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Based on the actual situation of cotton textile factory design in recent years, a comprehensive analysis was conducted from various aspects such as cotton textile process design, factory building design and public engineering design, and technical measures for comprehensive energy saving in cotton textile factory design were proposed.
my country’s textile products have great advantages in the international market, and domestic market demand still has great potential. There is still a broad market space for the development of the textile industry. Only by taking effective measures to build energy-saving textile factories can we promote the sustainable and healthy development of the textile industry. Based on many years of experience and lessons learned in the design of cotton textile factories, and from the aspects of process design, architectural design, and public engineering design, we summarized the matters that should be paid attention to during the design stage of textile factories and put forward energy-saving measures.
1. Energy-saving measures for workshop layout
The layout of the production workshop should be combined with the overall layout of the factory area to ensure that the process routes and factory pipelines are short and smooth. The population of the production workshop should be close to the raw material warehouse in the factory area, the finished product outlet should be close to the finished product warehouse or the printing and dyeing workshop, the sizing workshop should be close to the boiler room, and the spinning workshop and weaving workshop that consume a lot of power should be as close as possible to the power transformation and distribution station.
2. Choose energy-saving equipment
Process equipment selection is the key to energy conservation in the cotton textile industry. There are many types of cotton textile equipment and they consume a lot of electricity. Therefore, it is necessary to choose efficient, energy-saving, and environmentally friendly equipment to reduce energy consumption. For cotton spinning equipment, priority should be given to automatic continuous cotton spinning complete sets, for spinning equipment, priority should be given to fully automatic rotor spinning machines, compact spinning machines, vortex spinning machines, etc., and for winding machines, priority should be given to automatic winding machines. Weaving equipment should give priority to energy-saving and automated host equipment such as intelligent high-speed rapier looms, high-speed warp knitting machines, and high-speed air jet looms.
The energy consumption of the spinning process accounts for about 40% of the total energy consumption of spinning enterprises, of which 45% — to 55 span>% is consumed in twisting and winding, and 30% is consumed inside the spindle. Under normal circumstances, the electric energy consumed inside the empty spindle operation accounts for about 20% of the energy consumption in the spinning process, and the average energy consumption is 7～14w , the higher the operating speed, the greater the driving energy consumption. In 2015, the China Cotton Textile Industry Association released the “Recommended Catalog of Energy Saving and Emission Reduction Technologies for China’s Cotton Textile Industry”, recommending a new high-performance spindle energy-saving technology -TXD61 series High-speed and energy-saving spindle. Jihua 3542 Textile Co., Ltd. successfully used TXD6103 high-speed and energy-saving spindles for 4.5 ten thousand spindles in compact spinning. The spinning speed is increased by 11.5%, the energy consumption of spinning yarn is reduced by 11.49%, the annual saving of lubricating oil is 4.3t, and the annual use cost can be reduced. 115.6 million yuan. Auxiliary equipment should choose energy-saving motors for spinning systems, energy-saving air conditioners and other energy-saving equipment and air-jet loom air-saving technology.
3. Energy-saving measures for process design and process equipment layout
Cotton textile process design and process equipment layout are closely related to the products produced, and require careful analysis and research decisions based on final product performance, raw materials, product specifications, product quality and quantity, technical conditions and equipment performance.
3.1
Process Design
Cotton textile process design, equipment selection, table configuration and layout are the key to determining the workshop building area, construction investment and operating expenses, and are the core of cotton textile factory design. While satisfying product production, processing and manufacturing, various production equipment and processes need to be optimized. According to product characteristics and equipment performance, the production process parameters and the quantity of semi-finished products for each process should be reasonably designed and calculated. According to the selected process flow and product scale, determine Equipment matching. For machines equipped in the front and back processes of the same product, a fixed supply system should be established as much as possible.
3.2
Process flow
While meeting the needs of product production, the process flow should adopt high-quality, efficient, short-cut, continuous and automated process technology that is easy to operate. Semi-finished products are transported and stored between each process of textile production. In process design, it is important to consider how to facilitate the transportation and storage of semi-finished products in the process layout. The layout of the carding machine should be conducive to the transportation of cotton laps and slivers. It should be arranged in a straight line and connected with the upper and lower processes. The transportation and storage of drawing, combing and roving should be smooth and avoid cross-circuit.
3.3
Car width
When arranging the main process equipment, full consideration should be given to the transportation and storage of intermediate semi-finished products, and the width of the turning lane should be reasonably optimized to facilitate the connection of the upper and lower processes while ensuring normal operation. It is best to transport semi-finished products to the next process in one step, as much as possible avoidProper use of return air and control of the dew point of the air supply machine are not only beneficial to stabilizing the temperature and humidity in the workshop, reducing production fluctuations, and improving product quality, but can also significantly reduce air conditioning energy consumption.
