CN102704960A - Mineral efficient energy-saving emulsification liquid feeding unit - Google Patents
Mineral efficient energy-saving emulsification liquid feeding unit Download PDFInfo
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- CN102704960A CN102704960A CN2012101959098A CN201210195909A CN102704960A CN 102704960 A CN102704960 A CN 102704960A CN 2012101959098 A CN2012101959098 A CN 2012101959098A CN 201210195909 A CN201210195909 A CN 201210195909A CN 102704960 A CN102704960 A CN 102704960A
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Abstract
The invention discloses a mineral efficient energy-saving emulsification liquid feeding unit, which comprises a main liquid feeding module, an automatic liquid distribution module, an electric control module, a spare liquid feeding module, a recovery module and a working face. The mineral efficient energy-saving emulsification liquid feeding unit has the following functions of intensive liquid feed, emulsified liquid recovery and reuse, far-end guarding, automatic control, constant-pressure liquid feed, fixed-time liquid feed, automatic liquid distribution, perfect protection and mutual switch of a main pump and a spare pump. According to the mineral efficient energy-saving emulsification liquid feeding unit disclosed by the invention, long-distance transportation of ultrahigh pressure emulsification liquid is realized to satisfy the liquid use requirement of old mines and remote mining areas, and the installing volume of a unit is effectively lowered; and because of the adoption of a module-type integration assembling form, the unit has the advantages of small size, short liquid flowing path, small pressure loss, small occupied site area, easiness in installing and tidy and attractive machine room. The control system can be accessed into the industrial Ethernet of a mine by an Ethernet so as to realize the information share of an emulsification pump monitoring subsystem and an automated monitoring system of a whole mine, thereby providing stronger compatibility and expansibility.
Description
Technical field
The present invention relates to a kind of mining device, be specially a kind of mining energy-efficient emulsification feed flow unit.
Background technology
Colliery emulsification pumping station system be the colliery generally use aim at the power source that comprehensive mining hydraulic bracket or hydraulic prop provide high-pressure emulsion.Pumping plant is arranged near the mine down-hole coal excavation work plane, and each work plane is provided with a pumping plant, and each pumping plant is installed two emulsification pumps (the using and the reserved), and the installed capacity of emulsification pump separate unit is tens to hundreds of kilowatt.The general mode of operation continuously that adopts of pumping plant is when every every day, power consumption was hundreds of to a few megawatt, for the coal master wants consumer.
Along with the appearance and the enforcement of a series of energy-saving and emission-reduction policies of country and measure, coal mining enterprise payes attention to planned supply and use of electric power and using electricity wisely further, more and more pays attention to using the novel energy-conserving technology and equipment.2003; I adopt the hydraulic prop supported face with hydraulic coupling low (being generally below the 15MPa), characteristics such as fluid volume is few, emulsion does not reclaim according to small-size coal mine down-hole, China south; From reducing the maintenance and the using electricity wisely of equipment; Designed the scheme of setting up the ground central fluid supply, and white sand mineral bureau has set up in the Bai Shanping colliery domestic first ground central fluid supply pumping plant in the Hunan Province.Pumping plant is located near the surface plant well head of ground, has been equipped with the frequency conversion automatic control system, has realized the ground central fluid supply.Adopt ground central fluid supply mode to receive good effect with aspects such as reducing power consumption improving service life of equipment, in recent years in the Hunan majority middle and small scale coal mines applied.Colliery emulsification pumping plant moves to ground from the down-hole, changes central liquid supply system into by the distributing liquid-supplying system, itself is the technical important breakthrough of colliery feed flow, also is the change on the theory.This mode has also been created condition for Safety of Coal Mine Production except a large amount of saves energy of ability, saving equipment investment and maintenance cost, should vigorously promote the use.But; Therefore this technology still is in the elementary step before; Also exist key technical problem in the majority not to be resolved, therefore restricted it and further developed, particularly it is restricted aspect range of application; Only can use at the small-sized work plane that adopts the hydraulic prop supporting, to adopt be that master's colliery is then inapplicable to fully-mechanized mining working or to combine.Its concrete problem that exists has:
The one, unresolved fully-mechanized mining working low pressure emulsion reclaims multiplexing problem, and these are most at present for China to be master's colliery with comprehensive adopting, and particularly big-and-middle-sized colliery is inapplicable.
The 2nd, the remote problem of carrying of unresolved high-pressure emulsion.The coal mine fully-mechanized mining hydraulic support requires liquid supply pressure to reach MPa more than 30, and feed flow distance in most of collieries reaches thousands of rice, realize reliable delivery, the compressive resistance of its pipeline, unloading with key technology such as the pressure loss with Louing and need solution on the way.
The 3rd, the hybrid coal winning technology of unresolved employing (be mine not only existed to combine adopt but also have a conventional face) mine, each work plane needs with pressure not simultaneously, and a shared liquid-supplying system feed flow difficult problem.
The 4th, the problem that unresolved liquid supply pressure is stable.Unstable because of liquid supply pressure, cause the setting load of pillar non-constant, cause potential safety hazard.Though existing central liquid supply system has carried out VFC, only depend on adjusting emulsification pump rotating speed of motor to carry out pressure and regulate, in actual the use, pressure follow is undesirable, often causes bigger pressure oscillation, and electric motor starting is frequent, and is unfavorable to the equipment operation.
The 5th, unresolved many work planes often cause the selected device capacity superfluous with the flow rate calculation problem of liquid.After adopting central fluid supply, reduce though its installed capacity has significantly than distributing feed flow, because of the emulsification pump flow rate calculation is not still had unified design formulas, the installed capacity of selected emulsification pump is often bigger than normal, has the phenomenon of low load with strong power.
The 6th, it is whole that equipment does not become, and each parts distributing is installed.Parts such as the emulsification pump in the existing emulsification pumping plant, emulsification tank, liquid-adding device, control valve all adopt traditional disperse formula mounting means, and floor space is big, and stringing is many in the machine room; Line loss is big; Apparatus arrangement is mixed and disorderly, is not easy to centralized Control, and influences machine room and carry out production strictly in line with rules and regulations.
The 7th, equipment adopts on duty, the manual manipulation mode of conventional artificial, needs the support staff many, is unfavorable for mine automation construction, and causes the equipment operate miss easily.
The 8th, unresolved automatic liquid matching problem.Adopt artificial dosing mode, the dosing quality can not get assurance, and time-consuming, is not easy to management.
Summary of the invention
The technical problem that the present invention solved is to provide a kind of mining energy-efficient emulsification feed flow unit; The present invention is directed to the problem and the defective that exist in the above-mentioned background technology; From solving all collieries (particularly implementing to combine the colliery of adopting) central fluid supply problem is starting point; On the basis of studying for many years and testing; Key breakthrough super-pressure, the long technical barriers such as pressure that need different brackets apart from emulsion conveying technology and different operating face; Explore basic law and the fluid volume computational methods of the many work planes in colliery from theory and practice, optimize the selection designing method of critical pieces such as liquid-supplying system emulsification pump, high pressure feed pipe, energy storage equipment, emulsification tank, aim at the colliery and develop a kind of energy-efficient emulsification feed flow unit with liquid.This unit is installed on ground, be applicable to combining adopt, high-grade conventional mining, big gun adopt and mix the ground central fluid supply in all kinds of collieries such as coal mining.Unit is different according to installed capacity, is divided into super-huge, large-scale, medium-sized and small-sized four kinds of specifications, is applicable to the colliery of various scales respectively.
The technical problem that the present invention solved adopts following technical scheme to realize:
Mining energy-efficient emulsification feed flow unit comprises main feed flow module, automatic liquid matching module, electrical control module and work plane;
Shown in main feed flow module comprise that high pressure divides gate valve, high pressure total gate valve, accumulator, main emulsifying pump, liquid inlet control valve, strainer, safety valve, emulsion box, woven hose; The liquid feeding end of said main emulsifying pump connects strainer through liquid inlet control valve; Strainer is provided with in the emulsion box; The outlet end of main emulsifying pump, high pressure divide gate valve, accumulator, high pressure total gate valve to be connected successively with woven hose, and said woven hose is connected with feed flow pipe network on being laid on work plane;
Said automatic liquid matching module comprises water-delivery pump, outlet water control valve, oil-feed control valve, oil transfer pump, emulsion tank, feed cistern;
Said electrical control module comprises host computer, switch board, power cabinet, frequency converter, pressure sensor, liquid level sensor, concentration sensor; Said host computer connects the input of switch board through Ethernet; The input of switch board also connects pressure sensor, liquid level sensor and concentration sensor; The output of switch board connects water-delivery pump, oil transfer pump, main emulsifying pump, frequency converter, and said frequency converter connects main emulsifying pump; Said host computer is an Industrial Personal Computer (IPC).
