CN113864163A - Energy-saving modification method for high-pressure 4M32G-186 carbon dioxide compressor - Google Patents
Energy-saving modification method for high-pressure 4M32G-186 carbon dioxide compressor Download PDFInfo
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- CN113864163A CN113864163A CN202111297148.2A CN202111297148A CN113864163A CN 113864163 A CN113864163 A CN 113864163A CN 202111297148 A CN202111297148 A CN 202111297148A CN 113864163 A CN113864163 A CN 113864163A
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B39/00—Component parts, details, or accessories, of pumps or pumping systems specially adapted for elastic fluids, not otherwise provided for in, or of interest apart from, groups F04B25/00 - F04B37/00
- F04B39/12—Casings; Cylinders; Cylinder heads; Fluid connections
- F04B39/122—Cylinder block
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B37/00—Pumps having pertinent characteristics not provided for in, or of interest apart from, groups F04B25/00 - F04B35/00
- F04B37/10—Pumps having pertinent characteristics not provided for in, or of interest apart from, groups F04B25/00 - F04B35/00 for special use
- F04B37/18—Pumps having pertinent characteristics not provided for in, or of interest apart from, groups F04B25/00 - F04B35/00 for special use for specific elastic fluids
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B39/00—Component parts, details, or accessories, of pumps or pumping systems specially adapted for elastic fluids, not otherwise provided for in, or of interest apart from, groups F04B25/00 - F04B37/00
- F04B39/0005—Component parts, details, or accessories, of pumps or pumping systems specially adapted for elastic fluids, not otherwise provided for in, or of interest apart from, groups F04B25/00 - F04B37/00 adaptations of pistons
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B39/00—Component parts, details, or accessories, of pumps or pumping systems specially adapted for elastic fluids, not otherwise provided for in, or of interest apart from, groups F04B25/00 - F04B37/00
- F04B39/10—Adaptations or arrangements of distribution members
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P20/00—Technologies relating to chemical industry
- Y02P20/10—Process efficiency
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Abstract
The invention discloses an energy-saving modification method for a high-pressure 4M32G-186 carbon dioxide compressor, which comprises the following steps: the inner diameter of a 1-5-level cylinder body is improved, a 1-5-level piston is changed from a split type to an integral type, the outer diameter of the 1-5-level piston, the weight of the 1-5-level piston and an open type air valve of the 1-5 level are changed into a closed type air valve, and the outer diameter of the 1-5-level air valve, the outer diameter of a 1-5-level valve sheet and the clearance of an air valve air passage of the 1-5-level cylinder body are improved. After the improvement, the air pumping amount of each compressor can be increased by not less than 30%, the original design requirements of the compressor are broken through, the operation power of the compressor is kept unchanged, the energy consumption is not increased, the output of a compressor using enterprise is increased, a large amount of energy is saved, and great economic benefits are achieved.
Description
Technical Field
The invention belongs to the technical field of compressor modification, and particularly relates to an energy-saving modification method for a 146kg high-pressure 4M32G-186 carbon dioxide compressor.
Background
The large-scale compressor is one of the common equipments in chemical enterprises, and is difficult to modify after installation and use, and the modification difficulty and complexity are well known to those skilled in the art. Moreover, for different models of compressors, the modification method cannot be uniform due to different structures or pressures, and the modification method is modified correspondingly according to different models. For example, the 6M50 type raw material gas compressor is a common reciprocating nitrogen-hydrogen gas compressor (see fig. 1), which is one of the key equipments in chemical enterprises in China, and the total number of the equipments in the country is about 100, and it is necessary to ensure that the equipment operates normally 24 hours a day. Generally, a 6M50 type compressor includes a main motor 100, a multi-stage compression cylinder block 101 in which pistons are provided, and a gas valve 102 provided on the cylinder block 101; the piston and gas valve 102 are important components in the performance of the compressor. The Chinese patent numbers are: 201110332306.3, the invention patent application named "6M 50 type raw gas compressor increases the gas pumping amount, energy conservation and emission reduction' improves the existing 6M50 type compressor, the improvement method includes the following steps: 1) the pistons in the cylinders of each stage of the compressor are changed from split type to integral type; the piston body of the piston is of an integral structure, and an annular cavity is arranged in the piston body; 2) the thickness of the piston of each stage of cylinder is increased by 0.5 to 0.8 percent on the basis of the existing design standard of the thickness of the piston; 3) the air suction valve and the air discharge valve of each stage of cylinder comprise valve seats, valve plates, springs and lift limiters; the valve seat, the valve plate, the spring and the lift limiter are connected and fixed through a bolt and a nut in sequence; one end of the spring is fixed on the lift limiter, and the other end of the spring props against the back surface of the valve plate, so that the front surface of the valve plate is tightly attached to the valve seat to form a sealing surface; increasing the valve plate lift of the suction valve and the exhaust valve on each stage of cylinder by 11.5-13.6% on the basis of the existing valve plate lift design standard; 4) the equivalent flow area of an intake valve and an exhaust valve on each stage of cylinder is increased by 14.7-15.1% on the basis of the existing equivalent flow area design standard. The method solves the problems of serious piston abrasion and frequent replacement, and also solves the phenomenon that the compressor of the model is pulled by a big horse to be a small car. However, the field practice shows that the existing energy-saving modification method for the high-pressure 4M32G-186 carbon dioxide compressor can only achieve the design requirements, but cannot obtain greater energy-saving effect, so that the original design requirements are broken through.