According to process and product quality requirements, on the premise of ensuring operation quality, air conditioning energy-saving technologies such as “large and small environment” zoned air conditioning, multi-fan air supply system, heat energy transfer, variable frequency energy-saving spray, and automatic air conditioning control can be used. In a spinning workshop that generates a lot of heat, the electricity consumption can generally account for 60% to 70% of the electricity consumption of the spinning mill. Except for part of the electrical energy being converted into effective mechanical energy, the vast majority Part of it is converted into heat energy and dissipated into the workshop, causing excess heat in the workshop. The number of machines in the pre-spinning and roughening workshop is small, and the heat generated in the workshop is small. In winter, the heat generated by the machines alone is not enough to ensure the temperature of the workshop. In order to meet the process production requirements, additional heat is needed. In this way, the waste heat in the fine yarn workshop can be transferred to the pre-spinning and roughening workshop. The rough workshop air conditioning system saves energy through the mutual transfer and distribution of heat energy.
The location of the air conditioning room should be selected close to the load center of each workshop to reduce the length of the air return duct. It is best to locate it in a place that is convenient for air intake, return air, exhaust and air supply.
5.2
Dust removal
The energy-saving principle of the dust removal system is to rationally select and configure the dust removal system, make full use of the host pressure, balance the pressure of each dust removal interface, so that the pressure of each pipeline in the dust removal system is close, and reduce the waste of full pressure of the fan. Each part of the pipeline must maintain a corresponding wind speed to prevent dust accumulation, but the wind speed cannot be too high to avoid excessive resistance and a weakening of the dust removal air volume. The structure of the dust removal duct must not only ensure the uniform exhaust volume of each exhaust point, but also ensure that each exhaust point can maintain its required negative pressure.
The location of the dust removal room should be as close as possible to the process equipment or attached room to be filtered to shorten the dust removal pipeline and improve efficiency. The filtered air should be able to return to the workshop or air-conditioned room in the shortest possible way.
5.3
Refrigeration
The textile workshop generates a lot of heat and requires a lot of refrigeration capacity. In recent years, the profits of textile enterprises have been relatively low and their cooling capacity has been large, requiring textile air conditioning systems to operate as economically as possible.
Actively promote deep well recharge technology, use winter energy storage for summer cooling, and summer energy storage for winter heating. In order to effectively use the limited low-temperature winter irrigation well water, comprehensive dispatching of cooling capacity should be implemented, that is, mechanical cooling water is used to base the water during irrigation, and the shortage is supplemented with well water. This measure is more important for the implementation of the adjustment method of “low temperature water, small water volume, low dew point”.
Implement the principle of “one water for multiple uses”, so that low-temperature water can be reused first for spinning and then weaving. If the temperature of the final discharged water is still lower than that of the ground water, it can also be used as cooling water to improve the efficiency of refrigeration equipment.
Actively promote secondary water spray chambers to maximize the use of cold water cooling capacity. According to calculations, the use of secondary water spray chambers can save about 1/3 water in deep wells.
The refrigeration station should be close to the load center to shorten the chilled water transportation distance, reduce the chilled water pump lift, reduce operating power, and reduce pipeline cooling loss and water temperature rise. Decentralized refrigeration, designed and controlled on demand, facilitates energy adjustment.
5.4
Electrical
The workshop power transformation and distribution room should be arranged in the load center as much as possible to reduce the line loss and distribution loss of the power supply and distribution system, minimize reactive power, and improve the utilization rate of electrical energy. The transformer should be an energy-saving transformer with low loss and low noise to reduce energy consumption. The power factor is automatically compensated on the low-voltage side of the substation. After compensation, the power factor on the high-voltage side is above 0.9. Reasonably select cable and wire cross-sections based on economical current density and current carrying capacity. Take measures such as reactance filtering to suppress the content of harmonics in the line, and select high-efficiency and energy-saving motors. The motors should operate within the economic operating range. The lighting of large space areas is controlled centrally in lighting boxes according to work zones; other lighting is controlled locally using separate control switches, basically implementing single-light single control; lighting fixtures and light sources are each made of high-efficiency and energy-saving products. All substations and distribution stations implement microcomputer automatic control and protection. The operating parameters and status of each major electrical equipment are transmitted to the high-voltage switch station control room through the monitoring network, enabling centralized monitoring and control of electrical equipment and timely dispatching.
6. Conclusion
Energy-saving design is an important content in cotton textile factory design. It involves various aspects such as textile process design, factory building design, and public factory design. It is the result of the comprehensive application of various disciplines. Proper energy-saving design of textile factories can lay a solid foundation for energy-saving in cotton textile factories and provide conditions for comprehensive energy-saving, green and sustainable development of cotton textile enterprises. (
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