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1、电能控制十条金规10 Golden Rules for Power MasteryDPC April 200910 Golden Rules Power Mastery - DPC Performance & Investments April 2009210 能耗控制黄金箴言Golden Rules for Power Cost Reduction1)Optimise Ball Mill Power优化球磨机电耗优化球磨机电耗2)Minimise False Air 减少漏风减少漏风3)Manage Equipment Idling设备空转的管理设备空转的管理4)Vertical Mill
2、Power Optimisation立磨优化立磨优化5)Efficient Gas Handling 气体效能掌控气体效能掌控6)Power Monitoring 功率监测功率监测7)Production Management 生产管理生产管理8)Mastering Quality Impact on Power Consumption质量控制质量控制对效率的影响对效率的影响9)Mill Feed Size Control 控制入磨物料粒度控制入磨物料粒度10)Minimise Compressed Air 最小化压缩空气的消耗最小化压缩空气的消耗10 Golden Rules Power M
3、astery - DPC Performance & Investments April 20093RULE 1 :Optimise Ball Mills球磨优化球磨优化How does your mill measure up ?你的工厂如何进行测量？你的工厂如何进行测量？Can you tick all the boxes ?你能对所有方框的问题打对号码吗？你能对所有方框的问题打对号码吗？10 Golden Rules Power Mastery - DPC Performance & Investments April 20094Check instruments & Tune cont
4、rol loops检查仪检查仪表并对控制回路进行调节表并对控制回路进行调节Feed proportions喂料均喂料均匀匀Feed vs elevator kW喂喂料料vs提升机功率提升机功率Airflow control气体流气体流量控制量控制Mill outlet temperature磨机出料口温度控制磨机出料口温度控制Product temperature产产品温度品温度Electrical earMinimise false air减减少漏风少漏风Ball Mill Power Optimisation球磨功率优化球磨功率优化 (1) Operation Actions运行运行Rem
5、ove scrap media去除费介质去除费介质& clinker nibs和熟料和熟料渣块渣块保持磨机喂料的稳定性保持磨机喂料的稳定性Mill feedrate uniformity Separator efficiency 选选粉机功率粉机功率circulating load test循环负循环负荷试验荷试验Fine additions to separator avoid addition to mill向向旋风筒加细添加料旋风筒加细添加料-避免向磨机内加避免向磨机内加Check Feed检查检查喂料喂料Size粒径粒径Moisture湿度湿度Temperature温度温度Grinda
6、bility易磨性易磨性Minimise false air减少减少漏风漏风助磨机优化助磨机优化Grinding aid optimisationFollow elevator power-maintain circulating load跟踪跟踪提升机功率保持循环负荷提升机功率保持循环负荷优化袋收尘优化袋收尘清理功能清理功能Optimise bag filter cleaningOptimise bag filter cleaning优化滤袋提高优化滤袋提高滤袋清洁度滤袋清洁度Measure & maintain separator airflow测控并保持选粉机气体流量测控并保持选粉机气体
7、流量Measure & maintain mill airflow测量并保持磨机风量测量并保持磨机风量避免过粉磨避免过粉磨Avoid overgrinding 代表样品，代表样品，产品细度控制频率、执产品细度控制频率、执行控制卡片行控制卡片representative sample, product fineness control frequency & implement control card减少产品数量和保持减少产品数量和保持相似性相似性Minimise number products & aim to keep similarKPIs关键技术指标关键技术指标Production r
8、ate tph台时产量台时产量Mill drive power and kWh/t weekly磨机磨机驱动功率和驱动功率和kWh/t-每周每周Power Indicator Finish Mill水泥磨功率指水泥磨功率指示器示器 减少漏风减少漏风Minimise false air (heated mill)Set target ball charge level& make regular top ups设定充球量目标并进行定期设定充球量目标并进行定期的检查，使料位和球位在同的检查，使料位和球位在同一个水平面上一个水平面上10 Golden Rules Power Mastery - DP
9、C Performance & Investments April 20095Ball Mill Power Optimisation (2) Inspect and maintain at planned stoppages at least monthly & use opportunity stops球磨机功率优化（2）检查并每月至少进行一次计划停机或者利用停磨的机会进行维修 Check ball filling ratio & top up to target maintain level检查球的填检查球的填充率，物料与级配是否保持在同一充率，物料与级配是否保持在同一个平面上个平面上