Be provided with PLC in the said switch board, said PLC adopts the PID computing.
The present invention also comprises subsequent use feed flow module; Said subsequent use feed flow module comprises that subsequent use emulsification pump, high pressure divide gate valve, liquid inlet control valve, strainer, safety valve; Said subsequent use emulsification pump connects the output and the frequency converter of switch board respectively; The liquid feeding end of subsequent use emulsification pump connects strainer through liquid inlet control valve, and strainer is provided with in the emulsion box, and the outlet end of subsequent use emulsification pump, high pressure divide gate valve, pressure sensor and high pressure total gate valve to be connected successively.
The present invention also comprises recycling module, and said recycling module comprises the oil return pond, returns the liquid force (forcing) pump, liquid back pipe, and said oil return pond is connected with feed flow pipe network on being laid on work plane, and said oil return pond, time liquid force (forcing) pump, liquid back pipe are connected with emulsion box successively.
Compared with prior art, the present invention has following beneficial effect:
(1) central fluid supply function.Realize that each coal-face of full mine and other are with the shared liquid-supplying system in liquid place, promptly by ground unit central fluid supply.
(2) emulsion reclaims multiplexing function.Realization is reclaimed and is recycled combining the low pressure emulsion of adopting with the cantilever support work plane.
(3) far-end is on duty, controls function automatically.Behind host computer or switch board " key startup ", unit just gets into the automatic control running status of acquiescence, has " far-end " and " on the spot " two kinds of monitor modes.
(4) constant-pressure liquid supply function.Through installing frequency converter additional, cooperate the PID constant voltage closed-loop adjustment function of PLC, liquid-supplying system pressure is carried out regulating from motion tracking, guarantee that " feed flow as required " and liquid supply pressure are constant.
(5) the long distances of realization super-pressure emulsion satisfies old mine and the outlying exploiting field needs with liquid.Pumping plant supplies distal-most end work plane distance to reach more than the 5000m.
(6) effectively reduce the installed capacity of unit.Through optimizing the machine configuration set, utilize the proportionality action of big system feed flow, and, significantly reduce the installed capacity of emulsification pump through adopting frequency-changing pressure stabilizing to control and install additional measures such as big capacity accumulator fluid infusion.With respect to existing distributing liquid-supplying system, the installed capacity of emulsification pump reduces more than 80%, significantly reduces power consumption.
(7) timing feed flow function.Through setting the clock of PLC controller, realize timing automatic startup-shutdown.
(8) automatic liquid matching function.The one, guarantee that emulsion box has an amount of liquid measure; The 2nd, keep emulsion suitable oil, water to be arranged than (being that concentration meets the requirements).
(9) possesses perfect defencive function.Wherein the prerequisite protection of hydraulic system has feed flow overpressure protection, the overtime protection of low pressure operation, emulsion box liquid level superelevation and ultralow protection etc.; The prerequisite protection of electric part has major loop overcurrent protection, under-voltage and single phasing protection, earth leakage protective, motor overtemperature prote etc.When above fault takes place when, unit hard stop and self-locking and warning, after only pressing SR and carrying out " resetting ", can restarting systems.
(10) the mutual handoff functionality of main pump and stand by pump.When process pump breaks down, switch to the stand by pump operation, guarantee continuous liquid supply, do not influence mine normal production.
(11) unit adopts the integrated assembling form of modular, and volume is little, and fluid flow path is short, the pressure loss is little, and the occupied ground area is little, is easy to install, and machine room is neat and artistic.
(12) control system can insert the dried net of mine industry ether through Ethernet, realizes the Automatic monitoring systems information sharing of emulsification pump Monitor And Control Subsystem and full mine, has stronger compatibility and autgmentability.
Description of drawings
Fig. 1 is the principle sketch of the mining energy-efficient emulsification feed flow unit of the present invention.
Fig. 2 is PID control principle figure of the present invention.
Among the figure: 1 work plane, 2 oil return ponds, 3 times liquid force (forcing) pumps, 4 host computers, 5 switch boards, 6 power cabinets, 7 frequency converters; 8 water-delivery pumps, 9 outlet water control valves, 10 oil-feed control valves, 11 oil transfer pumps, 12 subsequent use emulsification pumps, 13 high pressure divide gate valve, 14 pressure sensors; 15 high pressure total gate valves, 16 accumulators, 17 main emulsifying pumps, 18 liquid inlet control valve, 19 liquid level sensors, 20 concentration sensors; 21 safety valves, 22 emulsion box, 23 emulsion tanks, 24 feed cisterns, 25 liquid back pipes, 26 woven hoses.
The specific embodiment
Be easy to understand and understand in order to make technological means of the present invention, creation characteristic, workflow, method for using reach purpose and effect, below further set forth the present invention.
As shown in Figure 1, mining energy-efficient emulsification feed flow unit comprises main feed flow module, automatic liquid matching module, electrical control module, subsequent use feed flow module, recycling module and work plane 1.
Shown in main feed flow module comprise that high pressure divides gate valve 13, high pressure total gate valve 15, accumulator 16, main emulsifying pump 17, liquid inlet control valve 18, strainer, safety valve 21, emulsion box 22, woven hose 26; The liquid feeding end of said main emulsifying pump 17 connects strainer through liquid inlet control valve 18; Strainer is provided with in the emulsion box 22; The outlet end of main emulsifying pump 17, high pressure divide gate valve 13, accumulator 16, high pressure total gate valve 15 and woven hose 26 to be connected successively, and said woven hose 26 is connected with feed flow pipe network on being laid on work plane 1.
Said automatic liquid matching module comprises water-delivery pump 8, outlet water control valve 9, oil-feed control valve 10, oil transfer pump 11, emulsion tank 23, feed cistern 24, and said water-delivery pump 8 provides the water source for emulsion box 22, and said oil transfer pump 11 provides oil sources for emulsion box 22.
Said electrical control module comprises host computer 4, switch board 5, power cabinet 6, frequency converter 7, pressure sensor 14, liquid level sensor 19; Concentration sensor 20; Said host computer 4 connects the input of switch board 5 through Ethernet; The input of switch board 5 also connects pressure sensor 14, liquid level sensor 19 and concentration sensor 20; The output of switch board 5 connects water-delivery pump 8, oil transfer pump 11, main emulsifying pump 17, frequency converter 7, and said frequency converter 7 connects main emulsifying pump 17, and said power cabinet 6 provides providing capability for system.
Said subsequent use feed flow module comprises that subsequent use emulsification pump 12, high pressure divide gate valve 13, liquid inlet control valve 18, strainer, safety valve 21; Said subsequent use emulsification pump 12 connects the output and the frequency converter 7 of switch board 5 respectively; The liquid feeding end of subsequent use emulsification pump 12 connects strainer through liquid inlet control valve 18; Strainer is provided with in the emulsion box 22, and the outlet end of subsequent use emulsification pump 12, high pressure divide gate valve 13, pressure sensor 14 and high pressure total gate valve 15 to be connected successively.
Said recycling module comprises oil return pond 2, returns liquid force (forcing) pump 3, liquid back pipe 25, and said oil return pond 2 is connected with feed flow pipe network on being laid on work plane 1, and said oil return pond 2, time liquid force (forcing) pump 3, liquid back pipe 25 are connected with emulsion box 22 successively.
The feed flow unit is installed near the grass surface plant auxiliary shaft mouth, and each mine only need be installed a cover.Two emulsification pumps are installed on the unit, and a worker one is equipped with.Unit adopts frequency conversion to control automatically, and at mine Centralized Monitoring center host computer is set by " unmanned " design, realizes the remote monitoring to unit.Operation of equipment can adopt " on the spot " and " long-range " dual mode, as long as carry out the automatic operational mode that " key startup " back just gets into acquiescence.
