Energy consumption issue during low-load operation of the device
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I would like to ask the experts here about the energy consumption of the device when it operates at low load. The device is used for the concentration of spent sulfuric acid; its main components include a distillation tower for separation, a heating boiler to evaporate water, and a vacuum pump to create a negative pressure environment for operation. The main energy consumptions are steam, circulating water, and electricity. For example, the original design called for 100% load, but due to market conditions, it may operate at 50–70% load for an extended period. I would like to know whether, during the actual operation of the device, energy consumption is solely related to the volume of processing
Although it has low energy consumption, it still matters
I think it must be related, right?
For production facilities, there is a relationship between energy consumption and processing capacity, but it is not a linear proportional relationship. Because the energy consumption of some utility systems is fixed and does not decrease as the volume of processing decreases. For example, steam boilers have a minimum processing capacity of their own, which cannot be reduced indefinitely. For non-frequency-variable pumps, power consumption remains basically constant.
Energy consumption and output do not vary in a proportional manner; for chemical companies, units with higher production volumes generally have lower energy consumption per unit of product compared to those with lower production volumes.
According to the pump’s performance curve, as the flow rate decreases, the motor’s power should also decrease; however, when the change in flow rate is minimal, the power consumption may not change much.
Thank you, moderator. But even by asking the design institute now, there isn’t much reliable data available, is there? There is also a lack of operational experience with similar installations in the past, so it is difficult to assess the economic viability of building large-capacity facilities that operate at low load levels Trouble comparing?
Regarding the issue of energy savings and consumption reduction in the absence of operational experience with similar systems, it is necessary to make use of design resources; while ensuring normal production does not suffer, continuous attempts can be made to implement projects aimed at saving energy at reduced load levels； 1. First, analyze the areas with potential for energy savings and support these analyses with design data. 2. Next, establish a project plan to determine which actions need to be taken. 3. Then, implement those identified actions or plans thoroughly and make attempts to put them into practice. 4. Finally, evaluate the results based on the data collected
Thank you very much. The current situation is that we don’t have any operating equipment; we are still in the initial stage of project research, and we need to decide whether to expand the scale right away or build something new later on. There’s no such thing as trying. The design institute has not done it.
Energy consumption is directly related to the load; neither overloading nor underloading represents an economical operating condition. For most devices, an operating efficiency of 80-85% of the rated load is the highest. (That’s how boilers work. The same is true for fans and pumps; one can check the performance curve charts of these devices. Regarding the topic raised by the original poster, could it be considered in terms of multiple main devices? Design first based on current capabilities and reserve space for future expansion (in fact, many companies do this). What troubles me about this project is whether, if using steam generated on-site, we should go straight for a large boiler or start with a smaller one. Many companies have suffered losses in this regard; it would be more economical to first install power generation units and turbines to meet the needs temporarily, and then upgrade to a proper boiler system later. For reference only