卷烟厂空调系统负荷特性及新型中央空调系统研究
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摘要
我国烟草行业规模大,产量高,在我国国民经济中占有重要的地位。烟草企业能源消耗高,而针对卷烟行业的节能研究还较少,行业节能减排的潜力和空间很大。在卷烟厂全年能耗中,空调系统能耗占全厂能耗的30%-50%,是卷烟厂能耗的主要部分,也是卷烟企业开展节能的重点对象。本文通过现场测试和模拟计算的方法,研究了现有空调系统存在的问题及其主要原因,并据此提出了一套新型的空调系统形式,该系统形式可有效地避免现有空调系统的不足。本文的主要贡献及结论有：
首先,通过对全国多个卷烟厂进行调研实测,明确了卷烟厂各环节的能耗现状及空调负荷特点,建立了卷烟厂的负荷计算模型,并进行了验证和修正；利用负荷计算模型,计算了全国5个代表城市的全年热湿负荷并总结出其特性；对多个卷烟厂空调系统的调研及模拟计算结果表明,现有空调系统能耗高的主要原因有冷热抵消、高质低用、冷机部分负荷率效率低、风机水泵选型大导致运行中出现“大风量、小焓差”及“大流量、小温差”、回风长距离输送带来的风机高能耗等。提高冷冻水的供水温度可实现一定的节能,但由于末端空调箱的冷源均来自于冷机,冷机的出水温度必须满足末端最低水温的需求,从而限制了冷机能效比的提高；在过渡季和冬季利用冷却塔实现免费供冷时,由于卷烟厂大多数生产车间要求全年恒温恒湿,而冷却塔的出水温度受室外气象参数影响大,从而不能保证免费供冷的连续性,一定程度上限制了其在卷烟厂的应用。
其次,为进一步了解卷烟厂的全年热湿负荷特性,本文提出了一种新的显热-潜热全年热湿负荷分析方法。把建筑的潜热负荷和对应的显热负荷分别按照横、纵坐标值描述在一张坐标图上,规定显热、潜热负荷为正时表示需要除显热、除湿,反之为加热、加湿。该负荷表达方法可方便直观地展示全年负荷的热和湿,为空气处理设备的设计和选型提供依据；同时根据全年负荷在四个热湿区的分布可明确空调全年的任务；利用显热-潜热负荷分析法对卷烟厂车间负荷进行分析,提出了适用于不同车间的全年热湿处理流程。
而后,提出了适用于卷烟厂的总线式中央空调系统及设备：1)取消冷冻水的集中制备,采用分散式的冷热源末端,根据各车间的需求进行设备的配置,实现灵活调节；2)利用水环输送接近于环境温度的低品位循环水作为末端的热源或热汇,实现对建筑的热回收,减少高品位冷/热源的输配损失；3)利用热管/蒸气压缩复合空调机组提高设备效率,实现自然冷源和高品位热源的高效利用。
最后,对总线式中央空调系统在不同地区卷烟厂应用的能耗进行了模拟计算,分析了其相对于全空气系统的节能性。结果显示,总线式中央空调系统具有很好的节能性。根据我国卷烟生产的分布,认为总线式中央空调系统在我国卷烟厂具有很好的应用前景。
Tobacco industry is an important sector of national economy in China because of its scale and output. The energy consumption in tobacco factory is huge and there is great potential of energy saving in tobacco enterprises because less attention has been paid in this area. Air conditioning system contributes30%-50%of the annual total energy consumption in cigarette factory, so more and more attention should be paid to finding ways of conserving energy in the system. The purpose of the dissertation is to find the main reasons which contribute to the unreasonable energy consumption by field test and simulation, and to propose a novel air conditioning system which can eliminate the disadvantages of existing air conditioning system. The main contributions and conclusions of the dissertation are as follows:
Firstly, the energy consumption of different sectors and cooling/heating load was investigated in several cigarette factories. A calculation model for cooling/heating load was built and verified by the test results. The annual cooling/heating load in five typical cities was calculated by this model and the features were summarized. After analyzing the test and simulation results, the main reasons that contribute to high energy consumption of existing air conditioning system were summarized as follows:(1) unnecessary cooling offset by reheating;(2) low efficiency of high grade energy;(3) low energy efficiency of chillers under partial cooling load;(4) much higher capacity of fans and pumps than the needed causing "large air volume, small enthalpy difference " and "large water flow rate, small temperature difference";(5) high energy consumption of fans caused by long distance distribution of return air. Energy can be saved by increasing the temperature of supplied chilled water to some extent, but the efficiency improvement of the chiller is restricted to the requirement of the terminal which needs the lowest temperature of chilled water. The application of free-cooling by cooling tower can also save energy in cool season, but the fluctuated temperature of cooling water from the cooling tower limits the energy saving ratio because of the constant temperature and humidity required in the whole year in most workshops of cigarette factory.