Feed flow pipe network and liquid back pipe net are respectively laid with the liquid work plane in feed flow machine room to down-hole from ground.Lay by laying (liquid back pipe need not established in the monomer supported face) with the path on feed flow pipeline and liquid back pipe road.The feed flow pipeline is delivered to each work plane with the high-pressure emulsion of ground feed flow unit output, supplies force piece to use liquid.The low pressure emulsion that support is flowed out on the liquid back pipe road is led and is back to the ground emulsification tank, forms emulsion closed cycle using system.When the pit mining degree of depth (hang down high) when being no more than 200m, can adopt the mode of directly returning liquid to return liquid, promptly directly utilize force piece hydraulic cylinder high and low pressure lateral pressure difference that the low pressure emulsion is pressed into liquid back pipe, directly lead back the ground emulsion box through liquid back pipe.When well depth is vertical high above 200m; Adopt the mode of directly returning liquid will cause support liquid-supplying system " back pressure " too high; Action to support brings interference; Even cause the support can not regular event, the auxiliary water booster system of liquid then should be set back at the bottom of the auxiliary shaft of mine, with each fully mechanized coal face return liquid through force (forcing) pump pressurization back the concentrated ground emulsion box that drains into.
For the mine that satisfies various scales uses; The feed flow unit is divided into four kinds of specifications by the size of installed capacity, promptly super-huge (power is more than the 200KW), large-scale (power is more than the 125KW), medium-sized (power is more than the 55KW), small-sized (power is more than the 15KW).Wherein super-huge unit is applicable to the mine of annual production 500～1000 tons; Large-scale unit is applicable to the mine of annual production 200～500 tons; Medium-sized unit is applicable to the mine of producing 30～200 tons per year; Minicomputer is applicable to the mine of producing per year below 300,000 tons, after specifically should calculating according to conditions such as mine working face what and support models, and the selection standard type.
Advanced at present frequency conversion control and remote control technology are automatically adopted in the control of emulsification pump; The highly sensitive pressure sensor that is provided with in the coupled system; Realization to emulsification pump frequency conversion control automatically, make the unit can be, and keep hydraulic coupling constant according to the liquid of how much carrying of down-hole fluid volume.Unit is provided with the automatic liquid matching unit; Adopt present state-of-the-art high-resolution concentration of emulsion used sensor, realize the online detection of concentration of emulsion used and adjusting are automatically guaranteed that emulsion box has enough emulsification liquid measures; Carry out dosing by correct water, oil ratio simultaneously, guarantee that concentration is suitable.Main electrical component such as PLC controller, relay, contactor, transmitter is installed in the switch board, devices such as touch-screen, control button, changeover switch are housed on its panel.PLC adopts and uses the FX of Mitsubishi more widely at present
2NSeries of products, systems soft ware adopt Mitsubishi's professional version to write main program.Host computer adopts Industrial Personal Computer (IPC), and Ethernet and optical cable transmission technology are adopted in the PLC communication in host computer and the switch board, adopts winCC to write host computer configuration interface.Touch-screen is as on-the-spot man-machine interface on the switch board, is used to operate, the setting of parameter and to the supervision of unit operation situation.Other is provided with video system, is used for the intuitive monitoring to situation such as machine room, equipment.
One, each function realizes principle and method for designing
(1) central fluid supply function
Surface plant is established the central fluid supply pumping plant on ground, and erecting bed feed flow unit in standing is installed two emulsification pumps on the unit, a job, and one is subsequent use.Emulsification pump becomes emulsion pressurization in the emulsification tank into high-pressure emulsion to delivered downhole.Lay main feed flow pipeline and branch line in the down-hole, high-pressure emulsion is delivered to each work plane, as the hydraulic power of support apparatus.For guaranteeing the requirement of required hydraulic coupling of different operating face and flow, mainly take following technology and measure:
1. in order to satisfy each with the demands of different of liquid place to emulsion pressure size; The outlet pressure of unit should be set for foundation by down-hole required maximum hydraulic pressure power work plane; Other can be adjusted to its required force value with pressure through the mode of one way pressure-reducing valve is set with the liquid place on each branch line.
According to pascal's principle, the setting pressure of feed flow unit outlet is calculated as follows:
P=F/(2Лr
2)+Δp
In the formula:
P-pumping plant outlet setting pressure (Mpa);
The setting load (N) of F-support single upright column supporting roof is required hydraulic coupling maximum functional face support single upright column setting load here;
R-fully mechanized mining supporter column cylinder body radius (mm);
The pressure loss (MPa) when Δ p-emulsion flows in pipe network, relevant with caliber and flow velocity.Because what liquid-supplying system was carried is the super-pressure emulsion, and flow is little, by contrast, the pressure loss of the pipe network of flowing through is very little, can ignore during calculating.
2. in order to satisfy the required traffic requirement of each a plurality of work planes operation simultaneously, be unlikely to make the installed capacity of unit superfluous again, mainly take following technological two technical measures:
The one, according to each work plane gap with liquid registration rule, the liquid supply rate of reasonable computation unit.The flow of unit calculates by following formula:
Q＝K
1K
2（Q
1＋Q
2+…?Q
n）
＝K
1K
2(2×V×3.14×d
1 2?/4+2×V×3.14×d
2 2/4+…2×V×3.14×d
n 2/4)
In the formula:
The flow of Q-emulsification pump (l/min);
K
1-Cai face overlap coefficient is got 1,2 and is adopted face and get 0.7,3 and adopt face and get 0.6,4 and adopt face and get 0.5 when adopting face for 1 ... (but being not less than 0.4);
K
2-accumulator fluid infusion coefficient, according to adding accumulator what, desirable 1～0.5, accumulator volume is big more, gets the small value;
Q
1, Q
2... Q
n-be respectively required emulsion flow (l/min) when respectively adopting the face setting prop;
V-setting prop speed (mm/s);
d
1, d
2... D
n-be respectively and respectively adopt face bracket upright post cylinder diameter (mm).
(2) emulsion reclaims multiplexing function
Adopt or cantilever support work plane and mine having to combine, emulsion return liquid system that must special reclaims the low pressure emulsion of work plane and recycle.Return liquid system mainly is made up of the auxiliary water booster system of liquid back pipe road and time liquid.The low pressure emulsion that support apparatus flows out in the lifting column process is directed at the ground emulsion box through return liquid system, recycles.When the pit mining vertical depth is no more than 200m, can take directly to return the liquid mode, the high and low pressure reduction of hydraulic cylinder is pressed into liquid back pipe with the low pressure emulsion when promptly utilizing the support action, directly leads back the ground emulsification tank through liquid back pipe; When the pit mining vertical depth surpasses 200m; If still adopt the liquid mode of directly returning; Return the big back pressure that liquid forms liquid-supplying system, the normal use of fully mechanized mining supporter is had very big influence, liquid then must be set back at the bottom of the mine auxiliary shaft assist water booster system; The low pressure emulsion of each work plane imports liquid return tank through liquid back pipe, again through auxiliary pump pressurized delivered to ground emulsification tank.Auxiliary force (forcing) pump is realized automatic start-stop by the control of liquid return tank liquid-level switch.
1. the setting of liquid back pipe.Liquid back pipe (comprising house steward and arm) is laid with the path with feed pipe, selects seamless steel pipe for use, and it connects the snap joint of the mining K type of employing, and its caliber is not less than corresponding feed pipe.
2. the calculating of auxiliary force (forcing) pump flow.Auxiliary force (forcing) pump flow can calculate according to fully-mechanized mining working advancing velocity and the liquid measure of returning of moving frame, and calculating formula is following:
q?=kq
1/t
In the formula:
Flow (the m of q-force (forcing) pump
3/ h);
The capacity coefficient of rich of K-pump gets 1.3;
q
1-whenever move a required fluid volume (m of support
3);
T-whenever moves a support required time (h).
3. the liquid return tank capacity confirms.Support uses liquid to use liquid as intermittence, and its time liquid measure is little, and the liquid return tank volume can design very for a short time, but in order to make force (forcing) pump be unlikely to frequent starting, has under enough installing space situation in the down-hole, can suitably increase the capacity of liquid return tank.Generally fetching the liquid pool capacity is 1m
3Liquid return tank adopts general steel plate to be made into the casing form.
