The choice of retrofit solution is based on the design of the D2800 fan with 850kW main motor can fully meet the power required by our factory fan from D2500 to D2800. However, because the 850kW motor of our factory was re-maintained by our company's thermal power plant due to multiple starts/releases, the maintenance cost is high and the quality requirements are standard. Considering the need for safe operation of the sinter plant/heart 0 and future development of the sintering process, the motor is also replaced at the same time. After investigation and analysis, the following three kinds of transformation plans were determined (to consider a wind turbine): (1) Overall replacement, consult with relevant manufacturers, redesign and manufacture a D2800 fan, need to invest 600,000 yuan, and the fan The foundation needs to be redesigned for casting and casting, and the construction period should be at least 25d.
(2) The foundation is unchanged, the casing is not changed, the rotor group is improved, the original power is changed to 1050kW motor, the motor base and gear coupling are redesigned, the fan foundation is strengthened, the transformation cost is 300,000 yuan, and the construction period is 15d. (3) Foundation No change, the casing does not change, the motor base and gear coupling are unchanged, the original power is changed to 1050kW motor, the fan foundation is reinforced, the transformation cost is 250,000 yuan, and the construction period is 12d.
According to the actual requirements, combined with the analysis and comparison of the above three schemes, our factory chose the third scheme. In order to ensure the construction period and quality, a research institute of Hunan Zhuzhou and our factory formed a joint design team to use the original D2500-11 rotor. The shaft of the group changes the number of rotor blades of the fan (from 16 pieces to 18 pieces) and the angle. The original power adopts the JRQ1512-41050kW motor made by Shanghai Motor Factory according to the requirements of our factory. The motor base and gear coupling are unchanged.
The transformation effect of our factory began to expand and renovate the No. 1 and No. 2 exhaust fans in January 1999. After the transformation, the starting time of the fan was 4243s, the working current was 87A, the operation was normal now, and the operating data reached the relevant standards. After the transformation, the production capacity has been significantly improved. The equipment operation data before and after the transformation of Unit 1 is as shown.
After the transformation of the equipment operation data before and after the transformation, the fan air volume No. 1 and No. 2 exhaust fans were expanded and rebuilt. The technical and economic indicators of our production have been greatly improved (the technical and economic indicators have been improved with No. 1 and No. 2). The expansion and reconstruction of the exhaust fan will be accompanied by the expansion of the No. 1 and No. 2 sintering machines. The main technical and economic indicators for the production before (1998) and after the transformation (1999) are shown.
Analysis of economic benefits after the transformation of the main technical and economic indicators before and after the transformation. (1) Direct economic benefits and cost-saving transformation benefits: Since the rotor rotor main shaft adopts the previous D2500 rotor main shaft of our factory, the single-item savings will cost 160,000 yuan. .
Increasing production efficiency: The annual output before the expansion of the fan is 1.25 million tons, and the annual output after the expansion of the fan is 1.4 million tons. Calculated according to the internal profit of 10 yuan / t. After deducting the influence of expansion factors of No.1 and No.2 sintering machines, the profit calculated by 50% is: (140-125)@10@50%=75 (ten thousand yuan) Power saving benefit: electricity consumption per ton of sinter mine in our factory For 28kWh, the production of 150,000 tons of sinter will increase the electricity consumption by 28@150,000 = 4.2 million kWh. After the renovation of the wind turbine, the electricity consumption will be 329kWh per year, and the electricity price will be calculated at 0.53 yuan/kWh. After deducting the influence of the expansion and expansion factors of No. 1 and No. 2 sintering machines, the calculation is based on 50%. The annual electricity saving benefit is: (420-329) @0.53@50%=20 (ten thousand yuan) The negative benefit of the expansion and expansion of the wind turbine expansion: the expansion of the wind turbine is only 120,000 kWh than the large and medium repairs.
(2) Indirect economic benefits Each 1st sinter mine produced by the Shungang Iron and Steel Plant means less imported 1t pellets, and the price of imported pellets and sinter is more than 100 yuan per ton. The annual increase of production of 150,000 tons of sinter in the sinter plant, after deducting the influence of the expansion and expansion factors of No. 1 and No. 2 sintering machines, calculated according to 50%, the expansion of the No. 1 and No. 2 exhaust fans will increase the profit of the group by 7.5 million yuan per year. .
After the expansion and expansion of the sintering machine fan, not only the output of the sinter is increased, but also the various indexes of the sinter plant are obviously improved, and the growth of sintering and ironmaking benefits is very significant.
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