed multiplexing technical barrier
Before this, why emulsification pumping plant in colliery is arranged on mining face under mine for a long time, and one of them topmost reason is exactly to solve the problem that fully-mechanized mining working low pressure emulsion reclaims.This project proposes back liquid pipeline to be set in liquid-supplying system and to add to reinstall liquid auxiliary pressure device, solves preferably the recycling problem of work plane low pressure emulsion, and making emulsification pumping plant move to ground becomes possibility.
Basic principle:
Emulsion reclaim line system is set in liquid-supplying system.Liquid back pipe and woven hose are laid with path, select seamless steel pipe, and pipeline adopts the quick connected mode of mining K type joint, caliber should >=with the caliber of path woven hose.This project has proposed two kinds and has returned liquid mode: the one, directly return the mode of liquid, and at work plane, apart from ground pump station, the discrepancy in elevation is installed while being not more than 200m, can directly by liquid back pipe, work plane low pressure emulsion be led back to ground emulsification tank.This mode is relatively simple; The 2nd, when work plane is greater than 200m apart from the ground pump station installation discrepancy in elevation, when laying back liquid pipeline, also need to arrange back liquid auxiliary pressure device, emulsion liquid return tank and force (forcing) pump are set at the bottom of auxiliary shaft.The low pressure emulsion of each work plane first imports the liquid return tank of auxiliary pressure device by liquid back pipe, then is delivered to ground emulsification tank after pressurizeing by auxiliary pump.Auxiliary pressurized pump adopts automatic control of liquid start-stop.
The major effect of obtaining:
(1) solve the recovery multiplying question of fully-mechanized mining working low pressure emulsion, made ground central liquid supply system apply and become possibility in each colliery, the whole nation, meanwhile, saved emulsification oil consumption, reduced coal production cost.
(2) other use liquid installations and facilities (as hydraulic prop, coal road support, hydraulic drill rig, behaviour's truck system etc.) at the recovery multiplying question that returns liquid with in liquid process, for colliery applying high voltage emulsion power source has been opened up bright prospects to utilize present principles can solve colliery.
(2) solved the remote conveying feed technique problem of high-pressure emulsion
More than in liquid-supplying system, emulsion pressure reaches 30MPa conventionally, fed distance is generally thousands of rice.This project has solved the technical barriers such as pipeline compressive resistance in emulsion course of conveying, leakage, linear loss and down-hole dismounting, has widened ground central fluid supply technology range of application.
Realize basic principle:
1. reasonable selection is carried tubing.From ground to each, use the main line in liquid place should adopt 16Mn steel high pressure seamless pipe.For ease of installing and moving, adopt the selection for pipeline high-pressure rubber pipe assembly in face.
2. reasonable selection caliber.Adopt big-diameter pipeline conveying high-pressure liquid certainly will cause pipe thickness to increase, construction cost increases, and makes troubles to installation, dismounting and the carrying of pipeline simultaneously.This project utilizes work plane for equalizing characteristics and the principle of liquid for gap, little with flow quantity of large system, the computational methods of employing science are selected caliber, make selected caliber very little (its internal diameter maximum is no more than 50mm), meet service condition under coal mine, reduced the construction cost of liquid-supplying system.
3. select suitable union form
The reliability that this project connects from pipeline and installation, dismounting convenience, the snap joint of high pressure KJ2 type is all selected in the connection between pipe.This kind of withstand voltage height of joint form (nominal pressure reaches as high as 100MPa), mount and dismount very conveniently, be applicable to subsurface environment and use.Steel pipe and the snap joint of KJ2 type adopt welding manner (note: weld seam must good groove, weld strength must not lower than steel pipe itself).Adopt face inner high voltage rubber tube assembly itself with the snap joint of KJ2 type, do not need to select else joint.
(4) structure innovation
1. complete machine adopts the traditional emulsification pumping plant of modular integrated mounting means to adopt split type layout and mounting means, in system, emulsification pump, emulsification tank, control valve etc. are and are respectively integrated, floor space is large, the interior stringing of machine room (or chamber) is many, line loss is large, apparatus arrangement is mixed and disorderly, is not easy to centralized Control, and affects machine room and carry out production strictly in line with rules and regulations.This unit adopts modular integrated mounting means, and equipment volume is reduced, and installation floor space is little, equipment good looking appearance, and system hydraulic slip reduces.Meanwhile, all parts adopt modularized design to be convenient to standardization and generalization, are convenient to maintenance, dismounting and transportation.
