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 different levels of pressure and flow to ensure optimal performance. Currently, this adjustment is made by manually regulating the pump's outlet valve. However, since the fabric weight is known at the end of the process, the valve is often only opened to about 30%, leading to significant energy waste—approximately 80% of the energy is lost through the valve. This inefficiency is due to the principles of fluid mechanics and the pump’s characteristic curve.
For example, in the MK8C-1LT high-temperature dyeing machine, the current operating current of the main pump is 24A. Based on this, the annual operating cost can be calculated as follows:
**Current Annual Cost:**
12 kW × 20 hours × 340 days × 0.7 yuan/kWh = 57,120 yuan (assuming a 0.85 efficiency factor).
After implementing a VLT frequency conversion system, the energy consumption is significantly reduced. The new power consumption is calculated based on the fact that the flow rate is reduced to 50% of the original design flow, and since power is proportional to the cube of the flow, the power requirement drops to 12.5% of the original. Therefore, the new annual cost becomes:
**Post-Transformation Annual Cost:**
12 kW × 50% (flow) × 50% (speed) × 50% (power) × 20 hours × 340 days × 0.7 yuan/kWh = 7,140 yuan.
This results in an annual saving of:
**Annual Savings:**
57,120 yuan – 7,140 yuan = **49,980 yuan**.
The initial investment for this project was around 22,000 yuan, making the return on investment very attractive.
Applying the same principle between June 2002 and September 2003, a total of five dyeing machines and one overflow sub-bleach machine were retrofitted with frequency converters, resulting in a total power transformation of 112 kW. Conservatively, this led to annual savings of approximately 270,000 yuan, with an initial investment of just 135,000 yuan. The benefits are clear and highly impactful, proving that energy-efficient upgrades can lead to substantial long-term savings and improved operational efficiency.
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