(3) the long distances function of super-pressure emulsion
In the liquid-supplying system of colliery, emulsion pressure reaches more than the 30MPa usually, and fed distance reaches thousands of rice.For guaranteeing that emulsion carries reliably, must guarantee the compressive resistance of pipeline, and must prevent that pipeline from leaking and reduce the pressure loss as far as possible on the way that simultaneously, for adapting under the service condition of down-hole, pipeline must dismounting, convenient in carrying.Specifically take following technical measures:
1. rationally choose tubing
Because what carry in the pipeline is highly pressurised liquid, collateral security reliability and safety and practice thrift the initial investment aspect and consider should be adopted the 16Mn steel high pressure seamless pipe from ground to each main line with the liquid place.Pipeline in the work plane should be selected the high-pressure rubber pipe assembly for use so that to install and move be main;
2. optimization PIPE DIAMETER CALCULATION
Main line (seamless steel pipe) internal diameter is calculated as follows:
d=
In the formula:
The flow (L/min) that Q-is responsible for should equal emulsification pump delivery and accumulator and discharge the flow sum.The flow that accumulator discharges is generally got 0.5～1 times of emulsification pump delivery;
V
1The flow velocity (m/s) of-emulsion in pipeline got 3～5 m/s;
After having confirmed the diameter of being responsible for, get the interior sebific duct internal diameter of the face of adopting 0.7～1 times for person in charge's internal diameter;
3. pipe thickness is calculated
Being responsible for (steel pipe) wall thickness is calculated as follows:
b=0.5?d?[
?－1]+a
In the formula:
B-thickness of steel pipe (mm);
The internal diameter of d-steel pipe (mm);
σ-steel pipe allowable stress (Mpa), seamless steel pipe is got 163 Mpa;
A-considers steel pipe foozle and corrosion in use and the thickness (cm) that increases, generally gets 0.1～0.2cm;
P
d-pipe internal pressure (Mpa);
4. union is selected
Consider the reliability that pipeline connects, anti-heads, and install and remove conveniently, all select for use the snap joint of high pressure KJ2 type to connect between the tube and tube.Welding manner (annotate: weld seam must good groove, and weld strength must not be lower than steel pipe itself) is adopted in steel pipe and the snap joint of KJ2 type.Adopt face inner high voltage rubber tube assembly itself and have the snap joint of KJ2 type, need not select joint else.
According to above design, selected pipeline not only has enough compressive resistances, and its caliber little (steel pipe that general mine employing internal diameter is no more than 50mm is enough), connects reliably, and the input expense is low, pipeline dismounting, convenient in carrying.
(4) equipment installed capacity miniaturized design
Structure through optimizing unit with adopt technology such as accumulator fluid infusion, installed capacity is significantly reduced, thereby reaches significant power savings.Mainly take following concrete measure:
1. change the ground central liquid supply system into by traditional down-hole distributing liquid-supplying system, the capacity of emulsification pump is reduced to original part.Mainly required maximum stream flow is confirmed when satisfying the operation of single force piece in the emulsification pump installed capacity of distributing liquid-supplying system, so selected emulsification pump capacity is big, the emulsification pump most of the time is in light load or no-load running state.After taking the central fluid supply mode, make full use of the proportionality action of big system feed flow, can improve the rate of load condensate of emulsification pump greatly.Through calculating, adopt its installed capacity of central fluid supply to be merely 1/2～1/4 (according to the number decision of coal mining work plane, the more minimizings of work plane number are more) of distributing installed capacity;
2. further reduce the installed capacity of emulsification pump through the mode that installs accumulator additional.Accumulator has the effect to liquid-supplying system fluid infusion and systems stabilisation pressure.Less or during without liquid, accumulator carries out accumulation of energy when each work plane fluid volume of down-hole, when system's fluid volume during greater than the emulsification pump delivery, accumulator replenishes emulsion to system.Like this, homogenizing the load of emulsification pump, further reduced the emulsification pump installed capacity;
The volume calculations of accumulator is following:
1. by keeping liquid-supplying system pressure stability condition to calculate the accumulator volume:
V
0＝
(1) in the formula:
V
0-accumulator volume (L);
Q
5-setting prop is closed flow in the preceding pipeline (l/min) with fluid valve;
P
Max-pumping plant outlet pressure fluctuation higher limit (Bar) is got P
MaxFor setting pressure+5%;
P
Min-pumping plant outlet minimum pressure value (Bar) is got-5% of setting pressure;
Valve opening or shut-in time (s) were got 0.5s when t-adopted the face setting prop;
L-produces the duct length (m) that impacts;
2. calculate the accumulator volume by the maximum stream flow of carrying out fluid infusion to system:
When a plurality of work planes were used liquid simultaneously in the down-hole, requiring accumulator to need maximum stream flow to the liquid-supplying system fluid infusion be 0.5～1 times of emulsification pump discharge capacity.According to on-the-spot practical measurement, the comprehensive mining hydraulic bracket setting prop time is t, and promptly accumulator in each setting prop activity duration domestic demand to the additional liquid measure of system is:
Q
，=?Qt
Again according to Boyle's law, the gas of certain mass, when temperature remained unchanged, the product of its pressure p and volume V equaled constant.It is 5% of accumulator nominal capacity that the bag type accumulator compressed nitrogen is reduced to the liquid measure that discharged at 95% o'clock by setting pressure, and then the accumulator volume is:
V
1=5?Q
，×10
－2 （2）
Comparison expression (1) and formula (2) dual mode result calculated are got higher value;
3. the accumulator operating pressure confirms
Accumulator is installed on the feed flow unit, and its nominal pressure should equal the rated pressure of unit, and its actual the blowing pressure should export 60～80% of setting pressure by unit and confirm.
(5) constant-pressure liquid supply function
Usually; Mining emulsification pump itself is provided with the mechanical compression adjusting device, but its reliability and pressure degree of regulation all do not reach desirable effect, because of its control sensitivity low; Often cause liquid-supplying system pressure to change greatly, can not guarantee the stable of force piece setting load.And, this voltage regulating mode, even emulsification pump under the unloading situation, still operates in full-speed state, power consumption and mechanical shock and wearing and tearing are bigger, cause equipment failure rate high, shorten application life.
For eliminating above-mentioned defective, mainly take following two measures:
The one, adopt frequency conversion to control automatically to unit.PLC has the PID regulatory function in the control system, is the control object with the liquid supply pressure, and the emulsification pump running speed is controlled, and when the down-hole fluid volume increases, improves the rotating speed of emulsification pump, otherwise, reduce its rotating speed, realization as required, constant-pressure liquid supply.
The PID constant voltage Principles of Regulation of feed flow unit are seen Fig. 2.The control system compares actual pressure value and the system pressure setting value that highly sensitive pressure sensor records; Its difference is carried out computing by the PID adjuster of PLC by the adjusting rule of predesignating; Draw conditioning signal; Control the output voltage and the frequency of frequency converter, thereby the rotating speed of change emulsification pump is to keep constant hydraulic pressure in the pipe network.
The 2nd, big capacity accumulator is set in liquid-supplying system, utilize the fluid infusion of accumulator and all pressure effects, guarantee that system pressure is constant.
(6) far-end is on duty, controls function automatically
This function is mainly realized by the automatic control system of feed flow unit.The control system mainly is made up of PLC switch board, peripheral various sensors and host computer.The PLC switch board is installed in the machine room scene, and host computer is located at the colliery centralized-control center.PLC and host computer link with Ethernet protocol, adopt Siemens's professional version to write main program and adopt winCC to write the configuration interface, realize on the spot communication and control with far-end.
Various sensors such as field erected pressure, liquid level, concentration, electric current, voltage with detected signal conveys to PLC; PLC carries out computing and processing according to the rule of predesignating to signal; It is exported signal on the one hand and realizes the control to various executing agencies; Transmit signals to host computer simultaneously, realize the far-end supervision.Operating personnel realize the control to site plant through the host computer that is installed in the mine centralized-control center.The switch board of control system for field is provided with touch-screen and various changeover switch and button, and operating personnel can realize on touch-screen the local operation of unit and the setting of controlling parameter.
Control to unit is provided with two kinds of modes of operation: the one, and " automatically " mode, after starting through host computer or field control cabinet one key, equipment just gets into the automatic control mode (all adopting this kind mode under the normal condition) of acquiescence; Another kind is " manually " mode, when automatic control system or frequency converter break down, can unit be converted into " manually " mode of operation.Manual mode is a power frequency operation, and power savings is poor, uses during only as emergent start.
(7) timing feed flow function
Set startup-shutdown period every day according to colliery rule on and off duty, the time clock feature of design timing start-stop emulsification pump realizes regularly startup-shutdown in PLC control software.Relieve the period in the colliery, work plane need not used liquid, the emulsification pump autostop; In the work plane normal operation period, emulsification pump starts automatically.
