Detection and improvement of air compressor cooling effect

1 Introduction to air compressor cooling system

The air compressor cooling system generally consists of a cylinder water jacket, an intercooler, an aftercooler, an oil cooler, a water pump, a pipeline, a water spray device, and a cooling pool. The cooling method is divided into two types: circulating water supply cooling and DC water supply cooling. The circulating water supply system is often used during the operation of the air compressor. In the circulating water supply system, the cooling principle of the air compressor is to directly pump the cooling water into the inner wall of the cylinder and the cylinder liner through the water pump, and flow in the gap between the two, and then the cooling water sequentially passes through the intercooler and the cylinder water of each level. The sleeve is finally discharged through the aftercooler to achieve air compressor cooling.

2 measures to improve the cooling effect of air compressor

2.1 Setting the cooling water filter

When the air is compressed and cooled, the moisture in the atmosphere condenses into water. In the process, a small amount of copper concentrate powder is contained in the air. A certain amount of sulfur and sulfide are present in the powder, and at a certain temperature, with water. A chemical reaction takes place to form an acid. The air compressor cooling chamber is made of cast steel, and the iron and iron are formed by acid and iron. As the use time increases, the interior of the intermediate cooling gas chamber is seriously corroded, and the shavings of different sizes are formed. In the intermediate cooling room, the cooling water drain hole is blocked, so that the condensed water cannot be discharged, and then the fins in the intermediate cooler are gradually blocked, resulting in poor cooling effect of the compressed air, causing the temperature between the stages to rise, causing an alarm and causing shutdown. In view of the blockage caused by impurities, the cooling water filter can be designed and installed according to the actual situation on the site, and installed on the cooling water inlet pipe. The appearance of the filter is cylindrical, and a filter device is added. After the water flows, the impurities are prevented from being around the filter screen, and the clean water flows out through the outlet pipe through the filter to improve the cooling effect.

2.2 Control the amount of water ingress

The amount of cooling water directly affects the cooling effect of the air compressor. The circulating water volume of the air compressor should be the sum of the amount of water required for the number of air compressor tables. From the physics point of view, the amount of cooling water in the air compressor is closely related to the pressure of the cooling water entering the unit. Generally, the lower limit water supply pressure entering the unit is not less than 0.12 MPa. The water supply pressure is increased, the water volume entering the unit water cooling system is also increased, and the cooling effect is good. However, the water pressure is too large, water seepage and water leakage will occur at the end of the intercooler end tube plate, which will hinder the normal operation of the unit. The water will enter the secondary cylinder to produce water hammer, and even cause a cylinder damage accident in severe cases. At the same time, if the water pressure is too large, the flow rate will increase and the water consumption will increase, which is also uneconomical. Therefore, before adjusting the water pressure, the consumption of cooling water of each air compressor must be determined. The cooling water consumption of each air compressor can be determined according to the technical performance requirements of the equipment, or calculated by the following formula: Q=60qV p, 1/k type: QD cooling water required per air compressor per hour, 1/ h; V pD air compressor displacement, m 3 /min; qD cooling 1m 3 air demand.

Then according to the amount of cold water, the water pump valve is opened to the maximum, and a liquid level transmitter is installed on the hot water well. The water level value will be transmitted to the frequency converter with standard electrical signals, and one set can be set on the frequency converter according to the process requirements. The water is not drained and adapted to the water level of the liquid level change rate. At this time, the inverter automatically adjusts the motor speed according to the cold water volume and water level to meet the working needs. Then use the gate valve to adjust the inlet water pressure, and use the water pump to directly send the cooling water to the unit water cooling system. The pump head can be calculated according to the water pressure of the inlet unit of 0.2MPa, and the water pressure can be controlled reasonably to improve the cooling effect.