2. the design of multi-functional, large capacity emulsion box
This project is in strict accordance with the universal standard of coal mine equipment, designs perfect in shape and function, security reliability is high, versatility good, safeguard emulsion box easy to use, structure is attractive in appearance.
The main feature of emulsification tank:
1. multiple functional.Installed emulsion automatic liquid mixing system additional, realized automatic liquid matching, guaranteed that emulsification liquid measure and concentration meet setting requirement.
2. all annex parts are installed on casing, and good integrity is attractive in appearance.
three, performance analysis
Coal industry is one of pillar industry of China.Emulsification liquid-supplying system in colliery plays a very important role guaranteeing normal production the in colliery.The development of this product has solved the multinomial technical barrier that emulsification liquid-supplying system in colliery exists, expanded the application of ground central fluid supply technology, simultaneously by measures such as technological innovation, optimized device structures, integrated, standardization, seriation and the miniaturization of equipment have been realized.Along with this product will produce huge economic and social benefit applying of each colliery of China.Make a concrete analysis of as follows:
(1) power savings is remarkable
Now take single medium size coal mine as examination object, to make comparisons to analyze power savings with unit feed flow and original distributing liquid-supplying system:
1. comparison condition:
(1) while applying unit feed flow, the emulsification pump installed capacity in colliery can be reduced more than 80%, get 80% here.
(2) two kinds of feed liquid way available machine times are basically identical, get the available machine time here to equate.
(3) rate of load condensate of distributing feed liquid way emulsification pump is 10% left and right, gets 10% here; Adopting unit feed flow emulsification pump rate of load condensate is 60% left and right, gets 60% here.
2. while disperseing feed flow, the power consumption of every day is calculated as follows:
The installed capacity of supposing colliery former employing distributing feed flow emulsification pump is N(KW), emulsification pump running time is t (h), the electricity consumption total amount of every day is:
W
1=W
unloaded+ W
load
＝0.4×N×（1－0.1）t＋N×（1－0.9）t
＝0.46Nt(KWh)
In formula:
W
1the electricity consumption total amount (KWh) of-full ore deposit emulsification pump every day;
W
unloadedthe electricity consumption total amount (KWh) of-full ore deposit emulsification pump no-load running;
W
loadthe electricity consumption total amount (KWh) of-full ore deposit emulsification pump load running;
The installation total capacity (KW) of the full ore deposit of N-emulsification pump;
T-emulsification pump running time every day (h);
0.4-emulsification pump no-load running consumption rate.
3. while adopting unit feed flow, the power consumption of every day is calculated as follows:
W
2=W
unloaded ,+ W
load ,
＝0.4×（1－0.8）N×（1－0.6）t＋（1－0.8）N×（1－0.4）t
＝0.152Nt(KWh)
In formula:
W
2the power consumption (KWh) of-unit every day;
W
unloaded ,the power consumption of-unit no-load running (KWh);
W
load ,the power consumption of-unit load running (KWh);
The installation total capacity (KW) of N-distributing feed flow emulsification pump;
T-emulsification pump running time every day (h);
0.4-emulsification pump no-load running consumption rate.
4. adopt the power saving rate of unit feed flow to be calculated as follows:
η＝
＝
＝67%
5. single colliery Spring Festival holidays electric weight calculates
While supposing certain Coal Exploitation with distributing feed flow, the installed capacity of emulsification pump is 375KW, and emulsification pump running time every day is 18 hours, and annual power consumption is
W
1 ，＝0.46×330×N×t＝0.46×330×375×18＝1024650KWh
Adopt the amount of electricity saving after feed flow unit to be:
ΔW=0.67×W
1 ，=0.67×1024650=686515 KWh
6. in each colliery, the whole nation, apply the amount of electricity saving estimation of technique
China has approximately 2.8 ten thousand, colliery at present, adopts after technique, and the whole nation can save electricity be:
ΔW
，＝28000×ΔW＝28000×686515＝192×10
8 KWh
(2) other performance analyses
1. equipment is installed on ground, and takes converting operation mode, and wearing and tearing and the spoilage of liquid supply equipment reduce greatly, extend 6～10 times the application life of emulsification pump, by single colliery, calculate, can be every year colliery and save 200,000 yuan of original equipment cost average out tos, 5,600,000,000 yuan of total costs are saved in national colliery.
2. emulsification pumping plant moves to behind ground, and the environment for use of equipment has obtained very big improvement, brings great convenience to the maintaining of equipment simultaneously, and on average each colliery year is saved approximately 100,000 yuan of maintenance costs, and 2,800,000,000 yuan of total costs are saved in national colliery.