10、Maintain average mill kW +/- 30 保持磨机平均功率保持磨机平均功率 Liner condition & wear衬板情况和磨损衬板情况和磨损 Charge condition Diaphragm vent grids隔仓板的通风篦隔仓板的通风篦 Diaphragm slot condition & blockage隔仓板篦缝状况和堵塞情况隔仓板篦缝状况和堵塞情况C1 Step height 40mmC1阶梯高度Height above charge高于级配Worn out liners磨损的衬板Contaminated chargeSlots peened ove
11、r受到敲击的篦缝受到敲击的篦缝Slots blocked篦缝堵塞篦缝堵塞Vent grid area too small通风篦区域太小通风篦区域太小 Check axial grinding profile检查轴向粉磨状况检查轴向粉磨状况 Check liners and balls coating检查衬板和抱球情况检查衬板和抱球情况 Check build up检查堆料检查堆料 Separator build ups & wear especially air seals10 Golden Rules Power Mastery - DPC Performance & Investments
12、 April 20096Ball Mill Power Optimisation (3) Support球磨机功率优化球磨机功率优化Cement Portal Grinding Domain水泥门户网水泥门户网-粉磨类粉磨类Procedures程序How to manage ball charge level如何管理充球量How to optimise a ball charge如何优化级配How to do a mill routine stop inspection如何进行磨机常规停机检查How to do a mill crash stop inspection如何进行磨机急停检查How
13、 to remove scrap from a ball mill circuit如何从球磨系统中去掉废渣How to check airflow through the mill如何检查磨机的分量How to manage liner wear in a ball mill如何进行球磨内的衬板磨损管理How to conduct a ball mill audit如何进行球磨审计Knowledge Documents知识文件Procedure for the audit of ball mill circuits球磨系统审计程序Guide Ball mill optimisation- Po
14、st Sevilla module 5指导-球磨优化-Post Secilla 模块5Vade mecum Grinding粉磨Technical Centre Process Team技术中心粉磨团队技术中心粉磨团队10 Golden Rules Power Mastery - DPC Performance & Investments April 20097RULE 2 :Minimise False Air减少减少漏风漏风Is your plant winning the battle ?你的工厂在这个环节胜利了吗？你的工厂在这个环节胜利了吗？10 Golden Rules Power
15、Mastery - DPC Performance & Investments April 20098Typical Sources of False Air 漏风来源Missing boltsFan Seals风机密封Doors检查孔Doors检查孔Flap Seals翻板阀密封Kiln Inlet Seal窑头密封？Clinker Chute熟料卸料槽Expansion Joints膨胀节Classifier Seal分级机密封Feeding Point喂料点Feeding Point喂料点Doors检查孔Doors检查孔Fan Seals风机密封Poke Holes捅料孔FlangesT
16、ie Rod Seals拉杆密封Kiln Hood Seals窑罩密封Fan Seals风机密封Seals密封Seals密封Casing cracks壳体裂缝Casing wear & corrosion壳体磨损和腐蚀Isolation 隔离阀dampersExpansion Joints膨胀节 Look for gaps / cracks / missing bolts / missing packing etc找出间隙、裂缝、丢失的螺栓、丢掉包装等找出间隙、裂缝、丢失的螺栓、丢掉包装等 Listen for whistling air听是否有呼啸的声音听是否有呼啸的声音 Look for
17、dust blowing out during start up开机时查找漏灰的地方开机时查找漏灰的地方10 Golden Rules Power Mastery - DPC Performance & Investments April 20099Manage False Air漏风的管理漏风的管理Prerequisite前提前提条件条件Teamwork 团队工作团队工作 Process工艺工艺, Maintenance and Production维修和生产维修和生产Actions行动行动Set target false air levels 设定漏风标准设定漏风标准Typical Val
18、ues标准值标准值Preheater 预热器预热器 5%Raw mill生料磨生料磨20 - 40% *Coal mill煤磨煤磨20 - 30% * Cement mills水泥磨水泥磨30 - 50% *Cooler exhaust蓖冷机排风蓖冷机排风 95%可靠性系数可靠性系数Annual incident stops 75%10 Golden Rules Power Mastery - DPC Performance & Investments April 200919Efficient Gas Handling (3) Support气体处理测量（3）-支持Cement Portal
19、水泥门户网How to measure fan efficiency of the main fans如何测定主风机效率How to improve fan efficiency by internal inspection如何通过风机内部的检查提高风机效率Technical Centre Process & Maintenance Teams技术中心、工艺和维修团队Gas handling training气体处理测量培训10 Golden Rules Power Mastery - DPC Performance & Investments April 200920RULE 6 :Powe