2.3 Reforming the compressor intercooler

After the intercooler is put into operation for a period of time, the inner and outer surfaces of the heat exchanger coil are corroded, the scale is serious, the heat exchange effect is lowered, and the outlet air temperature of the intercooler is increased, causing the compressor exhaust temperature to rise and the cooling difficulty to be increased. Insufficient exhaust and increased power consumption. In order to improve the cooling effect of the intercooler, it can be changed from the original fin tube type to the extruded lamination tube type, and the initial effect of the transformation is obvious, but the cooling effect begins to decrease after a period of time. In view of the above situation, the author believes that the treatment of the standard is not as good as the root cause, can be installed in the intercooler circulating cooling water inlet water descaling instrument or ion bar, can play the role of descaling and anti-scaling. Another measure is to replace the straight tube in the tubular heat exchanger with a new stainless steel bellows. Since the height between the peak and the trough of the stainless steel bellows is about 10 mm, the flow in the tube is divided into an equal-diameter flow pattern and an arc-shaped flow pattern, which causes the flow rate and pressure to periodically change, and the hot and cold fluid flows strongly, causing a strong disturbance. The flow state of the fluid reaches sufficient turbulence, which greatly destroys the actual thickness of the boundary layer and the fouling layer, and thus the heat transfer coefficient of the straight pipe is significantly improved. For the two-stage intercooling compressor with interstage cooling between high and low pressure cylinders, when designing the intercooler, the pressure is cooled to the inhalation state of the low pressure cylinder under constant pressure conditions to reduce the exhaust. Temperature, increase the amount of exhaust, and minimize the sum of the two levels of power consumption. In fact, it is difficult to ensure that the gas is perfectly cooled in the intercooler, that is, the temperature of the cooled gas is still higher than the inhalation temperature, and the volume of the gas is larger than the volume at the time of perfect cooling.

In view of this situation, since the volume of the high pressure cylinder is fixed, the interstage pressure in the intercooler can be increased, the volume of the high pressure cylinder can be reduced, the compression ratio can be redistributed, and the compressed air temperature can be cooled close to the suction state of the low pressure cylinder. Improve the cooling effect.

2.4 Adding water inlet pipes

For a pump with a relatively small inlet pipe, when the diameter is smaller than the outlet pipe, the pipe resistance is large, resulting in a small pump flow, and the efficiency of the pump is very low, which cannot meet the cooling needs of multiple air compressors. The gate valves of the air compressor and the aftercooler are all open, and the water inlet pipe limits the increase of the flow rate and cannot meet the demand. In addition, since the pump outlet only has a check valve and no gate valve adjustment, the amount of water in the hot and cold pool is extremely unbalanced. The cold water tank of our company is too small. The water pump of the cold pool is dried in half an hour, and the air compressor will be short of water. Over temperature and parking. For this reason, in the technical transformation, the two inlet water pipes of the standby pump are used for transformation, and the inlet pipe of the gate valve control, the cold water pump and the hot water pump is changed from one to two, which increases the equivalent pipe diameter and reduces The loss of water absorption resistance increases the flow rate to meet the demand. The hot water pump is also composed of two inlet pipes. The flow rates of the two pumps are almost the same, and the hot and cold water can be balanced to improve the cooling effect.

2.5 Control cylinder water jacket inlet water temperature

The main purpose of air compressor water cooling is to guide the frictional heat between the piston and the cylinder wall. In general, the air always contains a certain amount of water. After the humid air is compressed, the water vapor saturation temperature Ts is correspondingly increased. When the cylinder wall temperature is lower than the saturation temperature, the water vapor in the portion of the gas in contact with the cylinder wall releases the latent heat of vaporization and condenses into water on the surface of the cylinder wall, which deteriorates the lubrication of the cylinder and increases wear. The lower the cylinder wall temperature, the more condensate will be. When these waters cannot be removed in time, the cylinder volume factor is reduced and the displacement is reduced, resulting in a weakening of the cylinder water cooling effect. Therefore, the inlet water temperature of the cylinder water jacket should be determined according to the saturation temperature of the steam in the cylinder, which is generally 3035 °C. In areas with low temperatures and low relative humidity (eg Xi'an), parallel cooling systems are also considered.

2.6 Increasing the heat transfer coefficient of the cylinder wall and the pipe wall is known by heat transfer. The heat transfer coefficient of the cylinder wall and the pipe wall decreases with the increase of the scale thickness, and also causes the cooling effect of the air compressor to decrease. It is inevitable that scale is formed on the surface of the water jacket and the outer wall surface of the cooling pipe. Sodium hexametaphosphate (NaPO 3) 6 is a water-soluble chemical that acts with salt precipitates of calcium and magnesium to form a very stable complex salt of Na 2 like a colloid. The scale inside the cooling system becomes a dissolved double salt and is in a stable state. At the same time, it has the characteristics of stable bicarbonate and can maintain the stable state of supersaturated bicarbonate in aqueous solution. Therefore, the treatment of the cooling water with sodium hexametaphosphate not only prevents the precipitation of carbonates in the cooling water, but also eliminates the formed scale and increases the heat transfer coefficient of the cylinder wall and the tube wall, thereby improving the cooling effect.

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