3. average each minimizing down-hole, colliery emulsification pump duty personnel approximately 12 people, save approximately 360,000 yuan of personnel's wages every year;
4. guaranteed emulsion quality, extended top overhaul cycle and the application life of hydraulic support, individual prop, on average each colliery year is saved maintenance cost approximately 400,000 yuan.
5. emulsification pumping plant moves to behind ground, has reduced colliery downhole operations and attendant, and Safety of Coal Mine Production guarantee degree improves, and has eliminated the impact on subsurface environment such as the greasy dirt that emulsification pumping station operation produces, noise, heat, pernicious gas simultaneously.
6. the colliery of only using hydraulic prop supporting for part, because the natural pressure that ground pump station and mining face under mine elevation difference form, can significantly reduce emulsification pump outlet pressure, make emulsification pump in a kind of light running state, its power consumption further reduces, and service life of equipment further extends.
7. along with the foundation of coal mine ground central liquid supply system, built the application platform that hydraulic pressure of the colliery can be carried.Can predict, along with improving constantly of coal mine machinery degree, not nonoculture of high-pressure emulsion is the power source of comprehensive mining hydraulic bracket and hydraulic prop, also will be for other hydraulic test facilities of down-hole (as shaft bottom, shaft machine operation system, coal road hydraulic supports etc.), this will further advance the extensive use of colliery emulsification hydraulic installations and facilities.The advantages such as emulsion pressure energy is safe and reliable with it, have wide range of applications, easy to use, medium is cheap, unit volume medium transmitted power is large, by same electric energy, blast can, jointly form the main power source in colliery.
four, production development and application prospect analysis
(1) coal, as nonrenewable resources, plays irreplaceable effect in using energy source.Predict, within the regular period in the future, along with China's economic development, market is still in rising trend to the demand of coal.Colliery emulsification pump liquid-supplying system is one of essential corollary system in coal production process, and colliery liquid-supplying system is integrated, seriation, standardization are of great significance to ensureing normal production the in colliery, are the imbodies of colliery technological progress.The development of this product has been filled up China in this blank on the one hand, is the significant event that China's coal-mine equipment improves.
(2) before this, we apply technique principle, developed initial production, and the angle slope and loyal two collieries of justice that are arranged on Guizhou Xiang Neng Industrial Co., Ltd. are used, result of use is fine, from theory and practice, all prove the correctness of technique, there is very strong practicality, there is very large development space and application prospect.
(3) this unit has significant energy-saving effect, meets the energy-saving and emission-reduction policy and the requirement of using new technology, new material, new equipment of the current promotion of China.Using feed flow unit feed flow is very effective measures of one of coal mining enterprise's energy saving and efficiency increasing.Can predict, technique will be applied in each colliery, the whole nation rapidly.
More than show and described basic principle of the present invention, principal character and advantage of the present invention.The technician of the industry should understand; the present invention is not restricted to the described embodiments; that in above-described embodiment and manual, describes just illustrates principle of the present invention; without departing from the spirit and scope of the present invention; the present invention also has various changes and modifications, and these changes and improvements all fall in the claimed scope of the invention.Claimed scope of the present invention is defined by appending claims and equivalent thereof.
