By setting machine filter cleaning system of self-application, to protect the filter clean to avoid blocking network phenomenon, reduce the setting machine fire safety hazards, improve productivity, ensure the quality stability; reducing the height of the drying room, canceled All of the pull-type filter oven openings are used to reduce energy consumption to a greater extent; at the same time, the workload of the operator is reduced due to the automatic cleaning function. Therefore, the application of the technology of printing and dyeing companies to reduce fire hazards, improve product stability, reduce energy consumption, improve the degree of automation has played a positive role.
- Yuanxin Industrial Co., Ltd. Ding Bojun Bai Yuxuan
The shaping machine is an important equipment in the printing and dyeing process, and it is also the main cause of frequent fires in printing and dyeing enterprises. The energy consumption of the shaping process accounts for about 40% of the energy consumption of the entire printing and dyeing process. Therefore, improving the safety performance of the shaping machine and reducing the energy consumption for enterprise safety production and energy conservation is important.
It is often specified that the machine has high energy consumption and low safety factor.
Shape is the last step in the printing process, which greatly affects and determines the quality and performance of the product.
The shaping process of textile printing and dyeing is done in the drying room. The wet fabric will continue to pass through the drying room at a certain speed. The hot air provided by the heat source will enter the upper and lower air ducts with a certain flow rate after being adjusted by the air volume distribution mechanism under the action of a high-power blower set on the side of the drying room. The hot air nozzle is evenly distributed on the surface of the upper and lower air ducts adjacent to the fabric, and the hot air blown by the air blower forms a certain wind speed in the air passage through the hot air nozzle, and acts on the entire width of the wet fabric in both directions to realize ironing of the fabric. The hot and humid exhaust gas after ironing enters the exhaust heat exchanger through the air extractor, and is discharged after exchanging heat with the air at normal temperature.
Generally speaking, each setting machine is made up of eight or nine ovens. The length of a single drying room is 3m~4m, the width is 4m~5m, the volume is nearly 40m3, and the whole set is shaped. The equipment is bulky, and the number of power sources and heat sources is large, which makes the energy consumption of the shaping section account for more than 1/3 of the total energy consumption of the printing and dyeing production process, and the exhaust gas emissions account for more than 1/2 of the total discharge of printing and dyeing exhaust. For example, a medium-sized printing and dyeing enterprise with 10 setting machines has an annual electricity consumption of 20 million kWh in the fixed-section section. The same-scale enterprises in developed countries in Europe have adopted the advanced shaping equipment and control technology. The power consumption is only about 62% of China's, and the energy consumption is huge.
The special workflow of the setting machine also greatly increases the "hazard" of its use. Judging from the data currently available to the author, the shaper is very prone to fire, and even some business owners believe that the shaper does not catch fire. For example, in 2012, there were 158 fixed-machine fires in Shaoxing County, which seriously affected the safety of life and property.
Analysis shows that the shape machine is prone to fire, mainly caused by three aspects. First, the shaping machine uses heat transfer oil and electric heating as the heat source, and the heat conduction oil leakage and the electric heating temperature control device failure are easy to cause fire. Second, the fabric is heated by the shaping machine oven to produce organic oil and the fly ash and fiber particles generated on the surface of the fabric to form oil stains, which accumulate for a long time and easily cause fire in the oven. Third, due to some chemical fiber fabrics, static electricity is generated by mechanical friction, and the voltage can be as high as tens of thousands of volts, which easily causes static sparks, which may cause fire.
Therefore, how to prevent the fire of the shaping machine has become a key topic of concern for printing and dyeing enterprises. The production experience concludes that the heat transfer oil pipeline and temperature control device in the oven of the shaping machine should be inspected regularly, and qualified institutions should be hired to inspect the pipeline. If there is oil leakage, it should be disposed of in time; remove the oil pollution in the machine and the exhaust pipe in time. This measure is especially important for the elimination of fire hazards. In addition, the shaping machine should be technically modified in time, and a steam pipe should be added to the exhaust pipe to open the steam fire in the event of a fire; a wire mesh shield is installed on the heat sink to prevent the flying flower from falling on the heat sink to cause combustion.
