Discussion on improving technology of motor energy efficiency in salt enterprises

According to Article 17 of People's Republic of China (PRC) Energy Conservation Law, the production, import and sale of motors (Y, Y2 series) with the original standard energy efficiency level 3 will be prohibited. Y series motors have been listed in the compulsory elimination catalogue of mechanical and electrical products by CITIC Department. In order to implement the "Motor Energy Efficiency Improvement Plan (2013-2015)" issued by the Ministry of Industry and Information Technology and the General Administration of Quality Supervision, Inspection and Quarantine, accelerate industrial energy conservation and consumption reduction, promote industrial transformation, upgrade and green development, comprehensively improve the motor energy efficiency level of Inner Mongolia Lantai Industrial Co., Ltd. (hereinafter referred to as "the company"), accelerate the elimination of inefficient motors, save energy and reduce consumption, implement energy-saving technical transformation of motor system, select motors to replace inefficient motors, and adopt advanced technology to match motors with traction equipment.

1 concept of energy-saving motor

It mainly includes updating and eliminating inefficient motors and high power consumption equipment, reasonably matching the motor system, improving the motor efficiency, transforming the traditional mechanical mode with advanced power electronic technology transmission mode, and realizing the control of towed devices and equipment manufacturing.

2 energy-saving motor selection

(1) When a new motor is needed in a new project, it needs to be selected;

(2) When the old motor is damaged or the motor needs to be rewound, it needs to be selected;

(3) When the motor needs to be updated when it runs under low load or overload for a long time, it needs to be selected.

3 energy-saving motor effect

Compared with the common motor, the energy-saving motor optimizes the overall design, selects high-quality copper windings and silicon steel sheets, reduces various losses such as winding loss, core loss, wind-friction loss and load stray loss, reduces the loss by 20% ~ 30%, and improves the efficiency by 2% ~ 8%. The payback period of investment is generally 1 ~ 2 years.

4 Relevant policy documents of motor energy efficiency improvement

(1) the Ministry of industry and information technology issued by the national quality supervision, inspection and quarantine bureau on organizing the implementation of motor energy efficiency improvement plan (2013-

Notice of 2015);

(2) GB 18613-2006 Energy Efficiency Limits and Energy Efficiency Grades of Small and Medium-sized Three-phase Asynchronous Motors;

(3) GB 18613-2012 Energy Efficiency Limits and Energy Efficiency Grades of Small and Medium-sized Three-phase Asynchronous Motors;

(4) Other relevant national and industrial technical standards and specifications.

5 Description of energy-saving motor

The energy-saving efficiency of the motor should meet the requirements of Grade 2 energy efficiency and above in GB18613－2012 Energy Efficiency Limits and Energy Efficiency Grades of Small and Medium-sized Three-phase Asynchronous Motors, and it has passed the energy-saving product certification of China Quality Certification Center and obtained the energy-saving product certification certificate of China. Energy-saving motors are mainly improved in the following aspects in the manufacturing process:

(1) Electromagnetic optimization design, which comprehensively optimizes the system, air gap, groove fit and groove shape. Through repeated verification of a large number of prototype tests, the electromagnetic design ensures that the motor performance reaches priority;

(2) The iron core is made of high-quality silicon steel sheet with low iron loss and high permeability, and the electromagnetic wire is made of H-grade polyester imine enameled round copper wire QZY-2/180 with temperature resistance of 180℃, which greatly improves the performance of the motor, reduces the working temperature rise and loss, and thus achieves the purpose of improving the efficiency of the motor;

(3) Improve the bearing system of the motor, optimize the shape and design of the fan and hood, so as to reduce the mechanical loss of the motor;

(4) The new VPI vacuum dipping process is adopted, which strengthens the voltage impulse resistance of the whole coil, reduces the accident rate of inter-turn and inter-phase insulation, and improves the protection level and insulation level by one level less than that of the old motor.

6 implementation plan

(1) the principle of eliminating motor identification:

① Motors explicitly eliminated in the catalogue of the first, second and third batches of high-energy-consuming mechanical and electrical equipment issued by the Ministry of Industry and Information Technology;

② Motors with large room for improvement in efficiency shall work continuously for ≥ 8,000 hours throughout the year, and the load rate of motors below 55kW is 60% or above, and that of motors above 55kW is 90% or above;

③ meet the conditions of elimination and transformation in 2015;

④ High-energy-consumption motor with poor running state, high maintenance cost and lack of spare parts;

⑤ After elimination and transformation, the motor is of great help to the long-term operation of the device.