Disclosure of Invention
The invention aims to solve the technical problem of providing an energy-saving modification method of a high-pressure 4M32G-186 carbon dioxide compressor; the energy-saving transformation method can increase the gas production amount by more than or equal to 30 percent, breaks through the original design requirement of the compressor, keeps the operation power unchanged, does not increase the energy consumption, increases the yield for the compressor using enterprises, saves a large amount of energy, and has great economic benefit.
The existing high-pressure 4M32G-186 carbon dioxide compressor with the pressure of 146kg has the following structural parameters:
the running power of the motor is 2600 kw;
the inner diameter of the first-stage cylinder body is 1082 mm; the inner diameter of the secondary cylinder body is 622 mm;
the inner diameter of the third-stage cylinder body is 282 mm; the inner diameter of the four-stage cylinder body is 300 mm; the inner diameter of the five-stage cylinder body is 148 mm;
the outer diameter of the primary piston is 1073 mm; the outer diameter of the secondary piston is 615 mm;
the outer diameter of the tertiary piston is 276 mm; the outer diameter of the four-stage piston is 295 mm; the outer diameter of the five-stage piston is 144 mm;
primary piston weight 477 kg; the weight of the secondary piston is 480 kg;
the weight of the three-stage piston is 277 kg; the weight of the four-stage piston is 115 kg; the weight of the five-stage piston is 79 kg;
the outer diameter of the first-stage open type air valve is 305 mm; the outer diameter of the second-stage open type air valve is 235 mm; three-stage open type air valve external diameter
235 mm; the outer diameter of the four-stage open type air valve is 235 mm; the outer diameter of the five-stage open type air valve is 230 mm;
the outer diameter of the first-stage valve plate is 285 mm; the outer diameter of the secondary valve plate is 210 mm;
the outer diameter of the three-stage valve plate is 210 mm; the outer diameter of the four-stage valve plate is 210 mm; the outer diameter of the five-stage valve plate is 205 mm;
the clearance of the air passage of the air valve of the 1-3-level cylinder body is 30 mm;
the clearance of the air passage of the air valve of the 4-5-level cylinder body is 48 mm.
In order to solve the technical problems, the invention adopts the following technical scheme：
An energy-saving modification method for a 146kg high-pressure 4M32G-186 carbon dioxide compressor comprises the following steps:
s1, changing the inner diameter of the first-stage cylinder from 1082mm to 1085-1086mm, the inner diameter of the second-stage cylinder from 622mm to 625-626mm, the inner diameter of the third-stage cylinder from 282mm to 285-286mm, the inner diameter of the fourth-stage cylinder from 300mm to 303-304mm, and the inner diameter of the fifth-stage cylinder from 148mm to 154-156 mm;
s2, changing the split type of the piston into the integral type; and is
The outer diameter 1073mm of the first-stage piston is changed to 1076-1078mm, the outer diameter 615mm of the second-stage piston is changed to 618-620mm, the outer diameter 276mm of the third-stage piston is changed to 279-280mm, the outer diameter 295mm of the fourth-stage piston is changed to 297-298mm, and the outer diameter 144mm of the fifth-stage piston is changed to 148-150 mm;
the weight of the primary piston is 477kg changed to 179-181kg, the weight of the secondary piston is 480kg changed to 159-161kg, the weight of the tertiary piston is 277kg changed to 92-94kg, the weight of the quaternary piston is 115kg changed to 38-40kg, and the weight of the quinary piston is 79kg changed to 27-29 kg;
s3, changing the open air valve from the first level to the fifth level into a closed air valve; and is
The outer diameter of the first-stage air valve is changed from 305mm to 319-152 mm, the outer diameter of the second-stage air valve is changed from 235-266 mm, the outer diameter of the third-stage air valve is changed from 264-266mm, the outer diameter of the fourth-stage air valve is changed from 235mm to 254-256mm, and the outer diameter of the fifth-stage air valve is changed from 230mm to 249-251 mm;
s4, changing the outer diameter of the first-stage valve plate to 291-;
s5, changing the clearance of the air passage of the 1-3 level cylinder air valve from 30mm to 14-16 mm;
the clearance of the air passage of the air valve of the 4-5-grade cylinder body is changed from 48mm to 34-36 mm.
