Foundry Electrochemical Analysis Plant Illuminates Environmental Innovation

1 problems and causes analysis

(1) Since the self-ballasted mercury lamp used on the 311 m platform of the 20,000 m old workshop in the electrolytic copper workshop has a power of 450 W, the bulb itself has a high wattage and a large number of uses, resulting in an increase in total power (1117 kW). The power is large.

(2) The amount of mercury lamps used in the field is large but the illuminance is not obtained. This is caused by the light failure of the lamps themselves, the failure to replace them in time due to the problem of the light bulbs, and the lack of uniformity of the light on the spot and the light fog on the site.

(3) The mercury lamp in the workshop does not have any degree of protection. The acid mist in the workshop directly corrodes the bulb, the lamp socket and the wire, and the high temperature generated in the production process of the workshop also aggravates the damage speed of the bulb, and finally causes mercury. The lamp is seriously damaged, which increases maintenance and increases maintenance costs.

(4) The bulbs used are all replaced by the interior of the workshop, with more maintenance in the later period, frequent maintenance of workers, increased time spent on maintenance lighting, and affecting normal production time and reducing work efficiency.

(5) In the production process of the electrolytic copper workshop, the temperature of the electrolyte should be controlled at 60-65 °C, and a light source with strong fog penetration force is needed to meet the work. When the temperature outside the workshop is lower than that in the workshop or cloudy days The accumulation of a large amount of mist in the factory will cause operational errors and inconveniences, which may cause safety accidents.

2 transformation plan

211 standard

According to the average illuminance value of 50LX of the 20,000t old workshop in the electrolytic copper workshop, the standard illuminance recommended by the CIE International Lighting Commission is 50-200LX.

212 lamp performance selection

(1) The corrosive acid mist in the plant has high requirements on the protection level of the lamp, and it needs to be fully sealed. The protection level should reach IP65 or above, waterproof and dustproof. Taking into account the requirements of the acid mist inside the workshop on the anti-corrosion level of the luminaire, the optimised structural design and high-tech spraying technology luminaires should be used. The anti-corrosion grade should reach WF2, which can be used for a long time in harsh environments such as high temperature, humidity and corrosive. .

(2) The electrolytic copper workshop needs a light source with strong fog penetration to meet the working requirements. Because the temperature outside the workshop is lower than that in the workshop or when it rains in the cloudy day, a large amount of mist will accumulate in the workshop, resulting in operational errors and inconveniences, increasing the rate of product defects, reducing work efficiency, and easily causing safety accidents. Therefore, when selecting a light source, it is necessary to select a high-pressure sodium lamp that has a strong penetrating power.

(3) The radiation surface of the floodlight should be large, so as to reduce the number of lamps, reduce the total power of the lamps and save energy, and the maintenance and maintenance costs can be greatly reduced.

213 selection of lighting features

According to the requirements of the above environment for the lamps, the NSC9700 (250 W) anti-glare path lamp developed and produced by a company in Shenzhen was selected.

The main features of the luminaire are applicable to the environment: (1) The protection angle design and the mirror coating technology can effectively prevent glare, avoid eye fatigue caused by long-term work under this light, ensure safety and improve work efficiency.

(2) The diffuse reflection technology and the protection angle design can effectively prevent glare; at the same time, nano photocatalyst glass can be used to automatically decompose surface stains, and the light transmission effect can be maintained in a humid and dusty environment.

(3) Optimized structural design, high-strength aluminum alloy casing and special sealing and surface coating treatment, can be used for a long time in high temperature, humidity, dusty and corrosive environment.

(4) The radiation range of the luminaire is 135 degree angle flooding, and the radiation range can reach three 6 m spans. Increasing the radiation range reduces the number of luminaires while reducing the amount of luminaire maintenance.

(5) Effective heat dissipation structure and sealing and anti-corrosion treatment increase the reliability of the lamp and reduce the failure rate.

(6) The lamp adopts full-closed process design, the protection grade is IP65, waterproof and dustproof, and can be used reliably in all kinds of bad fog environment; the lamp adopts optimized structural design and high-tech spraying technology, anti-corrosion grade is WF2, corrosion resistance, resistance High temperature, long-term use in a variety of acid mist, salt spray and other harsh environments, never corroded, never rust.

214 installation method

(1) The ceiling-mounted installation method is adopted, and the interval between the lamps is 12 m, and the type of the characters is arranged to ensure uniform light source.

(2) Cables with different diameters of <10~14 mm can be adapted according to the needs of the site, and multiple lamps can be used in parallel.

3 energy efficiency

After the transformation, if the average illuminance value of the 20,000-ton old workshop in the electrolytic copper workshop is 50LX, the calculation formula of the required number of lamps is average / 2/ 015 = 901850 / (21000 / 2) / 015 = 16 sets of E average - ―Average illuminance; The total power before transformation is 450 W×26 sets= 11 700 W. The total power after transformation is 250 W×16 sets= 4 000 W. The total power reduced before transformation is 717 kW.

The electricity price is based on the average value of 0148 yuan / kWh; the lighting time is 12 h / d, and the year is 330 days.

(1) The electricity consumption for the day before the renovation is 1117×12 = 14014 kWh, and the electricity cost for 6 years is 14014×330 days×6 years×0148 yuan= 133 436116 yuan (2) The electricity consumption for the day after the renovation is 4×12 = 48 kWh, 6 years electricity fee is 48 × 330 days × 6 years × 0148 yuan = 45 61912 yuan (3) 1 month before the renovation, the lamp consumption of the workshop is about 4 ,, the unit price is 30 yuan, one month of bulb consumption At around 120 yuan, the consumption in 6 years is 8 640 yuan; the average life of the modified sodium lamp source is 50,000 h, which can be used in 1114 according to the daily 12 h, but according to the specific environment of the plant, it only needs 6 years. Replace the bulb once (the price of the bulb is 185 yuan / only), the cost is 16 sets × 185 = 2 960 yuan.

(4) The cost of the renovation is: 16×2 000 yuan = 32 000 yuan. If the expenses of the 6 years are used to recover the cost of the lamps, the time for purchasing the lamps and lanterns will be recovered for 2 years.

4 Conclusion

Through scientific and reasonable design methods, high-efficiency lighting sources, lamps and electrical accessories can be used to save energy and improve work efficiency.