Secondly, a new method of analyzing annual sensible and latent load was proposed to learn the load features in cigarette factory thoroughly. In this method, the hourly sensible load and latent load are taken as ordinate scale and horizontal axis separately. The positive sensible and latent load is defined as cooling and dehumidification, and the negative as heating and humidification. The distribution of hourly sensible load and latent load figures out the tasks of the air conditioning system in the whole year and helps people to design and select the air handling equipment conveniently. The proper annual air handling processes applied in different workshops can be obtained after the annual load of cigarette factory is analyzed by this sensible-latent load method.
Thirdly, a novel central air conditioning system based on energy-bus and integrated refrigeration system with thermosyphon function for cigarette factory is proposed. This system takes water loop as the energy distribution bus and the terminals are direct-expansion water cooling/heating AHUs with thermosyphon. The main advantages of the novel system is as follows:(1) no chilled water and decentralized terminals make the system be designed and adjusted flexibly according to the requirements of different workshops instead of centralized production of chilled water;(2) the water temperature in water loop is closer to the ambient than that of chilled water and high temperature heat source so that the heat rejected in building can be recovered easily and the cooling/heating loss during the distribution process can be reduced;(3) the direct-expansion water cooling/heating equipments with thermosyphon can effectively utilize the low grade natural source and high grade heat source.
Finally, the energy consumption of the new system applied in different cities was simulated and the energy saving rate compared to all-air system was analyzed. It is shown that the new system has great potential in energy saving. According to the distribution of the cigarette production, the new central air conditioning system has great application prospect in cigarette factory in China.
首先,通过对全国多个卷烟厂进行调研实测,明确了卷烟厂各环节的能耗现状及空调负荷特点,建立了卷烟厂的负荷计算模型,并进行了验证和修正；利用负荷计算模型,计算了全国5个代表城市的全年热湿负荷并总结出其特性；对多个卷烟厂空调系统的调研及模拟计算结果表明,现有空调系统能耗高的主要原因有冷热抵消、高质低用、冷机部分负荷率效率低、风机水泵选型大导致运行中出现“大风量、小焓差”及“大流量、小温差”、回风长距离输送带来的风机高能耗等。提高冷冻水的供水温度可实现一定的节能,但由于末端空调箱的冷源均来自于冷机,冷机的出水温度必须满足末端最低水温的需求,从而限制了冷机能效比的提高；在过渡季和冬季利用冷却塔实现免费供冷时,由于卷烟厂大多数生产车间要求全年恒温恒湿,而冷却塔的出水温度受室外气象参数影响大,从而不能保证免费供冷的连续性,一定程度上限制了其在卷烟厂的应用。
其次,为进一步了解卷烟厂的全年热湿负荷特性,本文提出了一种新的显热-潜热全年热湿负荷分析方法。把建筑的潜热负荷和对应的显热负荷分别按照横、纵坐标值描述在一张坐标图上,规定显热、潜热负荷为正时表示需要除显热、除湿,反之为加热、加湿。该负荷表达方法可方便直观地展示全年负荷的热和湿,为空气处理设备的设计和选型提供依据；同时根据全年负荷在四个热湿区的分布可明确空调全年的任务；利用显热-潜热负荷分析法对卷烟厂车间负荷进行分析,提出了适用于不同车间的全年热湿处理流程。
而后,提出了适用于卷烟厂的总线式中央空调系统及设备：1)取消冷冻水的集中制备,采用分散式的冷热源末端,根据各车间的需求进行设备的配置,实现灵活调节；2)利用水环输送接近于环境温度的低品位循环水作为末端的热源或热汇,实现对建筑的热回收,减少高品位冷/热源的输配损失；3)利用热管/蒸气压缩复合空调机组提高设备效率,实现自然冷源和高品位热源的高效利用。
最后,对总线式中央空调系统在不同地区卷烟厂应用的能耗进行了模拟计算,分析了其相对于全空气系统的节能性。结果显示,总线式中央空调系统具有很好的节能性。根据我国卷烟生产的分布,认为总线式中央空调系统在我国卷烟厂具有很好的应用前景。
Tobacco industry is an important sector of national economy in China because of its scale and output. The energy consumption in tobacco factory is huge and there is great potential of energy saving in tobacco enterprises because less attention has been paid in this area. Air conditioning system contributes30%-50%of the annual total energy consumption in cigarette factory, so more and more attention should be paid to finding ways of conserving energy in the system. The purpose of the dissertation is to find the main reasons which contribute to the unreasonable energy consumption by field test and simulation, and to propose a novel air conditioning system which can eliminate the disadvantages of existing air conditioning system. The main contributions and conclusions of the dissertation are as follows:
Firstly, the energy consumption of different sectors and cooling/heating load was investigated in several cigarette factories. A calculation model for cooling/heating load was built and verified by the test results. The annual cooling/heating load in five typical cities was calculated by this model and the features were summarized. After analyzing the test and simulation results, the main reasons that contribute to high energy consumption of existing air conditioning system were summarized as follows:(1) unnecessary cooling offset by reheating;(2) low efficiency of high grade energy;(3) low energy efficiency of chillers under partial cooling load;(4) much higher capacity of fans and pumps than the needed causing "large air volume, small enthalpy difference " and "large water flow rate, small temperature difference";(5) high energy consumption of fans caused by long distance distribution of return air. Energy can be saved by increasing the temperature of supplied chilled water to some extent, but the efficiency improvement of the chiller is restricted to the requirement of the terminal which needs the lowest temperature of chilled water. The application of free-cooling by cooling tower can also save energy in cool season, but the fluctuated temperature of cooling water from the cooling tower limits the energy saving ratio because of the constant temperature and humidity required in the whole year in most workshops of cigarette factory.
Secondly, a new method of analyzing annual sensible and latent load was proposed to learn the load features in cigarette factory thoroughly. In this method, the hourly sensible load and latent load are taken as ordinate scale and horizontal axis separately. The positive sensible and latent load is defined as cooling and dehumidification, and the negative as heating and humidification. The distribution of hourly sensible load and latent load figures out the tasks of the air conditioning system in the whole year and helps people to design and select the air handling equipment conveniently. The proper annual air handling processes applied in different workshops can be obtained after the annual load of cigarette factory is analyzed by this sensible-latent load method.
Thirdly, a novel central air conditioning system based on energy-bus and integrated refrigeration system with thermosyphon function for cigarette factory is proposed. This system takes water loop as the energy distribution bus and the terminals are direct-expansion water cooling/heating AHUs with thermosyphon. The main advantages of the novel system is as follows:(1) no chilled water and decentralized terminals make the system be designed and adjusted flexibly according to the requirements of different workshops instead of centralized production of chilled water;(2) the water temperature in water loop is closer to the ambient than that of chilled water and high temperature heat source so that the heat rejected in building can be recovered easily and the cooling/heating loss during the distribution process can be reduced;(3) the direct-expansion water cooling/heating equipments with thermosyphon can effectively utilize the low grade natural source and high grade heat source.
Finally, the energy consumption of the new system applied in different cities was simulated and the energy saving rate compared to all-air system was analyzed. It is shown that the new system has great potential in energy saving. According to the distribution of the cigarette production, the new central air conditioning system has great application prospect in cigarette factory in China.
引文
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