Preferably, in step S1, the change of the inner diameter of the primary cylinder from 1082mm to 1085-1086mm is achieved by concentric modification through a traveling crane finish grinding.
Preferably, in step S1, the change of the inner diameter of the secondary cylinder from 622mm to 625-626mm is realized by concentric modification through the traveling crane finish grinding.
Preferably, in step S1, the change of the inner diameter of the tertiary cylinder from 282mm to 285-286mm is realized by refining modification with a grinding mill.
Preferably, in step S1, the change of the four-stage cylinder inner diameter from 300mm to 303-304mm is realized by refining modification with a grinding mill.
Preferably, in step S1, the change of the inner diameter of the five-stage cylinder from 148mm to 154-156mm is realized by fine grinding modification.
Preferably, in step S2, the changing of the primary piston weight 477kg to 179-181kg is performed by changing the existing raw material 20#The steel is replaced by aluminum alloy L108 subjected to 500-degree hard oxidation treatment, and the piston is changed from a split type to an integral type.
Preferably, in step S2, the change of the weight of the secondary piston from 480kg to 159-161kg is realized by replacing the existing raw iron castings JT25-47C with aluminum alloy L108 which is subjected to 500-degree hard oxidation treatment, and changing the piston from split type to integral type.
Preferably, in step S2, the change of the weight of the tertiary piston 277kg to 92-94kg is performed by changing the existing raw material 35#The steel is replaced by aluminum metal subjected to 800-degree hard oxidation treatment, and the piston is integrally changed from a split type.
Preferably, in step S2, the change of the weight of the four-stage piston from 115kg to 38 kg to 40kg is made by changing the existing raw material 35#The steel is replaced by aluminum metal subjected to 800-degree hard oxidation treatment, and the piston is integrally changed from a split type.
Preferably, in step S2, the change of the weight 79kg of the five-stage piston to 27-29kg is made by changing the existing raw material 35#The steel is replaced by aluminum metal subjected to 800-degree hard oxidation treatment, and the piston is integrally changed from a split type.
Preferably, in step S5, the changing of the clearance of the air passage of the 1-3-stage cylinder air valve from 30mm to 14-16mm and the changing of the clearance of the air passage of the 4-5-stage cylinder air valve from 48mm to 34-36mm are realized by modifying a boring machine.
Any range recited herein is intended to include the endpoints and any number between the endpoints and any subrange subsumed therein or defined therein.
The starting materials of the present invention are commercially available, unless otherwise specified, and the equipment used in the present invention may be any equipment conventionally used in the art or may be any equipment known in the art.
The invention has the following beneficial effects：
1) After actual operation, the 146kg high-pressure 4M32G-186 carbon dioxide compressor modified by the modification method can increase the gas injection amount by more than 30% under the condition of maintaining the prior operating power 2600kw (without increasing energy consumption), breaks through the original design requirement of the compressor, thereby increasing the yield by more than 30% for the compressor using enterprises, saving a large amount of energy and having great economic benefit.
2) Because the integral piston is adopted to reduce the internal temperature of the compressor, and along with the reduction of the weight of the piston, dead gas in the clearance of the air passage of the air valve of the cylinder body has large rebound force and the like, the service life of the piston ring and the support ring is greatly prolonged.