Four measures to reduce the energy consumption of the shaping machine
At present, the main energy-saving methods of the shaping machine include direct gas combustion and heat supply, heat transfer oil heating to hot steam heating, new compact energy-saving shaping machine, waste heat recovery and so on.
Direct gas combustion heating is to install a direct combustion heating system in the oven of the shaping machine, so that the air is directly heated by the burner for burning natural gas, and the hot gas can be circulated in the hot oven to reach the required temperature, which can reduce the energy consumption. For example, after Changzhou Xurong Knitting Printing and Dyeing Co., Ltd. heat-conducting oil heating to direct-fired heating, the statistical analysis of single-consumption data in one year of operation compared with the un-reconstructed unit consumption, the shaping machine can save 18% of natural gas on average. .
The heat transfer oil is heated to heat steam. The heat transfer oil heating method of the shaping machine requires each company to set up a heat transfer oil boiler, but because the equipment is relatively simple, it is welcomed by enterprises. The disadvantage of this method is that the coal-fired heat-conducting oil boiler has low thermal efficiency, and it is difficult to remove dust and desulfurization, and the enterprise often does not do well and has great environmental pollution. The steam in the hot steam heating mode can be directly supplied from the thermal power plant by means of central heating, and the heat efficiency is high. The exhaust of used steam can be carried out through centralized remediation, which is easy to control pollution, and is a better way to save energy and reduce emissions. However, due to the need to lay a higher pressure steam pipe, the heat exchanger in the shaping machine also needs to be replaced, so the general enterprise is not very active in this technical transformation.
At present, there is a new type of compact energy-saving shaping machine on the international market. The hot air circulation is installed by the traditional left and right sides of the fan, and the fan is installed at the same time. In the form of upper and lower fans, the return air distance is short, the heat source is fully utilized, and the heat energy is wasted less. The volume of the new shaping machine is only 1/3 of that of the traditional shaping machine. The reduction of the volume reduces the heat dissipation area of ​​the body, and the internal energy of the oven is fully utilized. If the setting machine is not in direct contact with the ground, it can also save a lot of energy.
The exhaust gas emitted by the shaping machine accounts for 61% of the total heat energy, the exhaust gas discharge temperature of the processed chemical fiber product is 160 ° C ~ 170 ° C, and the exhaust gas discharge temperature of the processed cotton product is 100 ° C ~ 110 ° C, which saves a huge energy waste. The waste heat recovery heat exchanger is welded with an aluminum tube or a copper tube, and the high-temperature exhaust gas passes through the passage outside the heat exchange tube, and the fresh air passes through the passage in the heat exchange tube, and the two channels are completely isolated. The fresh air is sucked into the heat exchanger by the fan for heat exchange, and can be heated to a temperature difference of about 30 ° C ~ 40 ° C with the high temperature exhaust gas. Centralized waste heat recovery, the temperature of the heated fresh air is relatively high, but the airflow is relatively large, and the direct reuse will affect the internal airflow of the shaping machine. The barrel dryer can be used to fully utilize the heat energy of the exhaust gas. In addition, waste heat recovery can reduce the exhaust gas discharged from the shaping machine to 60 ° C ~ 70 ° C, to facilitate the purification of the exhaust gas.
Filter self-cleaning system to achieve its own structure optimization
In the process of drying and shaping the fabric, the staple fiber and the dust on the surface of the fabric are separated from the fabric by the action of hot air. The short fibers and dust collect in the air inside the oven and accumulate on the filter net above the radiator. Now all the setting machines use pull-out or built-in filter nets. According to the amount of dust generated by different fabrics, the operator can clean the pull-type filter without stopping the machine regularly; built-in filter It must be cleaned up under downtime.
