Automation transformation can increase the comprehensive efficiency of waste heat power generation production lines by 15% to 35%. The actual increase depends on the automation foundation of the production line, the stability of waste heat resources, and the status of supporting equipment. 1. Core efficiency improvement path (1) Precise control of process parameters
Automatically adjust the valve opening and induced draft/supply fan speed of the waste heat recovery unit to control the inlet temperature and furnace pressure of the waste heat boiler within the optimal process range (error ± 0.5 ℃, ± 0.02MPa), reducing ineffective heat leakage and exhaust heat loss. This contribution accounts for 30% to 40% of the total improvement.
Automatically matching the steam turbine inlet flow rate with the waste heat output load, eliminating the 10-15 second lag of manual adjustment, and avoiding energy consumption fluctuations caused by frequent load changes in the turbine. This contribution accounts for 25% to 35% of the total increase. (2) Fault and operation optimization
Online monitoring of key parameters such as wall temperature of waste heat boiler, turbine vibration, and auxiliary current, automatic triggering of interlock protection, reducing unplanned shutdown time by 40% to 60%, and minimizing waste heat caused by shutdown.
Sensors replace manual inspections, reducing the missed detection rate from 10% to 15% to less than 2%, timely detecting hidden problems such as heat transfer scaling and seal leakage, and reducing energy consumption caused by hidden faults (accounting for about 5% to 10% of total energy consumption). 2, Limitations on efficiency improvement
Initial automation level: The transformation of fully manual production lines has increased by 25% to 35%, while the transformation of semi-automatic production lines has increased by about 15% to 25%.
Waste heat stability: When the fluctuation amplitude of waste heat is greater than ± 20%, a flexible control system is required, otherwise the improvement amplitude will be reduced to 10%~15%.
Equipment service life: When the basic hardware service exceeds 10 years, sensors and actuators need to be upgraded synchronously, otherwise the renovation increase will be reduced by about 10%.