20、r monitoring功率检功率检测测You can only control what you can measure!你仅能控制你能测量你仅能控制你能测量到的到的10 Golden Rules Power Mastery - DPC Performance & Investments April 200921Power Monitoring (1) Measurement Requirements功率监测（1）-测量要求Install meters for each shop/area & main motors为每一个系为每一个系统单元和主电机安装计量设备统单元和主电机安装计量设备Me
21、ters linked to PCS & IP21 for best control of power将计将计量设备连接到量设备连接到PCS和和IP21，更好的控制效率，更好的控制效率Know equipment covered by each meter清楚每一个计量器清楚每一个计量器所覆盖范围所覆盖范围Study electrical distribution line diagram学习电器接线图Shops are often inter-mixed due to proximity of sub-stations or addition of equipment系统单元经常采用统一计量
22、导致各子项系统或附属设备能耗无法分开Check meter accuracy as necessary Need portable testing equipment必要时使用便携式测量设备检查计量设备的精确度必要时使用便携式测量设备检查计量设备的精确度Load curve prediction (depending on contract)负载曲线预报（根据约定）？负载曲线预报（根据约定）？10 Golden Rules Power Mastery - DPC Performance & Investments April 200922Power Monitoring (2) Trackin
23、g Consumption功率检查（2）-能耗跟踪Check power consumption regularly (minimum monthly) 规律性的检查功率消耗（每月至少一次）规律性的检查功率消耗（每月至少一次）Breakdown by shop, main equipment, separate auxilary equipment通过系统单元的细分，分离主副机Calculate specific consumption per shop & contribution to clinker & cement准确计算每一个系统单元的消耗，分配到熟料和水泥Analyse trend
24、s of consumption 分析消耗趋势Check shop specific consumption for various conditions检查不同工况下系统单元的准确消耗检查不同工况下系统单元的准确消耗Operation at nominal capacity set baseline consumption额定产量下的运转-设置基准消耗Operation in different modes e.g. compound, direct不同模式下的运转-例如混合粉末和分别粉末Different products 不同产品品种Operation at reduced capaci
25、ty减产时的运转During shop start up and shutdown开机和停机期间Etc.等等Cross check consumption using calculations e.g. for mills, fans, blowers & conveyors, etc.通过计算复核消耗，例如磨机、风机、鼓风机和输送设备通过计算复核消耗，例如磨机、风机、鼓风机和输送设备Reconcile total of consumption for all shops with monthly power bill通过月电耗表来合并？所有系统单元消耗通过月电耗表来合并？所有系统单元消耗10
26、 Golden Rules Power Mastery - DPC Performance & Investments April 200923Power Monitoring (3) Support功率监测（3）-支持Cement Portal 水泥门户网水泥门户网Best practice power tracking功率最佳实践的跟踪Best practice power metering requirements功率最佳实践的要求Technical Centre Process & Maintenance Teams技术中心技术中心 工艺和维修团队工艺和维修团队10 Golden Ru
27、les Power Mastery - DPC Performance & Investments April 200924RULE 7 :Production management生产管理生产管理Schedule your production to take advantage of low price power.用最低的功率成本制定生产用最低的功率成本制定生产计划计划10 Golden Rules Power Mastery - DPC Performance & Investments April 200925Production Management生产管理生产管理Detailed
28、 understanding of power contract clauses.详细理解供电合同条款Monitor electrical load for each shop监控每一个系统单元的电力负荷Track load curve to maximise equipment operation (especially mills) during cheap power periods在供电价格低的期间跟踪大型设备的负载曲线（特别是磨机）Preference to operate more efficient equipment e.g. roller press instead of b
29、all mill优先运行效率高的设备，比如辊压机取代球磨Avoid exceeding maximum demand避免查过最大需量Communicate load shedding schedule to production & maintenance teams for planning ？Record peak and off peak production hours记录峰谷时段开机时间Work closely with the BU energy purchasing manager密切配合能源采供经理10 Golden Rules Power Mastery - DPC Perf