(8) automatic liquid matching function
Automatic liquid mixing system is made up of parts such as PLC controller, liquid level sensor, concentration sensing receiver, water-delivery pump, oil transfer pump, emulsion box.Liquid level sensor and concentration sensor are installed in the emulsion box, realize the data acquisition to emulsification tank liquid level and strength of fluid, and signal are delivered to the PLC controller carry out calculation process.Water-delivery pump and oil transfer pump are set in system, are used for to emulsification tank supplementing water and oil emulsion.Water-delivery pump adopts constant displacement pump, and oil transfer pump adopts measuring pump, through flow and the running time of setting two pumps, realizes adding in proportion clear water and oil emulsion;
(1) automatic liquid feeding.Utilize liquid level sensor to set 3 liquid levels, i.e. " minimum liquid level ", " adding liquid level " and " position of rest " at emulsification tank.When liquid level in the pond was reduced to setting " adding liquid level ", PLC control water-delivery pump and oil transfer pump be liquid feeding in the pond simultaneously.When liquid level rose to " position of rest " of setting, water-delivery pump and oil transfer pump stopped liquid feeding.When liquid level is reduced to " minimum liquid level ", explain that liquid-supplying system serious leakage has taken place or added liquid systems fault to have occurred, the control system stops the emulsification pump operation, and sends alarm signal;
(2) adjusting of concentration of emulsion used.Concentration of emulsion used is set at 3%～5% scope by regulation.When the detected actual concentrations of control system is lower than 3%, then PLC control oil transfer pump isolated operation, Xiang Chizhong adds oil emulsion, and concentration is 3% to stop when above in addition always.When detected actual concentrations was higher than 5%, then PLC control water-delivery pump added clear water separately in the pond, and concentration is to stop in 3% o'clock in addition always.
(9) perfect defencive function
The control system mainly realizes following protection:
1. the low liquid level protection of emulsification tank
, liquid level in the pond (generally is set at when reducing to " minimum liquid level " of setting than " adding liquid level " low 100～200mm); Then be regarded as the serious leakage of liquid-supplying system or add liquid systems automatically liquid feeding fault automatically takes place; The control system carries out safeguard protection immediately; Frequency converter stops output, and emulsification is out of service, and shows failure cause.Have only liquid level to return to more than " minimum liquid level ", and after safety return circuit resetted, can restart emulsification pump;
2. the serious leakage protection of liquid-supplying system
When the continuous oepration at full load of emulsification pump (is that 50Hz is a decision condition with the frequency converter output frequency) surpasses setting-up time; And liquid-supplying system pressure does not reach setting value yet; Then be regarded as the serious leakage of liquid-supplying system, the control system carries out safeguard protection immediately, and shows failure cause.Have only safety return circuit resetted after, can restart emulsification pump;
3. the overload of motor and short-circuit protection
Current transformer on the main circuit power supply is sent to current transducer with the three-phase current that records, and converts standard signal into by current transducer and is delivered to PLC.When motor generation overload or short trouble, PLC compares actual current value and setting value, and its any phase actual current is during greater than setting value, and the control system carries out safeguard protection immediately, and shows failure cause;
4. voltage protection
Voltage protection mainly comprises ultra-voltage, under-voltage, protection such as single-phase.The three-phase voltage transmitter is that standard signal is sent to the PLC controller with the voltage transitions of power supply major loop; PLC compares the actual voltage value that records and setting range (get rated voltage 90～110%); When any phase actual voltage value exceeds setting value; The control system carries out safeguard protection, and shows failure cause;
5. motor overtemperature prote
Temperature pick up is set on motor housing, and transmits signals to the PLC controller, PLC compares actual temperature value and setting value (generally being set at 70 ℃), when reaching setting value, carries out safeguard protection, and shows failure cause;
6. frequency converter failure protection
Frequency converter itself is provided with fairly perfect protection, and when it broke down, its signal was sent to the PLC controller, and controller stops the frequency converter operation immediately, and shows failure cause.
(10) live video function for monitoring
Video system is set separately.The video system display screen is located at colliery centralized Control machine room (with host computer).In significant points such as pump house, every emulsification pump and emulsification liquid pools camera is installed, operating personnel can carry out intuitive monitoring to machine room panorama and equipment operation condition.
(11) soft start and soft stop function
Utilize frequency converter originally in the characteristic that starts and the stopped process medium frequency progressively raises or reduces, realize the soft start and the soft stop of emulsification pump.When emulsification pump started, frequency converter frequency progressively was increased to power frequency by zero, and motor speed is also corresponding progressively to raise; When stopping emulsification pump, the frequency converter output frequency progressively reduces to zero, and rotating speed of motor also progressively reduces to zero.The soft start of emulsification pump and soft stop process have been avoided electric and mechanical shock, have reduced energy consumption.
Two, main innovate point
The development of this unit has mainly realized following innovation:
(1) theory innovation
Proposed " feed flow big system equalization theoretical ", and derived " unbalanced " with liquid systems flow rate calculation formula.
The feed flow unit is that intermittence is used the liquid principle based on each face timbering under the coal mine, has proposed " feed flow big system equalization theoretical ", and has derived " unbalanced with liquid systems flow theory design formulas " (calculating formula is seen before and stated).This calculating formula is applicable to the designing and calculating of colliery central liquid supply system flow and emulsification pump installed capacity, sets up central liquid supply system for the colliery and has established theoretical foundation.Use the central liquid supply system of this formula design to meet objective reality, the installed capacity of equipment significantly reduces.
Coal mining face timbering operation is that intermittence is used liquid, and is big with the randomness of liquid, " one side one system " the distributing liquid-supplying system that adopts before this; When lectotype selection, the installed capacity of emulsification pump confirms according to satisfying maximum flow and the pressure during with liquid of work plane operation, therefore; The phenomenon of " low load with strong power " often appears in selected device, and the equipment in use overwhelming majority is in underloading or no-load running state the times, has wasted electric energy; Mechanical wear is big, and the equipment purchasing expense is high.This project has proposed " the big system equalization of feed flow is theoretical ", and utilizes the balanced principle of big system feed flow to draw " unbalanced with liquid systems flow theory design formulas ", has solved the computational problem of central liquid supply system installed capacity.
Algorithm thinking: regard the central fluid supply pipe network as an airtight pressure vessel.Emulsion decrement under high pressure depends on its modulus of elasticity, though emulsion has very little compression ratio, its volume is big more, and pressure is high more, and the volume of release is many more, and is strong more to the ftercompction ability of system.When work plane was used liquid, system did not depend merely on the emulsification pump delivery to replenishing of fluid volume and to guarantee, discharged and the coefficient result of emulsification pump feed flow and accumulator fluid infusion but expand at system's emulsion.Like this, the system pressure excursion reduces.According to this principle, liquid-supplying system is bigger, pressure is high more, and the self-adjusting ability of emulsion pressure is strong more, and liquid-supplying system pressure is more stable.Therefore, the central system system has pressure equalizing property preferably, with respect to the distributing liquid-supplying system, can significantly reduce the installed capacity of emulsification pump, and system pressure stability improves.
(2) application innovation
1. accumulator is applied to the liquid-supplying system fluid infusion, and derives the accumulator fluid replacement formula.
[0084]Usually, accumulator mainly works to reduce compression shock in hydraulic system.This project is used for accumulator system is carried out fluid infusion, and derives the design formulas of hydraulic accumulator amount infused, has expanded the purposes of accumulator, utilizes accumulator fluid infusion function simultaneously, significantly reduces the installed capacity of emulsification pump.
Accumulator fluid infusion basic principle is: less or during without liquid, accumulator carries out accumulation of energy when each work plane fluid volume of down-hole; When system's fluid volume during greater than the emulsification pump delivery, accumulator replenishes emulsion to system.According to Boyle's law, the gas of certain mass, when temperature remained unchanged, the product of its pressure p and volume V equaled constant.The liquid measure that the bag type accumulator compressed nitrogen discharges when being reduced to 95% (liquid-supplying system pressure allows fluctuation range) by setting pressure is 5% of an accumulator nominal capacity, and then accumulator volume is V
1=5 Q
,* 10
-2As the amount infused Q that has confirmed system
,The time, just can calculate accumulator volume.
2. with ground central fluid supply form, replace original down-hole distributing feed flow form
This unit is installed on the ground machine room; To the down-hole feed flow, realized the change of " replacing the down-hole " and " many " functions and form with a centralized equipment, expanded the function and the range of application of equipment with generation with ground; Improved functional performance; Reduced the initial investment of equipment and the maintenance cost in the use, the installed capacity of equipment reduces greatly, and power saving rate is high.
