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工业循环水泵站的能耗测评及优化运行研究
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摘要
节能降耗是我国经济和社会发展的一项长远战略。近年来各种节能降耗的措施、政策和目标在不断制订和完善,同时政府也相应投入大量资金用于支持节能降耗项目的开展。水泵站作为我国重要的通用机械和耗能设备,涉及多项政策措施和工程项目。因此,水泵及其系统的节能降耗具有重要的意义。
     能耗测试是对水泵及其系统运行做出能耗评价的前提,而水泵机组的优化运行与配置的经济性是实现泵站经济运行的重要方面,现有泵站主要采用阀门调节方式运行、相同型号水泵机组单调速运行或者相同型号水泵全调速方式运行。本文以某氧化铝循环水泵站为工程背景,开展了泵站能耗测评及优化运行与设备经济配置方案的研究,所做的主要工作如下:
     1.对水泵在变工况条件下运行时,水力能耗和机械能耗重积分计算的几何意义进行了详细讨论,提出了基于泵站流量运行规律的水泵运行效率的计算方法,解决了泵本身的效率无法反应系统某段时间内不同工况运行的问题。
     2.针对泵系统运行的节能空间分析预测存在的问题,提出了水泵系统供水能耗率的评价方法,该方法反映了泵系统的供需关系。
     3.根据水泵运行机理,分析了不同调节方法对水泵运行工况的能耗影响,提出了不同情况下水泵实际特性和装置实际特性的在线测试方法,并对某氧化铝循环水泵站中水泵的能耗进行了测试,详细分析了该泵站某天的水力能耗、机械能耗、运行效率和供水能耗率等能耗指标。
     4.针对目前大部分泵站采用相同水泵型号配置和变频器价格昂贵的现状,研究分析了单变频器配置条件下的泵站水泵运行效率低的原因,提出了增加一台小过渡泵来提高运行效率的策略,并建立了基于该配置的优化运行模型,以水泵轴功率最小为目标函数,模型中考虑了开机因子和调速比,约束条件有总流量约束、等扬程约束、高效区约束和最小调速比约束,用MATLAB遗传算法工具进行仿真计算,解决了泵站节能策略的经济性和实时性问题。
Energy-saving is a long-term strategy for China in the economy and society development. In recent years, various measures, policies, and objectives of energy-saving are developed and refined constantly. Meanwhile, the government has also invested a lot of money to support the energy-saving projects. As the main energy consumption equipments in our country, pump is involved in many policies, measures and projects. Therefore, water pump and its system play a significant role in reducing energy consumption.
     The energy consumption test is the prerequisite for energy consumption assessment of the pump and its system operation. While, the important aspect of the pump station economy operation is the optimal scheduling and the configuration of economical efficiency of pump station. At present, the adjustment of the pump station operation is mainly adjusted by valve, adjusted by signal invert with the same type pumps and adjusted by full invert with same type pumps. So, some research on energy consumption test and the optimal scheduling of the pump station based on the engineering background with an aluminum water pump station was carried on in this article. The main work and the achievement are as follows:
     1. The geometric meanings of multiple integral calculation, both hydraulic energy consumption and mechanical energy consumption, are discussed in detail when the pump operates under variable conditions. And a new method calculated operational efficiency of the pump station based on the run rules of the pump flow rate has been established to solve the problem that the efficiency of the pump itself can't reflect different operating condition within a certain period.
     2. Aiming at the issues in predicting the energy-saving space of the pump system operation, a method of evaluating the energy consumption rate of water pump system is proposed, which reflects the relation between the supply and demand.
     3. According to the principles of pump running, energy consumption under different operating modes is analyzed. And then an on-line monitoring method of the actual pump characteristics and pipeline system characteristics is presented. By this method, the pumps of an alumina circulating water pump station are tested and their performances such as hydraulic power, mechanical power and operation efficiency and so on are analyzed.
     4. Aiming at the situations that pumps of the same model are used in most pump stations and the price of frequency converter is too high, the reasons are analyzed for the low efficiency of pump assembly operating under the single frequency converter configuration condition. A strategy of adding a small transitional pump is put forward to increase operation efficiency and a model based on this strategy is constructed with the minimum shaft power being objective function. In this model, the starting factor and speed regulation ratio are taken into consideration and the constraints include the total flow, the equal head, the high efficiency zones and the minimum speed regulation ratio. The model is simulated by the MATLAB genetic algorithm toolbox and it solves the problems of the economy efficiency and real time of energy-saving strategy in the pump station.
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