30、ormance & Investments April 200926Production Management - Support Portfolio Management生产管理-支持部长管理Ex of minimum supply for the regulation supplierLoad curve decomposition to define the type of offers that can be interesting : bands, blocks.AdjustmentConsolidation per areaDetailed 2000 load curve per
31、site(ex hourly load curve)Consolidated load curveBuy thatUse thatSell thatCoordinated portfolio management for all plants within a market region10 Golden Rules Power Mastery - DPC Performance & Investments April 200927RULE 8 :Mastering quality impact on power consumption质量控质量控制对功率消耗的影响制对功率消耗的影响Quali
32、ty parameters have a huge impact on power consumption质量指标对功率消耗的巨大影响质量指标对功率消耗的巨大影响10 Golden Rules Power Mastery - DPC Performance & Investments April 200928Rapid clinker cooling Alite急速冷却熟料急速冷却熟料 硅酸三钙硅酸三钙 30mStable burning conditions稳稳定的燃烧环境定的燃烧环境FLUI 60Optimum Raw mix 原料配料优化原料配料优化grindability minimi
33、se quartz content易磨性系易磨性系数数-石英含量石英含量Optimum Raw meal residue 原料细度优化原料细度优化200m 2%90m: target designed to get good burnability为为得到较好的易烧得到较好的易烧性性Oxidising atmosphere空空气中氧含量气中氧含量Clinker Free游游离石灰离石灰Lime 1 -2 %Short burning zone缩短烧成缩短烧成带带Fuel residues 燃料筛余燃料筛余+200m 1% +90 m = 50% VM%KFUI 14Minimise free
34、silica residue 降低游离氧化硅降低游离氧化硅细度细度 at 45m (2.5%)10 Golden Rules Power Mastery - DPC Performance & Investments April 200929Mastering Quality Impact on Power (2)Plan to optimise clinker reactivity 对熟料煅烧的优化Minimise increase of raw grinding power尽量降低生料粉磨电耗Ensure burnability in good range保证易烧性在合理的范围内Maxim
35、ise saving in cement grinding power最大降低水泥粉磨电耗Ensure saturation of alkalis by sulfate控制合理的硫碱比Operate at optimum cement sulfate合理控制水泥三氧化硫含量Challenge exist SO3 level using statistical formula通过统计方法优化现有SO3含量Conduct trials to confirm optimum通过实验确定合理范围Ensure good control of product surface area avoid over
36、-grinding控制合理的水泥比表面积-避免过粉磨Consider to use/optimise grinding aid考虑使用/优化水泥助磨剂Challenge marketing & sales regarding cement strength targets, particularly for requests to increase?Develop and implement action plans - Work in conjunction with TC Raw Mix, Product & Process teams可执行的改进计划-联合技术中心原料配料，产品&工艺团队
37、一起完成此项工作10 Golden Rules Power Mastery - DPC Performance & Investments April 200930Mastering Quality Impact on Power (3) SupportCement Portal 水泥门户网水泥门户网10 Basic Facts on clinker熟料的10个基本原则Raw mix design (Best Practice)原料配料设计（最佳实践）Silica rejects in raw mix impact on quality (Best Practice)不合格的硅土在原料配料中影
38、响品质TYTP Uniformity indicatorsTYTP一致性指标Burning petcoke (Best Practice)燃烧How to start & optimise a burner如何使用 & 优化燃烧器Combustion Manual (Post Sevilla)煅烧手册Sulfating rules (Best Practice)硫酸盐原则（最佳实践）Communication between Manufacturing & Sales (Best Practice)制造 & 销售信息沟通Technical Centre Raw Mix, Product & P