Drawings
The following detailed description of embodiments of the invention is provided in connection with the accompanying drawings
FIG. 1 is a schematic diagram of the overall structure of a conventional 146kg high-pressure 4M32G-186 carbon dioxide compressor;
FIG. 2 is a schematic cross-sectional view of a cylinder;
FIG. 3 is an enlarged view of the portion A of FIG. 2 showing the clearance of the air passage of the cylinder valve;
FIG. 4 is a schematic diagram of a conventional open valve configuration;
fig. 5 is a schematic diagram of a conventional closed type gas valve structure.
Detailed Description
In order to more clearly illustrate the invention, the invention is further described below in connection with preferred embodiments. It is to be understood by persons skilled in the art that the following detailed description is illustrative and not restrictive, and is not to be taken as limiting the scope of the invention.
It will be understood that when an element is referred to as being "secured to" or "disposed on" another element, it can be directly on the other element or be indirectly on the other element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or be indirectly connected to the other element.
It will be understood that the terms "length," "width," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," and the like, as used herein, refer to an orientation or positional relationship indicated in the drawings that is solely for the purpose of facilitating the description and simplifying the description, and do not indicate or imply that the device or element being referred to must have a particular orientation, be constructed and operated in a particular orientation, and is therefore not to be construed as limiting the invention.
Furthermore, the terms "first", "second" and "first" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of the present invention, "a plurality" means two or more unless specifically defined otherwise.
The invention provides an energy-saving reconstruction method of a 146kg high-pressure 4M32G-186 carbon dioxide compressor based on the prior art, which comprises the following steps:
s1, changing the inner diameter of the first-stage cylinder from 1082mm to 1085-1086mm, the inner diameter of the second-stage cylinder from 622mm to 625-626mm, the inner diameter of the third-stage cylinder from 282mm to 285-286mm, the inner diameter of the fourth-stage cylinder from 300mm to 303-304mm, and the inner diameter of the fifth-stage cylinder from 148mm to 154-156 mm;
s2, the piston is changed from split type to integral type, the step of changing split type to integral type refers to Chinese patent numbers as follows: 201110332306.3, entitled "6M 50 type raw material gas compressor improvement method for increasing gas production amount, saving energy and reducing emission"; because the split type piston is easier to cause the temperature in the cylinder body to rise, the split type piston is transformed into the integral type by the transformation method of the patent, the transformation can not only reduce the internal temperature of the cylinder body, but also prolong the service life of the piston ring and the support ring;
the outer diameter 1073mm of the first-stage piston is changed to 1076-1078mm, the outer diameter 615mm of the second-stage piston is changed to 618-620mm, the outer diameter 276mm of the third-stage piston is changed to 279-280mm, the outer diameter 295mm of the fourth-stage piston is changed to 297-298mm, and the outer diameter 144mm of the fifth-stage piston is changed to 148-150 mm; it can be seen from the data that the variation in the piston outer diameter and cylinder inner diameter are matched;
the weight 477kg of the primary piston is changed into 179-181 kg; it can be understood that the transformation that the weight is slightly lightened can be realized by modifying the primary piston from a split type to an integral type and increasing the annular cavity in the integral piston; meanwhile, the material of the piston used at present is 20#Steel, and also by the existing material 20 of the piston#Steel is replaced with a lightweight material (e.g., aluminum alloy) to reduce weight;
the weight of the secondary piston is changed from 480kg to 159-161 kg; it will be appreciated that it is not sufficient to modify the two-stage piston from split to monobloc only, and since the piston material used in the past is iron castings JT25-47C, it is also necessary to replace the piston material with a lighter material (e.g., aluminum alloy) from iron castings JT 25-47C;
the weight of the three-stage piston is changed to 277kg to 92-94 kg; it will be appreciated that this step of modifying the three-stage piston from split to monolithic is not sufficient, since the piston material used is 35#Steel, therefore, the piston material is required to be 35#Replacement of steel with lighter materials (e.g., hard-oxide treated aluminum metal);
the weight of the four-stage piston is changed into 115kg to 40 kg; it will be appreciated that this step is not sufficient to modify the four-stage piston from a split version to a monolithic version, since the piston material used is 35#Steel, therefore, the piston material is required to be 35#Replacement of steel with lighter materials (e.g., hard-oxide treated aluminum metal);
the weight of the five-stage piston is changed from 79kg to 27-29 kg; it will be appreciated that this step of modifying the five-stage piston from split to monolithic is not sufficient since the piston material used is 35#Steel, therefore, the piston material is required to be 35#Replacement of steel with lighter materials (e.g., hard-oxide treated aluminum metal);
