The main pump in the overflow dyeing machine plays a crucial role in generating a specific pressure and flow of water, which is then directed through nozzles to circulate the fabric during the dyeing process. Different fabric weights require varying levels of pressure and flow to ensure optimal performance. Currently, this adjustment is made by manually regulating the outlet valve of the pump. However, since we only operate at the end weight of the fabric, the valve is typically opened only about 30%, leading to significant energy waste—approximately 80% of the energy is lost through the valve, based on fluid mechanics principles and pump characteristics.
For example, in the MK8C-1LT high-temperature dyeing machine, the current operating current of the main pump is 24A. The annual operating cost under this setup can be calculated as follows:
**Current Annual Operating Cost:**
12 kW × 20 hours/day × 340 days/year × 0.7 yuan/kWh = 57,120 yuan
After implementing a VLT frequency conversion system, the power consumption is significantly reduced. The flow rate is adjusted to 50% of the original design flow, and since power is proportional to the cube of the flow rate, the power requirement drops by 50%³ (or 12.5%). Therefore, the new annual operating cost becomes:
**Post-Transformation Annual Operating Cost:**
12 kW × 50% (flow) × 50% (speed) × 50% (power) × 20 hours/day × 340 days/year × 0.7 yuan/kWh = 7,140 yuan
**Annual Savings:**
57,120 yuan - 7,140 yuan = **49,980 yuan**
The initial investment for this project was 22,000 yuan, making the return on investment very attractive. Based on this principle, between June 2002 and September 2003, five dyeing machines and one overflow sub-bleach machine were retrofitted with VLT frequency drives. The total power reduction amounted to 112 kW, and with conservative estimates, the annual savings reached approximately 270,000 yuan, with an initial investment of just 135,000 yuan.
This transformation not only improved energy efficiency but also contributed to long-term cost savings and environmental sustainability. It’s a clear example of how modern technology can optimize traditional industrial processes.
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