39、rocess Teams技术中心原料配料，产品技术中心原料配料，产品 & 工艺团队工艺团队10 Golden Rules Power Mastery - DPC Performance & Investments April 200931RULE 9 :Mill feed size control控制入控制入磨物料粒度磨物料粒度Crushers are more efficient at crushing than mills - optimise & control mill feed size破碎机破碎破碎机破碎效力高于磨机效力高于磨机 优化优化 & 控制入磨物控制入磨物料料10 Gold
40、en Rules Power Mastery - DPC Performance & Investments April 200932Mill Feed Size Control (1)控制入磨物料粒度（控制入磨物料粒度（1）Observe mill feed size on feed belt in regular inspection route在日常的巡检在日常的巡检路线观察入磨物料粒度路线观察入磨物料粒度Check feed size grading检查粒度分布检查粒度分布Check crusher baskets / breaker plates, etc检查破碎机篦检查破碎机篦子、
41、反击板等子、反击板等Check for wear of crushing parts检查破检查破碎零部件磨损碎零部件磨损Check condition of screens / grizzly检查筛子检查筛子/格筛状况格筛状况Check size of incoming materials检查矿检查矿山物料粒度山物料粒度VRM max feed size typically 70mm, beware of excessive fines原料原料立磨典型粒度立磨典型粒度70mm，防止粒度过细，防止粒度过细Ball mill feed size球磨机物料粒度球磨机物料粒度 95% 25mmChec
42、k hammer orientation检查锤头检查锤头磨损倾向磨损倾向10 Golden Rules Power Mastery - DPC Performance & Investments April 200933Mill feed size control (2) Actions控制入磨物料粒度 行动Set target maximum feed size (also for VRM max fines % passing 1mm)设定最大的物料粒度（同样包含原料立磨最高允许%几的物料小于1mmAgree contract feed size with supplier of inco
43、ming materials同供应商确认入破碎机的物料粒度合同Define & implement inspection plan (Production & maintenance) to include:定义 & 执行巡检计划包含（产品 & 维修)Mill feed size observation (weekly)观察入磨物料粒度（每周）Crushers & screens inspection破碎机筛子巡检Incoming materials feed size入破碎机物料粒度Occasional size grading check (monthly, depending upon
44、crusher wear)临时的物料粒度检查（每月，由破碎机磨损情况决定）Consider possibility to produce a smaller crusher product to reduce power consumption, but take care to also consider:考虑尽可能的生产小粒度物料以降低功率消耗，但必须考虑以下问题：Increased crusher wear破碎机磨损增加Reduced crusher throughput - Increased operating time减低破碎机产量增加破碎机开机时间Potential for ex
45、cessive fines (low level dust & VRM vibration)过多的细粉（低水平的粉尘原料立磨振动）10 Golden Rules Power Mastery - DPC Performance & Investments April 200934Mill feedsize control (3) Support控制入磨物料粒度（）支持Cement Portal 水泥门户网水泥门户网Ball mill optimisation post Sevilla球磨机优化Technical Agenda Study VRM原料立磨原理学习Technical Centre R
46、aw Mix & Process Teams技术技术中心原料配料工艺团队中心原料配料工艺团队10 Golden Rules Power Mastery - DPC Performance & Investments April 200935RULE 10 :Minimize compressed air最最小化压缩空气的消耗小化压缩空气的消耗Typical compressed air energy efficiency 10-15 % - use it wisely压缩空气典型的能源效率压缩空气典型的能源效率10-15%-精精明地利用它明地利用它10 Golden Rules Power M
47、astery - DPC Performance & Investments April 200936Minimise Compressed Air (1) Improvements最小化压缩空气的消耗（1）- 改进Replace intake filters更换进气更换进气滤芯滤芯 Optimise system pressure avoid excessive pressure优化系统压力优化系统压力-避免使用过高压力避免使用过高压力Change outlet filter elements regularly定期更换出口滤定期更换出口滤芯芯Systematic leaks inspect
48、ion, tagging & repair系统漏气巡检，标记系统漏气巡检，标记 & 修理修理Ultra-sonic leak detection ?发现超音速发现超音速泄露？泄露？Eliminate inappropriate use by alternate methods 通过循环交替用气的方通过循环交替用气的方法代替不合理运用法代替不合理运用Check condensate traps检测空气被检测空气被压缩时冷凝物压缩时冷凝物Check bag filters for leaking diaphragm valves检查检查袋式除尘器隔膜阀袋式除尘器隔膜阀/膜片阀泄露量膜片阀泄露量Sw