s3, changing the open air valve from the first level to the fifth level into a closed air valve; fig. 4 is a schematic view showing an existing open type gas valve structure, and fig. 5 is a schematic view showing an existing closed type gas valve structure (for example, as disclosed in the chinese patent No. 201110332306.3 entitled "modification method for increasing gas injection amount, saving energy and reducing emission of 6M50 type raw material gas compressor"); and is
The outer diameter 305mm of the first-stage air valve is changed into 319-containing 321mm, the outer diameter 235mm of the second-stage air valve is changed into 264-containing 266mm, the outer diameter 235mm of the third-stage air valve is changed into 264-containing 266mm, the outer diameter 235mm of the fourth-stage air valve is changed into 254-containing 256mm, and the outer diameter 205mm of the fifth-stage valve plate is changed into 224-containing 226 mm; the improvement of the outer diameter of the air valve is matched with the improvement of the cylinder body, and the fact that the outer diameter of the air valve and the inner diameter of the cylinder body are not in direct size relationship is noticed because the air valve is arranged on the side wall of the cylinder body;
s4, changing the outer diameter of the first-stage valve plate to 291-; the outer diameter of the valve plate is improved to be matched with the outer diameter of the air valve;
s5, changing the clearance of the air passage of the 1-3 level cylinder air valve from 30mm to 14-16 mm;
the clearance of the air passage of the air valve of the 4-5-grade cylinder body is changed from 48mm to 34-36 mm.
In the invention, the 'clearance of the air passage of the cylinder air valve' means that: the gap 200 is formed between the edge 1011 of the inner diameter of the cylinder body and the bottom 1021 of the air valve, and for convenience of understanding, the gap data is the shortest distance between the edge 1011 of the inner diameter of the cylinder body and the bottom 1021 of the air valve; that is, for example, 48mm of clearance of the air passage of the cylinder air valve means that the shortest distance between the top point of the inner diameter edge 1011 of the cylinder and the bottom 1021 of the air valve is 48mm, as shown in fig. 2 and 3.
Generally speaking, with the increase of the transformation of the inner diameter of the cylinder body, the outer diameter of the piston is correspondingly increased, the load of the whole compressor is increased, and the increased air-pumping quantity is obtained along with the increase of the load and has no great economic value. However, the improvement of the cylinder inner diameter of the invention is increased, the piston is correspondingly enlarged, and the existing load 2600kw running power can still be maintained by the following reasons: first, the total weight of the 5-stage piston in the present invention is reduced from 1428kg to about 500kg, and the load of the compressor is reduced by a portion as the weight of the piston is reduced; secondly, changing the clearance of the air passage of the 1-3-stage cylinder air valve from 30mm to 14-16 mm; the clearance of the air passage of the 4-5-stage cylinder air valve is changed from 48mm to 34-36mm, so that dead air formed by the existence of the clearance of the air passage of the cylinder air valve in the air passage of the cylinder air valve is changed into live air or free air. That is to say, through practical observation, it is found that gas in the clearance of the air passage of the cylinder air valve is difficult to enter the cylinder body and then enter the cylinder body to be compressed to form product gas, the gas in the clearance of the air passage of the cylinder air valve is dead gas, and each cylinder body has 10 air valves, so that the dead gas in the clearance of the air passage of the cylinder air valve is not a small number, and partial dead gas can be changed into live gas through the transformation of the clearance of the air passage of the cylinder air valve, so that the productivity is improved. In conclusion, by the means, the invention can increase the air-inflating quantity by more than 30% under the condition of maintaining the prior operating power 2600kw unchanged (without increasing energy consumption), and breaks through the original design requirement of the compressor, thereby increasing the yield by more than 30% for the compressor using enterprises, saving a large amount of energy and having great economic benefit.
As an embodiment, in step S1, the change of the inner diameter of the primary cylinder from 1082mm to 1085-1086mm is performed by concentric modification through a traveling finish.
As an embodiment, in step S1, the change of the inner diameter of the secondary cylinder from 622mm to 625-626mm is realized by concentric transformation through traveling finish grinding.
As an example, in step S1, the change of the inner diameter of the tertiary cylinder from 282mm to 285-.
As an example, in the step S1, the change of the inner diameter of the four-stage cylinder from 300mm to 303-304mm is realized by refining modification with a grinding mill.
As an example, in step S1, the change of the inner diameter of the five-stage cylinder from 148mm to 154-156mm is realized by fine grinding modification.
