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The direct cost of medium density fiberboard production accounts for a considerable proportion, about 50%-70%, mainly the consumption of wood, coal, electricity, glue and spare parts. Different regions, different equipment, different management and other factors make the cost very different. The author is engaged in the production of medium density fiberboard for many years, and now I will talk about energy saving and consumption reduction measures.
1. Strengthening technological transformation of equipment and increasing production is an effective way to reduce consumption
In 1997, our company purchased a production line of 30,000 m3 per year from Shanghai Wood-based Panel Machinery Factory. In July 1999, our company cooperated with Shanghai Wood-based Panel Machinery Factory to carry out technical transformation of the hot-press unit, from the original 7-layer (4" x16") to 9-layer, and the rest was slightly modified, theoretically increasing production by nearly 30%. . It worked well after the transformation. The increase in production reduces unit consumption (the total consumption increases little). According to statistics, after the transformation, the average power consumption of the medium density fiberboard was reduced by 30k W·h/m3, the coal consumption was reduced by A03t/m3, and the consumption was significant.
Our company's drying system original design radiator area of ​​1500, drying fan model G4-68-1nSD, air volume of 96,000 m3 / h, dry pipe diameter work 1250mm, length 100m, can not meet the drying requirements of the hot press transformation after production increase, especially It is difficult to dry when it is raining, when the wood is fresh or when the weather is cold. In February 2002, the drying system was modified and the dryer radiator and drying fan were replaced. The area of ​​the radiator after replacement is 2374, the dry fan model G4-68-14D, the air volume is 160,000 m3/it (the damper is not fully open), and the drying pipe is extended appropriately. The drying effect after the transformation is obvious, which not only improves the steam utilization rate, but also effectively ensures the drying ability.
Equipment operating rate is a guarantee of production. Through years of exploration, our company has explored a set of effective equipment management methods, that is: daily maintenance by special personnel, every class of organic electric patrols, hidden danger records and analysis in time, major faults are promptly eliminated, and problems are handled uniformly during maintenance. This greatly reduces the occurrence of faults and reduces maintenance time. At the same time, the training of employees was strengthened, and non-equipment failures such as blocking the air duct, plugging the dust collector and plugging the discharge pipe were reduced, and the equipment operation rate was accordingly increased.
In 2002, our company produced 61,000 m3 of medium density fiberboard, and the contribution of the above aspects accounted for a large proportion. The coal consumption is 0.25t/m3, and the power consumption is 208kW·h /m3. The energy saving effect is obvious.
2 reduce power consumption and improve power efficiency
Medium-density fiberboard enterprises are large consumers of electricity. The installed capacity of domestic production lines of 30,000 m3/a is about 3800 kW, and 50,000 rn3/a is about 5000 kW. You can save power consumption in the following ways:
(1) In the power distribution room, the automatic reactive power compensation device or the local compensation (large motor) is used to improve the power factor. The medium density fiberboard factory has more motors, and the energy saving effect is obvious.
(2) Adopt advanced frequency conversion technology. The medium density fiberboard production line has more fans. According to statistics, our company's production of fans (including boilers) installed capacity of 893kW, accounting for 24% of the total installed capacity of production equipment, many fans are not working at full capacity, that is, there is a phenomenon of large horse-drawn cars, low efficiency. The frequency conversion technology can solve this problem well, not only has significant energy saving effect, but also reduces the fan failure rate. In the production of medium density fiberboard, there are many places where variable frequency technology can be used, such as boiler feed water pump, water supply system, vertical and horizontal saw feed of the sawing section, and the pump set of the hydraulic system of the hot press which is often unloaded.
(3) In the production of medium density fiberboard, the electric energy consumed by the hot mill accounts for about 48% of the total consumption (the data of our company), which is the key to reducing the power consumption. At present, many enterprises use imported one-way tooth grinding discs, and the energy saving effect is good. According to the author's test, the energy saving is up to 16% 20%; the imported two-way tooth grinding sheet also has a certain energy saving effect, generally around 5%. The type of grinding disc to be used should take into account the requirements of the condition of the chip, the power consumption, the life of the plate, the price of the plate, the replacement time of the machine, and the quality of the fiber. Different companies have different requirements, and different companies have different priorities.
3 boiler energy saving
There are mainly the following measures:
(1) Recycling condensed water from hot press and dryer) The temperature of the condensate of the hot press and dryer is generally controlled at 150~170 °C, and it has a certain pressure. It can be injected into the soft pool by certain means. Normal temperature water is heated to 70~85 °C, which not only saves soft water, but also saves a lot of coal. It is estimated that the coal saving rate produced by our company is about 10%.
(2) Wastes in the production of medium density fiberboard, such as bark, garbage, side strips, sanding powder, etc., not only effectively reduce coal consumption, but also help to improve the environment.
(3) Take measures such as cogeneration or differential pressure power generation to make comprehensive use of energy. At present, many companies have adopted such measures and achieved good results. In particular, the application of back pressure superheated steam after power generation in "back-pressure steam turbine" in dryers, hot presses and even in wood chip cooking is worth exploring. A subsidiary of our company is conducting research work in this area.
(4) Utilization of boiler flue gas. Most of the set of imported lines have an “energy plantâ€. The flue gas generated by the “energy plant†is used to heat the heat transfer oil and generate saturated steam, which is then used to dry the fiber. Our company has done experiments with boiler flue gas for fiber drying. During the test, the coal consumption is reduced, the power consumption is reduced, the direct cost is reduced, and the energy saving effect is good. However, due to the high sulfur content in the coal and the instability, the corrosion of the pipeline and the adverse effect on the fiber quality cause the test to stop, however, the condition does not burn. Coal companies (such as burning natural gas, etc.) can explore this issue.
Energy conservation and consumption reduction, the pursuit of profit maximization is always the goal of the enterprise. The above is just a rough understanding of the author's work practice, for peer reference.
Energy-saving and consumption-reducing measures for medium density fiberboard production enterprises
In recent years, the production of medium density fiberboard has developed rapidly, the scale of production of enterprises has been continuously expanded, the import production line has been continuously introduced, and the production of medium density fiberboard is leaving the “micro-profit eraâ€. Therefore, energy saving and production cost reduction are the enterprises to win in the competition. Fundamental measures.