49、itch off compressors when not in use (idling 25-30%power)不使用不使用时关闭空压机（空压机空载时功率时关闭空压机（空压机空载时功率25-30%）Automatic pressure control自动压力控制自动压力控制Monitor filter P监测滤芯压差监测滤芯压差Condensate trap control minimize leakage冷凝物控制冷凝物控制-降低压降低压气泄漏气泄漏Monitor pressure at usage points监测使用压力监测使用压力Control dryer using moistur
50、e sensor通过湿度传感器通过湿度传感器控制干燥器控制干燥器Variable speed compressor for control ? 可控压缩机速度可控压缩机速度Remove unused pipe-work拆除不使用的管拆除不使用的管道系统道系统Match compressor size to demand按标准值匹配按标准值匹配型号型号Check if pipe size is sufficient检查管径是否检查管径是否足够足够Match air quality to use压气等级与压气等级与使用要求相符使用要求相符Examine pipe-work layout short
51、est distance to point of use. 检查检查管道系统布置图管道系统布置图- 管道至使用点最短路线管道至使用点最短路线 Consider loop system 考虑系统循环考虑系统循环Replace elbows by sweeping bends 大弯曲半径弯头大弯曲半径弯头代替肘型弯头代替肘型弯头Intake cool air best进气冷空气进气冷空气最佳最佳Waste heat recovery ?余热重复利用？余热重复利用？10 Golden Rules Power Mastery - DPC Performance & Investments April
52、200937Minimise Compressed Air (2) - Specific Cases最小化压缩空气的消耗-特殊案例Homogenising compressors均匀化空压机Check effectiveness of blending检查混合效率Consider conversion of high energy to low energy design考虑将高能耗转变为低能耗Pneumatic conveying气力输送设备Check conveying velocity /pipe size / conveying air volume检查输送速度/管道直径/输送气量Nu
53、mber of bends转弯点数量Pipeline route管线长度Bag filters袋式除尘器Optimisation of pulsing cycles优化喷吹循环Check for leaking purge valves检查放气阀泄漏（提升阀？）Air blasters and air purges for cleaning 清灰用空气炮和空气清洗？Optimise cleaning cycles according to plant needs根据工厂需要优化清灰循环10 Golden Rules Power Mastery - DPC Performance & Inves
54、tments April 200938Minimise Compressed Air (3) Improvement Opportunities最小化压缩空气的消耗（3）- 改进机会Operation & Maintenance 操作及维修Monitor system efficiency (kW/Nm3)监测系统效率(kW/Nm3)Monitor demand curve 监测需求曲线Optimise system pressure match supply to needs 优化系统压力- 依据使用需求Eliminate inappropriate usage (ex: bearing c
55、ooling) 消除不合理的使用（例如: 轴承冷却）Conduct regular system inspection including leak detection & repair 管理系统日常检查包含泄漏 检查 & 维修Remove unused pipe-work 拆除不使用的管道系统Control & Instrumentation 控制 & 自动化仪表Pressure control 压力控制Pressure indication at usage points 使用点压力指示Compressor shutdown / variable speed compressor 空压机停
56、机 / 可调速的空压机Moisture control for dryer 干燥后压气水分控制Review System Design 重新审核系统设计Pipe size 管道直径Shortest distance to usage points 管道至使用点最短距离Bend design 弯曲设计Air intake Compressor sizes 压缩机型号 Match air quality to usage requirement 压气等级与使用要求相符Waste heat recovery 余热重复利用10 Golden Rules Power Mastery - DPC Perf
57、ormance & Investments April 200939Minimise Compressed Air (4) Support最小化压缩空气的消耗（4）- 支持TC Maintenance & Process Teams技术中心 维修 & 工艺团队 External Specialists 其余专家Energy Efficiency & Suppliers Internet能源效率 & 供应商-互联网Tips www.eere.energy.govSuppliers Compressed air manuals:供应商压缩空气手册http:/www.atlascopco.co.uk/ukus/news/productnews/compressedairmanual.asp