Claims (4)
1. the energy-saving emulsified feed flow unit of mining high efficiency, comprises main feed flow module, automatic liquid matching module, electric control module and work plane, it is characterized in that:
Shown in main feed flow module comprise that high pressure divides gate valve, high pressure total gate valve, accumulator, main emulsifying pump, liquid inlet control valve, strainer, safety valve, emulsion box, woven hose, the liquid feeding end of described main emulsifying pump connects strainer by liquid inlet control valve, strainer arranges in emulsion box, the outlet end of main emulsifying pump, high pressure divide gate valve, accumulator, high pressure total gate valve to be connected successively with woven hose, and described woven hose is connected with the feed flow pipe network being laid on work plane;
Described automatic liquid matching module comprises water-delivery pump, outlet water control valve, oil-feed control valve, oil transfer pump, emulsion tank, feed cistern;
Described electric control module comprises host computer, switch board, power cabinet, frequency converter, pressure sensor, liquid level sensor, concentration sensor, described host computer connects the input of switch board by Ethernet, the input of switch board is Bonding pressure sensor, liquid level sensor and concentration sensor also, the output of switch board connects water-delivery pump, oil transfer pump, main emulsifying pump, frequency converter, and described frequency converter connects main emulsifying pump; Described host computer is Industrial Personal Computer (IPC);
At ground surface plant, establish central fluid supply pumping plant, feed flow unit is installed in standing, two emulsification pumps are installed on unit, a job, one is standby; Emulsification pump becomes emulsion pressurization in emulsification tank into high-pressure emulsion to delivered downhole; In down-hole, lay main liquid feeding pipeline and branch line, high-pressure emulsion is delivered to each work plane, as the hydraulic power of support apparatus; For guaranteeing the requirement of the required hydraulic coupling of different operating face and flow, take following measures:
(1) in order to meet each different requirements to emulsion pressure size with liquid place, the outlet pressure of unit should be according to setting by down-hole required maximum hydraulic pressure power work plane, other by the mode of one way pressure-reducing valve is set on each branch line, are adjusted to its required force value by pressure with liquid place;
According to pascal's principle, the setting pressure of feed flow machine set outlet is calculated as follows:
P=F/(2Лr
2)+Δp
In formula:
P-pumping plant outlet setting pressure;
The setting load of F-support single upright column supporting roof is required hydraulic coupling maximum functional face support single upright column setting load here;
R-fully mechanized mining supporter column cylinder body radius;
Pressure loss when Δ p-emulsion flows in pipe network, relevant with caliber and flow velocity; What carry due to liquid-supplying system is super-pressure emulsion, and flow is little, and by contrast, the pressure loss of the pipe network of flowing through is very little, during calculating, ignores;
(2) in order to meet the required traffic requirement of each a plurality of work planes operation simultaneously, be unlikely to again to make the installed capacity of unit superfluous, mainly take two technical measures of following technology:
The one, according to liquid registration rule for each work plane gap, calculate the liquid supply rate of unit; The flow of unit calculates by following formula:
Q＝K
1K
2（Q
1＋Q
2+… Q
n）
＝K
1K
2(2×V×3.14×d
1 2 /4+2×V×3.14×d
2 2/4+…2×V×3.14×d
n 2/4)
In formula:
The flow of Q-emulsification pump;
K
1-Cai face overlap coefficient is got 1,2 and is adopted face and get 0.7,3 and adopt face and get 0.6,4 and adopt face and get 0.5 when adopting face for 1 ..., but N adopts face value, be not less than 0.4;
K
2-accumulator fluid infusion coefficient, according to the number of added accumulator, gets 1～0.5, and accumulator volume is larger, gets the small value;
Q
1, Q
2... Q
n-be respectively required emulsion flow while respectively adopting face setting prop;
V-setting prop speed;
D
1, d
2... d
n-be respectively and respectively adopt face bracket upright post cylinder diameter.
2. the energy-saving emulsified feed flow unit of mining high efficiency according to claim 1, is characterized in that: in described switch board, be provided with PLC, described PLC adopts PID computing.
3. the energy-saving emulsified feed flow unit of mining high efficiency according to claim 1, it is characterized in that: also comprise standby feed flow module, described standby feed flow module comprises that standby emulsification pump, high pressure divide gate valve, liquid inlet control valve, strainer, safety valve, described standby emulsification pump connects respectively output and the frequency converter of switch board, the liquid feeding end of standby emulsification pump connects strainer by liquid inlet control valve, strainer arranges in emulsion box, and the outlet end of standby emulsification pump, high pressure divide gate valve, pressure sensor and high pressure total gate valve to be connected successively.
4. according to the energy-saving emulsified feed flow unit of the mining high efficiency described in claim 1 or 3, it is characterized in that: also comprise recycling module, described recycling module comprises oil return pond, returns liquid force (forcing) pump, liquid back pipe, described oil return pond is connected with the feed flow pipe network being laid on work plane, and described oil return pond, time liquid force (forcing) pump, liquid back pipe are connected successively with emulsion box.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201210195909.8A CN102704960B (en) | 2012-06-14 | 2012-06-14 | Mineral efficient energy-saving emulsification liquid feeding unit |
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| CN103174634B (en) * | 2013-03-27 | 2015-08-12 | 北京中矿赛力贝特科技有限公司 | A kind of emulsion power pack intelligent control system and controlling method |
| CN103629529A (en) * | 2013-12-10 | 2014-03-12 | 郑州煤机综机设备有限公司 | High-pressure fluid control device for mechanized mine |
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| CN113339025A (en) * | 2021-06-04 | 2021-09-03 | 煤炭科学研究总院 | Hydraulic system and hydraulic support group |
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