As one example, in step S2, changing the primary piston weight 477kg to 179-181kg is accomplished by changing the existing material 20 to#The steel is replaced by aluminum alloy L108 subjected to 500-degree hard oxidation treatment, and the piston is changed from a split type to an integral type.
As known to those skilled in the art, the "hard oxidation treatment" is an electrochemical treatment method, and forms a hard oxide film with extreme hardness, high temperature resistance, wear resistance, high electrical resistance and corrosion resistance on the surface of pure aluminum or aluminum alloy material. This technology has been widely used in various industrial and military applications, and is part of the prior art.
As an example, the secondary piston weight of 480kg is changed to 159-161kg in step S2 by replacing the existing raw iron castings JT25-47C with 500 degrees hard-oxidized aluminum alloy L108 and changing the piston from split type to integral type.
As an example, in step S2, changing the weight of the tertiary piston 277kg to 92-94kg is performed by changing the existing stock 35#The steel is replaced by aluminum metal subjected to 800-degree hard oxidation treatment, and the piston is integrally changed from a split type.
As an example, in step S2, the change of the weight of the four-stage piston from 115kg to 38 kg to 40kg is made by changing the existing raw material 35#The steel is replaced by aluminum metal subjected to 800-degree hard oxidation treatment, and the piston is integrally changed from a split type.
As an example, in step S2, the change of the weight 79kg of the five-stage piston to 27-29kg is made by changing the existing raw material 35#The steel is replaced by aluminum metal subjected to 800-degree hard oxidation treatment, and the piston is integrally changed from a split type.
As an embodiment, in the step S5, the change of the clearance of the air passage of the 1-3-grade cylinder air valve from 30mm to 14-16mm and the change of the clearance of the air passage of the 4-5-grade cylinder air valve from 48mm to 34-36mm are realized by modifying a boring machine.
Example 1
The high-pressure 4M32G-186 carbon dioxide compressor of a compressor workshop of Tianyuan Shanxi chemical industry Limited company of Jinneng stock control equipment manufacturing group is reformed as follows:
s1, changing the inner diameter of the first-stage cylinder from 1082mm to 1085mm, changing the inner diameter of the second-stage cylinder from 622mm to 625mm, changing the inner diameter of the third-stage cylinder from 282mm to 285mm, changing the inner diameter of the fourth-stage cylinder from 300mm to 303mm, and changing the inner diameter of the fifth-stage cylinder from 148mm to 155 mm;
s2, changing the split type of the piston into the integral type; and is
The outer diameter of a first-stage piston is changed from 1073mm to 1077mm, the outer diameter of a second-stage piston is changed from 615mm to 619mm, the outer diameter of a third-stage piston is changed from 276mm to 279mm, the outer diameter of a fourth-stage piston is changed from 295mm to 297mm, and the outer diameter of a fifth-stage piston is changed from 144mm to 149 mm;
the weight of a primary piston is changed into 477kg, the weight of a secondary piston is changed into 160kg, the weight of a tertiary piston is changed into 93kg, the weight of a quaternary piston is changed into 115kg, and the weight of a quinary piston is changed into 28 kg;
s3, changing the open air valve from the first level to the fifth level into a closed air valve; and is
Changing 305mm of the external diameter of the first-stage air valve into 320mm, changing 235mm of the external diameter of the second-stage air valve into 265mm, changing 235mm of the external diameter of the third-stage air valve into 265mm, changing 235mm of the external diameter of the fourth-stage air valve into 255mm, and changing 230mm of the external diameter of the fifth-stage air valve into 250 mm;
s4, changing the outer diameter of the first-stage valve plate to 292mm, the outer diameter of the second-stage valve plate to 210mm to 235mm, the outer diameter of the third-stage valve plate to 230mm, the outer diameter of the fourth-stage valve plate to 230mm, and the outer diameter of the fifth-stage valve plate to 225 mm;
s5, changing the clearance of the air passage of the 1-3 level cylinder air valve from 30mm to 15 mm;
the clearance of the air passage of the air valve of the 4-5-grade cylinder body is changed from 48mm to 35 mm.