The basic principle that realizes:
Near the surface plant well head of ground, the central fluid supply machine room is set, a feed flow unit is installed in the machine room, two emulsification pumps are installed on the unit, a worker one is equipped with.Emulsification pump becomes emulsion pressurization in the emulsification tank into high-pressure emulsion, with constant compression force to delivered downhole.Lay main feed flow pipeline and branch line in the down-hole, high-pressure emulsion is delivered to each work plane, as the hydraulic power of support.Like this, the distributing feed flow that has replaced the former installation of mining face under mine with the central fluid supply form.
3. the frequency conversion automatic control technology is applied to the feed flow unit
The original emulsion power pack in colliery is because be installed in mining face under mine, and environment for use is poor, receives the restriction of condition such as explosion-proof simultaneously, all adopts simple manual control mode.This unit is installed in ground, for condition has been created in the automation control of equipment.This project adopts frequency conversion and automated control technology that unit is controlled; Realize the remote-controlled operation and the monitoring of constant-pressure liquid supply and equipment, not only improved the feed flow quality, significantly reduced power consumption simultaneously; Save the machine room duty personnel, improved the Coal Production automatization level.
The basic principle that realizes:
Unit is provided with the frequency conversion automatic control system, and the control system mainly is made up of frequency converter, PLC controller, peripheral various sensors and host computer.Frequency converter is used for the control to the emulsification pump motor speed.With the PLC controller is that the control core system controls the operation and the automatic liquid matching of unit.Host computer is located at the colliery centralized-control center.PLC and host computer link with Ethernet protocol, and control The software adopted Siemens professional version is write main program and adopted winCC to write the configuration interface, form on the spot and remote communication and control.The control system mainly realizes the controls such as automatic startup-shutdown, constant voltage, automatic liquid matching and various protections to unit.
Various sensors such as field erected pressure, liquid level, concentration, electric current, voltage with the signal conveys that detects to PLC; PLC carries out computing and processing according to the rule of predesignating to signal; It is exported signal on the one hand and realizes the control to various executing agencies; Transmit signals to host computer simultaneously, realize the far-end supervision.The host computer and the on-the-spot PLC that are installed in the mine centralized-control center adopt the ethernet communication agreement to link, and operating personnel realize the control to site plant through host computer.Be installed in on-the-spot switch board and be provided with touch-screen and various changeover switch and button; On touch-screen, can realize to realize execute-in-place through changeover switch and button to equipment to the various operations of equipment with to the setting of each controlling parameter and fault inquiry etc.
The main effect that obtains:
(1) " feed flow as required " and " constant-pressure liquid supply " have been realized.Little or during without liquid, emulsification pump is in the slow-speed of revolution or stopped status when the work plane fluid volume; When the down-hole fluid volume increases, the corresponding raising of emulsification pump rotating speed; When system's fluid volume surpassed the emulsification pump delivery, accumulator carried out fluid infusion to system.Like this, just remained the constant of liquid supply pressure.(2) practiced thrift the emulsification pump duty personnel.After adopting central fluid supply and controlling automatically, the down-hole operator has been reduced in the colliery, has practiced thrift cost of labor, has improved personnel's safety guarantee degree.(3) improved the colliery automaticity, through rationally setting the start/stop time of emulsification pump, accomplished to keep away the peak simultaneously with regard to the paddy electricity consumption.
(3) technological innovation
1. successfully solve fully-mechanized mining working low pressure emulsion and reclaimed multiplexing technical barrier
Before this, why emulsification pumping plant in colliery is arranged on mining face under mine for a long time, and one of them most important reason is exactly to solve the problem that fully-mechanized mining working low pressure emulsion reclaims.This project proposes in liquid-supplying system, to be provided with back liquid pipeline and reinstalls the auxiliary water booster system of liquid with adding, and solves the recycling problem of work plane low pressure emulsion preferably, and making the emulsification pumping plant move to ground becomes possibility.
Basic principle:
Emulsion reclaim line system is set in liquid-supplying system.Liquid back pipe and woven hose are laid with the path, select seamless steel pipe for use, and pipeline adopts the quick connected mode of mining K type joint, caliber should >=with the caliber of path woven hose.This project has proposed two kinds and has returned the liquid mode: the one, directly return the mode of liquid, and promptly the discrepancy in elevation is installed when being not more than 200m apart from ground pump station at work plane, can directly work plane low pressure emulsion be led back the ground emulsification tank through liquid back pipe.This mode is relatively simple; The 2nd, when work plane is installed the discrepancy in elevation greater than 200m apart from ground pump station, when laying back liquid pipeline, the auxiliary water booster system of liquid need be set back also, emulsion liquid return tank and force (forcing) pump promptly are set at the bottom of auxiliary shaft.The low pressure emulsion of each work plane imports the liquid return tank of auxiliary water booster system earlier through liquid back pipe, again through being delivered to the ground emulsification tank after the auxiliary pump pressurization.Auxiliary force (forcing) pump adopts the automatic control of liquid start-stop.
The main effect that obtains:
(1) solved the multiplexing problem of recovery of fully-mechanized mining working low pressure emulsion, the ground central liquid supply system is applied in each colliery, the whole nation becomes possibility, simultaneously, has practiced thrift the emulsification oil consumption, has reduced the Coal Production cost;
(2) utilize present principles can solve the colliery other with liquid installations and facilities (like hydraulic prop, coal road support, hydraulic drill rig, behaviour's truck system etc.) with the multiplexing problem of recovery of returning liquid in the liquid process, for colliery applying high voltage emulsion power source has been opened up bright prospects.
(2) solved the remote conveying technology problem of high-pressure emulsion
Emulsion pressure reaches more than the 30MPa usually in the liquid-supplying system, and fed distance is generally thousands of rice.This project has solved technical barriers such as pipeline compressive resistance in the emulsion course of conveying, leakage, linear loss and down-hole dismounting, has widened ground central fluid supply technical application scope.
Realize basic principle:
1. rationally select conveying tubing for use.Should adopt the 16Mn steel high pressure seamless pipe from ground to each main line with the liquid place.For ease of installing and moving, adopt the selection for pipeline high-pressure rubber pipe assembly in the face;
2. rationally select caliber for use.Adopt big-diameter pipeline to carry highly pressurised liquid certainly will cause pipe thickness to increase, construction cost increases, and makes troubles for simultaneously installation, dismounting and the carrying of pipeline.This project utilizes work plane to be equalizing characteristics and the principle of gap with liquid, little with flow quantity of big system; The computational methods of employing science are selected caliber for use; Make selected caliber very little (its internal diameter maximum is no more than 50mm), meet service condition under the coal mine, reduced the construction cost of liquid-supplying system.
3. select suitable union form
Reliability that this project connects from pipeline and installation, dismounting convenience, the snap joint of high pressure KJ2 type is all selected in the connection between the pipe for use.The withstand voltage height of this kind joint form (nominal pressure reaches as high as 100MPa), installation and removal are very convenient, are applicable to that subsurface environment uses.Welding manner (annotate: weld seam must good groove, and weld strength must not be lower than steel pipe itself) is adopted in steel pipe and the snap joint of KJ2 type.Adopt face inner high voltage rubber tube assembly itself and have the snap joint of KJ2 type, need not select joint else.
(4) structure innovation
1. the traditional emulsification pumping plant of the modular integrated mounting means of whole machine using adopts split type layout and mounting means; Emulsification pump, emulsification tank, control valve etc. are and respectively are one in the system, and floor space is big, and the interior stringing of machine room (or chamber) is many; Line loss is big; Apparatus arrangement is mixed and disorderly, is not easy to centralized Control, and influences machine room and carry out production strictly in line with rules and regulations.This unit adopts modular integrated mounting means, and equipment volume is reduced, and the installation floor space is little, the equipment good looking appearance, and system's hydraulic slip reduces.Simultaneously, all parts adopt modularized design to be convenient to standardization and generalization, are convenient to maintenance, dismounting and transportation;
2. the design of multi-functional, big capacity emulsion box
This project is in strict accordance with the universal standard of coal mine equipment, designs perfect in shape and function, security reliability is high, versatility is good, maintenance is easy to use, structure is attractive in appearance emulsion box.
The main feature of emulsification tank:
1. multiple functional.Installed the emulsion automatic liquid mixing system additional, realized automatic liquid matching, guaranteed that emulsification liquid measure and concentration meet the setting requirement;
2. all annex spares are installed on the casing, and good integrity is attractive in appearance.