There are three disadvantages in the structure of the above two types of filters and the way to clean the dust. First, the pull-type filter has openings in each oven, and there is heat loss in the working and cleaning state. At the same time, due to the poor sealing effect at the opening, the temperature difference will also occur, resulting in dripping. Second, the pull-out filter requires the operator to clean it regularly; the built-in filter must be shut down and cooled to clean it. During this period, the amount of dust in the filter screen is reduced from large to small due to less dust on the filter screen, which affects the inconsistent product quality under the same process conditions. Third, when the pull-type filter is cleaned, it needs to be pulled out of the oven one by one (some dust will fall on the radiator during the cleaning), and the dust under the cleaning needs to be cleaned again, the workload is large, and the cleaning cycle is long. . The built-in filter must be shut down and cooled to clean the dust. If it encounters changing batches, changing colors, dusty dust, etc., stop → cool down → clean up → warm up → start up, the difficulty of cleaning and the workload is large, and the heat is wasted too Large, low production efficiency.
The newly developed filter belt of the self-cleaning system of the setting machine is passed under the cloth in the oven, and the two sides of the cloth are fixed on the dial of the stenter guide rail, when the cloth enters the tenter setting machine. After the oven, the hot air in the oven blows the fabric through the tuyere, so that the dust on the fabric falls onto the filter guide.
The filter guide belt is rotated by the driving belt of the guide belt to take the dust out of the oven, and the belt with the dust needs to be vacuumed first, and the way of vacuuming is to pass the air through the blower in the blowing pipe. The air is blown from the mouthpiece to the filter guide belt, and the dust on the filter guide belt is blown into the dust suction tank, and then sucked into the dust box from the lower portion of the dust suction tank, and filtered into the dust box, so that The vacuum treatment is completed. At the same time, the filter belt can be cleaned by water, and the water spray pipe sprays water onto the water washing roller, and the dust on the filter belt is flushed into the water tank.
The correcting device detects the position signal of one side of the filter belt through the photoelectric probe, and sends the signal to the control cabinet of the tenter setting machine. The control cabinet of the stenter determines the movement of the correcting cylinder according to the position signal, and corrects the movement of the cylinder, and corrects The roller can be rotated a certain angle to ensure that the filter guide belt is always in the proper position on the correcting roller without the filter belt offset.
Automatic cleaning device reduces workload
The filter self-cleaning system replaces the traditional pull-type filter network, and the automatic cleaning device is designed in the system to avoid the cleaning effect caused by the dirt of the mesh belt. The running speed, cleaning cycle and cleaning time of the rotary mesh belt can be arbitrarily set in the operation interface. It can effectively ensure the cleaning of the filter net, completely avoid the problem of blocking the net and reduce the fire hazard. The system eliminates the opening of all the suction filter ovens, and the oven height is reduced by 15 cm to minimize heat loss. The system automatically designs the dust collection device, which greatly reduces the workload of the operators.
A company in Zhejiang has installed a filter self-cleaning system and a fixed-type machine without the system. The specific data is as follows:
According to the comparison of the above table, the output of A setting machine is 984.32kg/h, the output of B setting machine is 835.42kg/h, the output of A machine is 17.8% higher than the output of B machine; the power consumption of A setting machine is 83.19 degrees/h. The power consumption of the B setting machine is 106.46 degrees/h, and the power consumption of the A machine is 22% lower than that of the B machine.
In general, the application of the self-cleaning system of the shaping machine filter can ensure the cleaning of the filter net, avoid the phenomenon of blocking the net, reduce the safety hazard of the setting machine, improve the output, ensure the quality stability, and reduce the drying room. The height eliminates the opening of all the suction filter ovens, which can reduce the energy consumption to a greater extent. At the same time, the automatic cleaning function is adopted, which reduces the workload of the operators. Therefore, the application of this technology has played a positive role in printing and dyeing enterprises to reduce fire hazards, improve product stability, reduce energy consumption, and improve automation.
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