In step S1, the change of the inner diameter of the primary cylinder body from 1082mm to 1085mm is realized by performing concentric transformation through fine grinding of a travelling crane;
in step S1, the inner diameter of the secondary cylinder is changed from 622mm to 625mm by concentric transformation through fine grinding of a travelling crane;
in step S1, the inner diameter of the three-stage cylinder body is changed from 282mm to 285mm by carrying out concentric transformation through fine grinding of a travelling crane;
in step S1, the change of the inner diameter of the four-stage cylinder from 300mm to 303mm is realized by fine grinding modification by a line mill;
in step S1, the change of the inner diameter of the five-stage cylinder from 148mm to 155mm is realized directly through the replacement of a cylinder sleeve in the cylinder body;
in step S2, changing the primary piston weight 477kg to 180kg is accomplished by changing the existing charge 20 to a new charge#The steel is replaced by aluminum alloy L108 subjected to hard oxidation treatment at 500 ℃, and the split type of the piston is changed into the integral type;
in step S2, the change of the weight of the secondary piston from 480kg to 160kg is realized by replacing the existing raw iron casting JT25-47C with aluminum alloy L108 subjected to 500-degree hard oxidation treatment and changing the piston from split type to integral type.
In step S2, changing the weight of the tertiary piston to 277kg to 93kg is performed by changing the existing material 35 to#The steel is replaced by aluminum metal subjected to 800-degree hard oxidation treatment, and the piston is integrally changed from a split type.
In step S2, the change of the weight of the four-stage piston from 115kg to 39kg is made by changing the existing raw material 35#The steel is replaced by aluminum metal subjected to 800-degree hard oxidation treatment, and the piston is integrally changed from a split type.
In step S2, the weight of the five-stage piston is changed from 79kg to 28kg by changing the existing raw material 35#The steel is replaced by aluminum metal subjected to 800-degree hard oxidation treatment, and the piston is integrally changed from a split type.
In step S5, the change of the clearance of the air passage of the 1-3-level cylinder air valve from 30mm to 15mm and the change of the clearance of the air passage of the 4-5-level cylinder air valve from 48mm to 35mm are realized by modifying a boring machine.
The examination conditions of the 1 improved high-pressure 4M32G-186 carbon dioxide compressor are as follows:
first, analysis from the perspective of increased throughput
1) The operating power of the improved compressor is maintained at 2600 kw;
2) the produced product gas (air pumping amount) is increased by 31 percent;
3) the problem of frequent replacement of the piston ring and the support ring is solved;
4) calculating according to the increase of 31% of the air-inflating quantity after modification, namely:
increase the air pumping quantity per minute by 186m3*0.32＝57.66m3(186 type means an air-blowing amount of 186 m/min3)
The air pumping quantity per hour is increased by 57.66 × 60 ═ 3459.6m3，
Increasing air pumping quantity 3459.6m every day3*24＝83030.4m3，
The gas production amount is increased to 83030.4m every year3*365＝30306096m3。
Secondly, analyzing from the aspects of energy conservation and emission reduction
After transformation, one station can save 7060560 degrees electricity/year (2600 x 0.31 x 24 x 365) under the condition of the same yield;
one compressor is converted into standard coal saving 7060560 x 0.36/1000-2541.80 ton/year;
one compressor reduces carbon dioxide emissions 2541.80 0.269-683.74 tons/year;
one compressor reduced the sulfur dioxide emissions 2541.80 x 0.085-216.05 tons/year.
As will be appreciated by those skilled in the art, the 146kg high pressure 4M32G-186 carbon dioxide compressor is counted nationwide200The machine is left and right, so that if the machine is modified in large batch, huge energy materials can be saved, and the discharge of a large amount of harmful gas can be reduced.
It should be understood that the above-described embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the embodiments of the present invention. Other variations and modifications will be apparent to persons skilled in the art in light of the above description. Not all embodiments are exhaustive. All obvious changes and modifications which are obvious to the technical scheme of the invention are covered by the protection scope of the invention.