Three, performance analysis
Coal industry is one of pillar industry of China.Emulsification liquid-supplying system in colliery plays crucial effect to guaranteeing the colliery ordinary production.The development of this product has solved the multinomial technical barrier that emulsification liquid-supplying system in colliery exists; Expanded ground central fluid supply The Application of Technology; Simultaneously through measures such as technological innovation, optimizing equipment structures, integrated, standardization, seriation and the miniaturization of equipment have been realized.Along with this product will produce huge economic and social benefit applying of each colliery of China.Make a concrete analysis of as follows:
(1) power savings is remarkable
Existing serves as the examination object with single medium size coal mine, analyzes power savings to use unit feed flow and original distributing liquid-supplying system to make comparisons:
1. comparison condition:
When (1) using the unit feed flow, can the emulsification pump installed capacity in colliery be reduced more than 80%, get 80% here;
(2) two kinds of feed liquid way available machine time basically identicals take away the machine time here to equate;
(3) rate of load condensate of distributing feed liquid way emulsification pump is about 10%, gets 10% here; Adopting unit feed flow emulsification pump rate of load condensate is about 60%, gets 60% here.
2. the power consumption of every day calculates as follows when disperseing feed flow:
The installed capacity of supposing colliery former employing distributing feed flow emulsification pump is N (KW), and emulsification pump running time is t (h), and then the electricity consumption total amount of every day is:
W
1=W
Unloaded+ W
Load
＝0.4×N×（1－0.1）t＋N×（1－0.9）t
＝0.46Nt(KWh)
In the formula:
W
1The electricity consumption total amount (KWh) of-full ore deposit emulsification pump every day;
W
UnloadedThe electricity consumption total amount (KWh) of-full ore deposit emulsification pump no-load running;
W
LoadThe electricity consumption total amount (KWh) of-full ore deposit emulsification pump load running;
The installation total capacity (KW) of the full ore deposit of N-emulsification pump;
T-emulsification pump running time every day (h);
0.4-emulsification pump no-load running consumption rate.
3. the power consumption of every day calculates as follows when adopting the unit feed flow:
W
2=W
Unloaded ,+ W
Load ,
＝0.4×（1－0.8）N×（1－0.6）t＋（1－0.8）N×（1－0.4）t
＝0.152Nt(KWh)
In the formula:
W
2The power consumption (KWh) of-unit every day;
W
Unloaded ,The power consumption of-unit no-load running (KWh);
W
Load ,The power consumption of-unit load running (KWh);
The installation total capacity (KW) of N-distributing feed flow emulsification pump;
T-emulsification pump running time every day (h);
0.4-emulsification pump no-load running consumption rate.
4. adopt the power saving rate of unit feed flow to calculate as follows:
η＝
＝
＝67%
5. single colliery Spring Festival holidays electric weight calculates
Suppose that the installed capacity of emulsification pump was 375KW when distributing feed flow was adopted in certain colliery, emulsification pump running time every day is 18 hours, and then annual power consumption does
W
1 ，＝0.46×330×N×t＝0.46×330×375×18＝1024650KWh
Amount of electricity saving behind the employing feed flow unit is:
ΔW=0.67×W
1 ，=0.67×1024650=686515?KWh
6. apply the amount of electricity saving estimation of this technology in each colliery, the whole nation
China has about 2.8 ten thousand of colliery at present, then adopt this technology after, but whole nation save electricity is:
ΔW
，＝28000×ΔW＝28000×686515＝192×10
8?KWh
(2) other performance analyses
1. equipment is installed on ground, and takes the converting operation mode, and the wearing and tearing and the spoilage of feed flow equipment reduce greatly; Prolong 6～10 times the application life of emulsification pump; Calculate by single colliery, can be the colliery every year and practice thrift 200,000 yuan of original equipment cost average out tos, 5,600,000,000 yuan of total costs are practiced thrift in then national colliery.
2. after the emulsification pumping plant moved to ground, the environment for use of equipment had obtained very big improvement, brought great convenience for simultaneously the maintaining of equipment, and on average each colliery year is practiced thrift about 100,000 yuan of maintenance cost, and 2,800,000,000 yuan of total costs are practiced thrift in then national colliery.
3. on average about 12 people of down-hole emulsification pump duty personnel, about 360,000 yuan of annual saving personnel wage are reduced in each colliery;
4. guaranteed the emulsion quality, prolonged the top overhaul cycle and the application life of hydraulic support, individual prop, on average each colliery year is practiced thrift maintenance cost about 400,000 yuan.
5. after the emulsification pumping plant moves to ground, reduced colliery downhole operations and attendant, Safety of Coal Mine Production guarantee degree improves, and has eliminated the influence to subsurface environment such as the greasy dirt that the emulsification pumping station operation produces, noise, heat, pernicious gas simultaneously.
6. the colliery of only using the hydraulic prop supporting for part; Because the natural pressure that ground pump station and mining face under mine elevation difference form; Can significantly reduce the emulsification pump outlet pressure; Make emulsification pump be in a kind of light running state, its power consumption further reduces, and service life of equipment further prolongs.
7. along with the foundation of coal mine ground central liquid supply system, built the application platform that hydraulic pressure of the colliery can be carried.Can predict; Along with improving constantly of coal mine machinery degree; Not nonoculture of high-pressure emulsion is the power source of comprehensive mining hydraulic bracket and hydraulic prop; Also will be used for other hydraulic test facilities of down-hole (like shaft bottom, well head behaviour truck system, coal road hydraulic support etc.), this will further advance the extensive use of colliery emulsification hydraulic pressure installations and facilities.The emulsion pressure energy is safe and reliable with it, have wide range of applications, easy to use, advantage such as medium is cheap, unit volume medium transmitted power is big, with same electric energy, blast can be the same, constitutes the major impetus source in colliery jointly.
Four, production development and prospect Analysis
(1) coal plays irreplaceable effect as nonrenewable resources in using energy source.Predict that in the regular period in the future, along with China's economic development, market is still in rising trend to the demand of coal.Colliery emulsification pump liquid-supplying system is one of essential corollary system in the Coal Production process, and the colliery liquid-supplying system is integrated, seriation, standardization are of great significance to ensureing the colliery ordinary production, are the imbodies of colliery technological progress.The development of this product has been filled up China in this blank on the one hand, is the significant incident that the China's coal-mine equipment improves;
(2) before this; We use this know-why, have developed initial production, and are installed in the angle slope and justice loyal two collieries use of Hunan, Guizhou ability Industrial Co., Ltd.; Result of use is fine; All prove the correctness of this technology to have very strong practicality from theory and practice, have very big development space and application prospect;
(3) this unit has obvious energy-saving effect, meets the energy-saving and emission-reduction policy and the requirement of using new technology, new material, new equipment of the current promotion of China.Using feed flow unit feed flow is that energy-conservation the carrying of coal mining enterprise imitated very effective measures.Can predict, this technology will be applied in each colliery, the whole nation rapidly.
More than show and described basic principle of the present invention, principal character and advantage of the present invention.The technician of the industry should understand; The present invention is not restricted to the described embodiments; That describes in the foregoing description and the manual just explains principle of the present invention; Under the prerequisite that does not break away from spirit and scope of the invention, the present invention also has various changes and modifications, and these variations and improvement all fall in the scope of the invention that requires protection.The protection domain that requires of the present invention is defined by appending claims and equivalent thereof.
Claims (4)
1. mining energy-efficient emulsification feed flow unit comprises main feed flow module, automatic liquid matching module, electrical control module and work plane, it is characterized in that
Shown in main feed flow module comprise that high pressure divides gate valve, high pressure total gate valve, accumulator, main emulsifying pump, liquid inlet control valve, strainer, safety valve, emulsion box, woven hose; The liquid feeding end of said main emulsifying pump connects strainer through liquid inlet control valve; Strainer is provided with in the emulsion box; The outlet end of main emulsifying pump, high pressure divide gate valve, accumulator, high pressure total gate valve to be connected successively with woven hose, and said woven hose is connected with feed flow pipe network on being laid on work plane;
Said automatic liquid matching module comprises water-delivery pump, outlet water control valve, oil-feed control valve, oil transfer pump, emulsion tank, feed cistern;
Said electrical control module comprises host computer, switch board, power cabinet, frequency converter, pressure sensor, liquid level sensor, concentration sensor; Said host computer connects the input of switch board through Ethernet; The input of switch board also connects pressure sensor, liquid level sensor and concentration sensor; The output of switch board connects water-delivery pump, oil transfer pump, main emulsifying pump, frequency converter, and said frequency converter connects main emulsifying pump; Said host computer is an Industrial Personal Computer (IPC).
