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What is a good choice for a blast furnace gas blower these days? Our factory previously used conventional motors controlled by hydraulic couplings; now, with the expansion of our coking operations, we’re not sure whether frequency-controlled motors or conventional blowers with ordinary couplings would be better. Please provide some guidance!
It is inevitable for frequency converters to replace hydraulic couplings. Comparison between high-voltage frequency converters and hydraulic couplings: The speed control range of high-voltage frequency converters is 0–100%; and if the mechanical strength of the motor and the load permits, and if the motor does not experience overcurrent, the frequency converter can also allow the machine to operate at speeds above its normal limit. The speed regulation range of a hydraulic coupling is generally 40–95%; that is, a speed loss of about 5% occurs at high speeds, which affects the output of the unit. The minimum speed that a hydraulic coupling can achieve is generally only 40% of the rated speed. In some cases, this level of speed is not sufficient to meet the requirements for speed control, and it also hinders further improvement in energy savings (for example, in dust removal from smelting furnaces, the fans can operate at very low speeds or even not at all during certain periods, yet the hydraulic coupling still has to operate at 40% of its rated speed, resulting in wasted electrical energy). High-voltage frequency converters maintain high efficiency across the entire speed regulation range (above 96%), whereas hydraulic couplings exhibit lower efficiency at lower speeds, resulting in significant losses that greatly reduce the energy-saving benefits of speed regulation. High-voltage frequency converters enable true soft starting of motors and driven machinery, completely eliminating the problem of start-up shocks; if required by the process, the motor can be started repeatedly multiple times in a short period of time. A hydraulic coupling cannot solve the problem of motor starting; the motor still needs to start directly. A starting device is required, the starting shock is significant, and frequent starting is not possible. When modifying a motor’s speed using a high-voltage frequency converter, it is sufficient to disconnect the original switch and the connection cables of the motor, then connect the frequency converter instead. The connection between the motor and the mechanical components remains unchanged, no modifications to the infrastructure are required, and there are no limitations related to the location. To carry out a speed control modification using a hydraulic coupling, it is necessary to insert the hydraulic coupling between the motor and the shaft that connects to the machinery; this requires moving and remolding the equipment foundation, and in some cases, there may not be enough space for this. The motor is modified for speed control using a high-voltage frequency converter; in the event of a failure of the converter, the motor can still operate directly on the mains power supply, thereby avoiding production losses. The hydraulic coupling serves as the link between the motor and the mechanical equipment; once it fails, the loaded machinery cannot operate, and it is necessary to shut down the machine for repairs to the hydraulic coupling, resulting in production losses. High-voltage frequency converters are high-tech devices with high reliability and require almost no maintenance. A hydraulic coupling is a mechanical device that includes multiple systems such as oil circuits and water circuits; it has a high failure rate and requires extensive maintenance, which results in a reduction in effective production time. High-voltage frequency converters do not incur additional costs depending on the motor speed; whereas for motors with low speeds but high capacity, hydraulic couplings are used for speed control, and the cost of such hydraulic couplings **increases, and in some cases it becomes impossible to use them. Relatively speaking, for speed control of ordinary motors, the initial investment in high-voltage frequency converters is higher than that of hydraulic couplings, but frequency converters require almost no operating costs later on. Hydraulic couplings require regular maintenance, including maintaining a dedicated maintenance team and frequently spending money on replacing water and oil, resulting in high operating costs. High-voltage frequency converters feature a high degree of intelligence, offer high speed control precision, and can operate in a closed-loop mode, thereby enhancing the automation level of factories, reducing the need for staff, improving the working environment, and lowering the workload. Hydraulic couplings have poor speed control accuracy; they cannot be considered for automatic control, nor can they be interfaced with computers. In addition, they leak water and oil, and the work area often becomes very dirty, resulting in an extremely poor working environment. In short, if users have equipment that requires speed control, from our perspective, unless funds are particularly tight, it is not recommended to use hydraulic couplings. Another article on \"Comparison between high-voltage frequency converters and hydraulic couplers for speed control\" can be found at the following addresses: http://www.gzktl.com/techarticles/jszl994.htm http://bbs.hcbbs.com/viewthread.php?tid=306978
We are using two variable-frequency gas fans, which are very easy to use; the adjustment of the flow rate is also prompt, with a fast response time. Variable frequency drives come in analog and digital versions; those that are more advanced generally use digital signals, as they offer greater stability. Hydraulic couplings also require the use of transmission oil, which adds an extra step; this leads to energy waste and makes maintenance more complicated. It is recommended to use gas fans equipped with variable-frequency motors.