Claims (8)
1. The energy-saving modification method of the high-pressure 4M32G-186 carbon dioxide compressor is characterized by comprising the following steps of:
s1, changing the inner diameter of the first-stage cylinder from 1082mm to 1085-1086mm, the inner diameter of the second-stage cylinder from 622mm to 625-626mm, the inner diameter of the third-stage cylinder from 282mm to 285-286mm, the inner diameter of the fourth-stage cylinder from 300mm to 303-304mm, and the inner diameter of the fifth-stage cylinder from 148mm to 154-156 mm;
s2, changing the split type of the piston into the integral type; and is
The outer diameter 1073mm of the first-stage piston is changed to 1076-1078mm, the outer diameter 615mm of the second-stage piston is changed to 618-620mm, the outer diameter 276mm of the third-stage piston is changed to 279-280mm, the outer diameter 295mm of the fourth-stage piston is changed to 297-298mm, and the outer diameter 144mm of the fifth-stage piston is changed to 148-150 mm;
the weight of the primary piston is 477kg changed to 179-181kg, the weight of the secondary piston is 480kg changed to 159-161kg, the weight of the tertiary piston is 277kg changed to 92-94kg, the weight of the quaternary piston is 115kg changed to 38-40kg, and the weight of the quinary piston is 79kg changed to 27-29 kg;
s3, changing the open air valve from the first level to the fifth level into a closed air valve; and is
The outer diameter of the first-stage air valve is changed from 305mm to 319-152 mm, the outer diameter of the second-stage air valve is changed from 235-266 mm, the outer diameter of the third-stage air valve is changed from 264-266mm, the outer diameter of the fourth-stage air valve is changed from 235mm to 254-256mm, and the outer diameter of the fifth-stage air valve is changed from 230mm to 249-251 mm;
s4, changing the outer diameter of the first-stage valve plate to 291-;
s5, changing the clearance of the air passage of the 1-3 level cylinder air valve from 30mm to 14-16 mm;
the clearance of the air passage of the air valve of the 4-5-grade cylinder body is changed from 48mm to 34-36 mm.
2. The energy-saving modification method for the high-pressure 4M32G-186 carbon dioxide compressor as claimed in claim 1, wherein: in step S1, the change of the inner diameter of the primary cylinder from 1082mm to 1085-1086mm is realized by performing concentric transformation through traveling finish grinding;
preferably, in step S1, the change of the inner diameter of the secondary cylinder from 622mm to 625-626mm is realized by concentric modification through traveling fine grinding;
preferably, in step S1, the change of the inner diameter of the tertiary cylinder from 282mm to 285-286mm is realized by fine grinding modification by a grinding mill;
preferably, in the step S1, the change of the inner diameter of the four-stage cylinder from 300mm to 303-304mm is realized by refining modification with a grinding mill;
preferably, in step S1, the change of the inner diameter of the five-stage cylinder from 148mm to 154-156mm is realized by fine grinding modification.
3. The energy-saving modification method for the high-pressure 4M32G-186 carbon dioxide compressor as claimed in claim 1, wherein: in step S2, changing the primary piston weight 477kg to 179-181kg is accomplished by changing the existing material 20#The steel is replaced by aluminum alloy L108 subjected to 500-degree hard oxidation treatment, and the piston is changed from a split type to an integral type.
4. The energy-saving modification method for the high-pressure 4M32G-186 carbon dioxide compressor as claimed in claim 1, wherein: in step S2, the change of the weight of the secondary piston from 480kg to 159-161kg is realized by replacing the existing raw iron castings JT25-47C with aluminum alloy L108 subjected to 500-degree hard oxidation treatment and changing the piston from split type to integral type.
5. The energy-saving modification method for the high-pressure 4M32G-186 carbon dioxide compressor as claimed in claim 1, wherein: in step S2, the change of the weight of the three-stage piston 277kg to 92-94kg is carried out by changing the existing raw material 35#The steel is replaced by aluminum metal subjected to 800-degree hard oxidation treatment, and the piston is integrally changed from a split type.
6. The energy-saving modification method for the high-pressure 4M32G-186 carbon dioxide compressor as claimed in claim 1, wherein: in step S2, the four-stage piston is weightedThe amount of 115kg is changed to 38-40kg by changing the existing raw material 35#The steel is replaced by aluminum metal subjected to 800-degree hard oxidation treatment, and the piston is integrally changed from a split type.
7. The energy-saving modification method for the high-pressure 4M32G-186 carbon dioxide compressor as claimed in claim 1, wherein: in step S2, the weight 79kg of the five-stage piston is changed into 27-29kg by changing the existing raw material 35#The steel is replaced by aluminum metal subjected to 800-degree hard oxidation treatment, and the piston is integrally changed from a split type.
8. The energy-saving modification method for the high-pressure 4M32G-186 carbon dioxide compressor as claimed in claim 1, wherein: in the step S5, the change of the clearance of the air passage of the 1-3-level cylinder air valve from 30mm to 14-16mm and the change of the clearance of the air passage of the 4-5-level cylinder air valve from 48mm to 34-36mm are realized by modifying a boring machine.
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