2. mining energy-efficient emulsification feed flow unit according to claim 1 is characterized in that: be provided with PLC in the said switch board, said PLC adopts the PID computing.
3. mining energy-efficient emulsification feed flow unit according to claim 1; It is characterized in that: also comprise subsequent use feed flow module; Said subsequent use feed flow module comprises that subsequent use emulsification pump, high pressure divide gate valve, liquid inlet control valve, strainer, safety valve; Said subsequent use emulsification pump connects the output and the frequency converter of switch board respectively; The liquid feeding end of subsequent use emulsification pump connects strainer through liquid inlet control valve, and strainer is provided with in the emulsion box, and the outlet end of subsequent use emulsification pump, high pressure divide gate valve, pressure sensor and high pressure total gate valve to be connected successively.
4. according to claim 1 or 3 described mining energy-efficient emulsification feed flow units; It is characterized in that: also comprise recycling module; Said recycling module comprises the oil return pond, returns liquid force (forcing) pump, liquid back pipe; Said oil return pond is connected with feed flow pipe network on being laid on work plane, said oil return pond, return the liquid force (forcing) pump, liquid back pipe is connected with emulsion box successively.
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Cited By (18)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103100334A (en) * | 2013-02-28 | 2013-05-15 | 徐州五洋科技股份有限公司 | Emulsified liquid supplying system for underground coal mine |
| CN103174634A (en) * | 2013-03-27 | 2013-06-26 | 张会珍 | Intelligent control system and control method of emulsion pump station |
| CN103629529A (en) * | 2013-12-10 | 2014-03-12 | 郑州煤机综机设备有限公司 | High-pressure fluid control device for mechanized mine |
| CN106286438A (en) * | 2016-09-20 | 2017-01-04 | 山西汾西矿业（集团）有限责任公司 | Fully-mechanized mining working emulsion pump constant-pressure liquid supply system and control method thereof |
| CN108302096A (en) * | 2018-02-01 | 2018-07-20 | 广州光谷机电科技有限公司 | A kind of hydraulic pressure control device and method |
| CN108591636A (en) * | 2018-06-19 | 2018-09-28 | 河北西伯力特种橡胶有限公司 | Electro-hydraulic long-range feed flow super-pressure flexible pipe of control of high-wear-resistance mining heavy caliber and preparation method thereof |
| CN108916144A (en) * | 2018-07-04 | 2018-11-30 | 北京航天发射技术研究所 | A kind of dynamic hydraulic combined oil supply system |
| CN108916153A (en) * | 2018-07-05 | 2018-11-30 | 北京航天发射技术研究所 | It is a kind of for lifting the gas drive Oil-source control method and system of Multi-stage cylinder |
| CN110067585A (en) * | 2019-05-23 | 2019-07-30 | 青岛同创管道***有限公司 | Remote central liquid supply system, control method and its assembling repair method |
| CN110424997A (en) * | 2019-07-31 | 2019-11-08 | 太原理工大学 | Method of the prediction work face hydraulic bracket system with machine speed and hydraulic stability |
| CN110741263A (en) * | 2017-06-30 | 2020-01-31 | 深圳迈瑞生物医疗电子股份有限公司 | Liquid supply device, sample analyzer and liquid supply method |
| CN112432057A (en) * | 2020-10-29 | 2021-03-02 | 上海五航航空技术有限公司 | Remote liquid supply system for fully mechanized coal mining face of coal mine |
| CN113123829A (en) * | 2021-03-19 | 2021-07-16 | 北京天地玛珂电液控制***有限公司 | Centralized liquid supply system |
| CN113236313A (en) * | 2021-06-04 | 2021-08-10 | 煤炭科学研究总院 | Hydraulic system and hydraulic support |
| CN113250727A (en) * | 2021-05-08 | 2021-08-13 | 中煤科工开采研究院有限公司 | Low back pressure return fluid pipeline control system |
| CN113339025A (en) * | 2021-06-04 | 2021-09-03 | 煤炭科学研究总院 | Hydraulic system and hydraulic support group |
| CN113441024A (en) * | 2021-06-29 | 2021-09-28 | 东风本田汽车零部件有限公司 | Centralized liquid supply system |
| CN113719307A (en) * | 2021-07-28 | 2021-11-30 | 中国矿业大学 | Intelligent liquid supply system for hydraulic support and working method |
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|---|---|---|---|---|
| CN103100334B (en) * | 2013-02-28 | 2015-03-25 | 徐州五洋科技股份有限公司 | Emulsified liquid supplying system for underground coal mine |
| CN103100334A (en) * | 2013-02-28 | 2013-05-15 | 徐州五洋科技股份有限公司 | Emulsified liquid supplying system for underground coal mine |
| CN103174634A (en) * | 2013-03-27 | 2013-06-26 | 张会珍 | Intelligent control system and control method of emulsion pump station |
| CN103174634B (en) * | 2013-03-27 | 2015-08-12 | 北京中矿赛力贝特科技有限公司 | A kind of emulsion power pack intelligent control system and controlling method |
| CN103629529A (en) * | 2013-12-10 | 2014-03-12 | 郑州煤机综机设备有限公司 | High-pressure fluid control device for mechanized mine |
| CN106286438A (en) * | 2016-09-20 | 2017-01-04 | 山西汾西矿业（集团）有限责任公司 | Fully-mechanized mining working emulsion pump constant-pressure liquid supply system and control method thereof |
| CN110741263A (en) * | 2017-06-30 | 2020-01-31 | 深圳迈瑞生物医疗电子股份有限公司 | Liquid supply device, sample analyzer and liquid supply method |
| CN110741263B (en) * | 2017-06-30 | 2023-12-01 | 深圳迈瑞生物医疗电子股份有限公司 | Liquid supply device, sample analyzer and liquid supply method |
| CN108302096A (en) * | 2018-02-01 | 2018-07-20 | 广州光谷机电科技有限公司 | A kind of hydraulic pressure control device and method |
| CN108591636A (en) * | 2018-06-19 | 2018-09-28 | 河北西伯力特种橡胶有限公司 | Electro-hydraulic long-range feed flow super-pressure flexible pipe of control of high-wear-resistance mining heavy caliber and preparation method thereof |
| CN108916144A (en) * | 2018-07-04 | 2018-11-30 | 北京航天发射技术研究所 | A kind of dynamic hydraulic combined oil supply system |
| CN108916153A (en) * | 2018-07-05 | 2018-11-30 | 北京航天发射技术研究所 | It is a kind of for lifting the gas drive Oil-source control method and system of Multi-stage cylinder |
| CN110067585A (en) * | 2019-05-23 | 2019-07-30 | 青岛同创管道***有限公司 | Remote central liquid supply system, control method and its assembling repair method |
| CN110424997A (en) * | 2019-07-31 | 2019-11-08 | 太原理工大学 | Method of the prediction work face hydraulic bracket system with machine speed and hydraulic stability |
| CN112432057A (en) * | 2020-10-29 | 2021-03-02 | 上海五航航空技术有限公司 | Remote liquid supply system for fully mechanized coal mining face of coal mine |
| CN113123829A (en) * | 2021-03-19 | 2021-07-16 | 北京天地玛珂电液控制***有限公司 | Centralized liquid supply system |
| CN113123829B (en) * | 2021-03-19 | 2023-08-04 | 北京天玛智控科技股份有限公司 | Centralized liquid supply system |
| CN113250727A (en) * | 2021-05-08 | 2021-08-13 | 中煤科工开采研究院有限公司 | Low back pressure return fluid pipeline control system |
| CN113236313A (en) * | 2021-06-04 | 2021-08-10 | 煤炭科学研究总院 | Hydraulic system and hydraulic support |
| CN113339025A (en) * | 2021-06-04 | 2021-09-03 | 煤炭科学研究总院 | Hydraulic system and hydraulic support group |
| CN113441024A (en) * | 2021-06-29 | 2021-09-28 | 东风本田汽车零部件有限公司 | Centralized liquid supply system |
| CN113719307A (en) * | 2021-07-28 | 2021-11-30 | 中国矿业大学 | Intelligent liquid supply system for hydraulic support and working method |
| CN113719307B (en) * | 2021-07-28 | 2022-05-03 | 中国矿业大学 | Intelligent liquid supply system of hydraulic support and working method |
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