Air compressor for non-ferrous metal smelting industry
In the field of non-ferrous metal smelting, air compressors, as key power equipment, are widely used in core process links such as blast furnace blowing, alumina transportation, and electrolytic cell control. Its stable operation is directly related to smelting efficiency, energy consumption control and environmental protection standards. The following is a professional explanation from three aspects: application scenarios, equipment selection, and operation and maintenance:
1. Core application scenarios
- blast furnace smelting process
- functional orientation: Provide high temperature and high pressure hot air (1000-1300℃) for blast furnace to improve reaction efficiency in furnace.
- technical requirements: An air preheating system needs to be equipped to heat the compressed air to above 800℃ to ensure stable hot air temperature.
- Alumina delivery system
- functional orientation: The alumina powder is transported to the electrolytic cell by pneumatic transportation, and the transportation distance can reach 500 meters.
- technical requirements: A precise pressure regulating valve is required to ensure that the delivery pressure fluctuation is ≤±0.01MPa to avoid powder clogging.
- Electrolytic cell control system
- functional orientation: Drive the pneumatic valve to adjust the electrolyte flow, and control the tank voltage fluctuation ≤± 5mV.
- technical requirements: An oil-free air compressor needs to be equipped to prevent oil from polluting the electrolyte.
2. Key elements of equipment selection
- environmental worthiness design
- High temperature resistant design: The motor protection level must reach IP66, and the bearing lubrication system must adapt to the ambient temperature of 60 ° C.
- anti-corrosion measures: The compressed air pipe is made of 316L stainless steel, and key components are nickel plated.
- Energy efficiency optimization configuration
- variable frequency drive system: Automatically adjust the speed according to the gas load, and the power saving rate can reach 20%-35%.
- heat recovery device: Recovering compression heat is used to preheat air or produce hot water, improving overall energy efficiency by 15%.
- Redundant security design
- hot standby system: Automatic switching time of main and standby machine is ≤5 seconds to ensure continuous air supply.
- pressure sustaining valve: Keep the system pressure ≥0.4MPa during power failure to prevent process interruption.
III. Typical equipment configuration scheme
| process links | Recommended equipment types | key parameters |
|---|---|---|
| blast furnace blast | Centrifugal air compressor + air preheater | Exhaust pressure 0.8-1.2MPa, temperature 1200℃ |
| Alumina transportation | Screw air compressor + precision pressure regulating valve | Exhaust pressure 0.6MPa, pressure fluctuation ±0.01MPa |
| Electrolytic cell control | Oil-free scroll air compressor + sterilization filter | Oil content ≤0.003mg/m³, cleanliness ISO 5 |
4. Operation and maintenance specifications
- Key points for daily inspection
- vibration monitoring: Identification of bearing faults through spectrum analysis, vibration speed ≤4.5mm/s.
- temperature monitoring: Motor bearing temperature ≤75℃, compressed air outlet temperature ≤ ambient temperature +15℃.
- Regular maintenance projects
- air filter: Replace the filter element every 2000 hours, and the cleaning cycle is ≤500 hours.
- lubrication system: Change the lubricating oil every 4000 hours of operation, and the oil viscosity grade complies with ISO VG 32.
- Energy efficiency evaluation system
- specific power test: Measure the specific power (kW/m³/min) quarterly and compare it with the benchmark value.
- leak detection: Ultrasonic leak detection is carried out every year to repair leakage points above DN15.
V. Technological development trends
- intelligent upgrade: Remote monitoring, fault warning and energy efficiency analysis are realized through the Internet of Things to reduce operation and maintenance costs.
- green low-carbon technology: Using energy-saving technologies such as magnetic suspension bearings and permanent magnet motors, the system energy efficiency is improved by 10%-20%.
- modular design: Develop container-type air compression stations to achieve rapid deployment and flexible expansion.
conclusion
Non-ferrous metal smelting enterprises need to select suitable air compressors based on process characteristics, and ensure long-term stable operation of the equipment through scientific selection, meticulous maintenance and energy efficiency optimization. With the application of digital twins and edge computing technologies, air compression systems are evolving in the direction of “self-sensing, self-decision-making, and self-optimization”, providing strong support for enterprises to save energy and reduce consumption and enhance competitiveness.