(2) Under the condition that the center height, base length, series and power of the motor are not changed as much as possible, the YE3 series super motor is preferentially purchased for replacement.

(3) The principle of motor replacement is that it will not affect the long-term stable production of the device: that is, if there is a spare motor, it can be replaced after stopping the equipment; if it can't be replaced during the production process, it can be replaced during the shutdown and maintenance period.

(4) After the scheme is reviewed and approved, immediately organize to complete the technical transformation work in the mode of contract energy management.

(5) Design of motor implementation scheme. Energy-saving motor is suitable for electric drive system with long running time and high load rate. The principle of energy saving is to reduce the internal loss of the motor in the process of electromechanical conversion when the motor is running, improve the operating efficiency and save electric energy by a large margin. Technically, through scientific loss analysis, three-phase "sine" winding, matching and slot size design techniques and fans are adopted. Comprehensive energy-saving technologies such as special technology and high-quality effective materials can reduce the copper (aluminum) consumption, iron consumption, mechanical wind friction and stray loss in the motor, so that the total loss of the motor can be reduced (20% ~ 30%) and the efficiency can be increased by 2% ~ 8%.

7 Energy saving benefit analysis

The energy saving of the motor is due to its higher efficiency, lower loss and larger energy saving space than ordinary motors. The calculation formula of the annual energy saving △E relative to the latter is as follows:

Calculation formula of motor power saving

Description:

(1) The motor runs for 8000h every year, the load rate is 75%, and the electricity price is 0.419 yuan/kWh;

(2) The existing quotation is the price without special requirements. If there are special requirements, the price increase will be 8%.

(3) Identify the eliminated low-voltage motor according to the identification principle of eliminated motor. There are 152 units in No.1 Sodium Plant of the company, with the total replacement power of 2998.6kW; There are 155 units in the second sodium plant of the company, with the total replacement power of 5208．6kW; There are 193 sodium chlorate plants in the company, with a total replacement power of 4795.35kW; There are 147 thermal power plants in the company, with a total replacement power of 3526.74kW; There are 162 isocyanuric acid chloride plants in the company, with a total replacement power of 3362.85kW; There are 65 CPE plants in the company, with a total replacement power of 1379．1kW: There are 12 sets in Lanfeng Company, and the total replacement power is 200kW.

8 payback period of investment

8.1 Adopt contract energy management mode.

Involving the list of replacement motors, the total number of motors to be purchased and replaced is 886, the total power of motors is 21471.24kW, the purchase amount of motor equipment is 4,138,900 yuan, the annual total electricity saving is 2358710.9kW•h, and the annual total electricity saving is 1,012,800 yuan.

8.2 The government promotes and subsidizes energy-saving motor standards.

Energy-saving motor standard

Within the range of 0.55kW≤ rated power ≤22kW, the motor power involved in the project is 5785.24kW×58 yuan/kWh.

= 335,500 yuan; Within the range of 22kW＜ < rated power ≤315kW, the motor power is 15686kW×31 yuan/kWh = 486,300 yuan, and the total state subsidy cost is 821,800 yuan.

8.3 Project Investment and Energy Saving Income (Table 2)

Energy-saving benefit distribution table

8.4 Energy-saving benefit distribution scheme of energy-saving service companies and energy-using units

After the energy-saving benefit sharing period ends (see Table 3), the ownership of this batch of motors belongs to the energy-using units, and the energy-saving benefits generated in the future will be obtained by the energy-using units.

Project investment and energy-saving income

9 Investment estimation

The total investment cost of the project is 4,138,900 yuan, 886 identified low-voltage obsolete motors are eliminated, and the estimated investment cost is 3,067,100 yuan after deducting the government subsidy and the recycling cost of used motors.

10 conclusion

(1) Economic benefits. A total of 886 backward low-voltage motors with a total power of 21471.24kW were eliminated by the company's sodium production branch, involving the list of replacement motors. The annual total electricity cost saved was 1,012,800 yuan, the state subsidy cost was 821,800 yuan, and the waste motor disposal cost was 250,000 yuan. After the implementation of this project, the one-time annual cost savings will be 2,084,600 yuan.

(2) Social benefits. The elimination of backward motors meets the requirements of national energy conservation and emission reduction, which has a good energy-saving effect. At the same time, it also improves the overall equipment level of the company.