1 In recent years, with the development of China's national economy, the proportion of energy demand has increased sharply. Electric energy has become more and more important as a widely used energy source. Among them, aluminum smelting enterprises account for a large proportion of electricity consumption, and advocate energy saving and high efficiency. It has become a main line of the development of factory lighting technology in aluminum electrolysis enterprises. It has improved the traditional lighting system, so that the lighting of aluminum electrolysis plant should not only meet the requirements of users but also have energy-saving effects. This is an important development of energy saving and emission reduction work for aluminum electrolysis enterprises. direction. The two electrolysis plants of 260 160 kA prebaked aluminum electrolysis cells in our first phase are arranged vertically. The roof of the plant is a single-pass inclined factory. The length of each workshop is 953.3 m, the width is 21 m, and the minimum short height of the steel roof of the factory. It is + 10. 60 m, the highest short height is 13.00 m, and the area of ​​each workshop is: 20 019. 3 m2. The working environment of the electrolysis plant is high dust and harmful gases such as HF. Since the design time of the factory was around 1984, due to the limitation of the lighting design technology of the factory at that time, each factory lighting was arranged in two rows in the longitudinal direction, and installed at the flue end and the aluminum end at intervals of about 6 575 mm according to the position of the roof steel beam of the plant. 2ç›450W self-ballasted mercury lamps, plus channel lighting, a factory has a total of 321 lamps, a total of 643 两个 two plants. Since the lamps of the self-ballasted mercury lamp do not have any sealing measures, the surface of the bulb and the reflective layer on the inner surface of the lampshade are seriously ashed, which greatly reduces the luminous flux reaching the electrolyzed ground. According to the actual measurement, the average illumination of the working face of the factory is only 7 6~8 lux; at the same time, the lampshade of this type is extremely easy to damage, causing the bulb to have no reflector for collecting light downwards, so that some of the light is wasted to the ceiling of the plant and wasted electric energy; compared with the new energy-saving lamp Larger and shorter life. In order to further reduce energy consumption, the staff is provided with a comfortable working environment, and the lighting system of the first-stage electrolysis plant is designed and modified.
2 lighting system renovation program
2. 1 choice of lamps
The function of the luminaire is to protect the light source and to form the required light output of the light source, and the luminaire should meet the requirements of the working environment. According to the layout of the electrolysis plant and the characteristics of the working environment of high dust and HF-containing gas, the aluminum electrolysis production is a visual feature of rough operation according to the requirements of the standard value of the illuminance on the work surface of the national workplace. The general illumination range is 20-50 lux. Requirements, the lighting system design uses 22-inch reflective suspension lamps, 400 W metal halide lamps (referred to as metal halide lamps), the luminous flux is selected at 32 000 lm.
The sealing level is above IP54. The ballast is installed in the sealed housing at the top of the lamp. The bottom of the lamp is sealed with 5 mm high temperature resistant tempered glass to ensure the luminous efficiency of the lamp and save the unit high maintenance cost. See the technical data comparison of self-ballasted high-pressure mercury lamps and high-pressure sodium lamps.
1Comparison of technical data of self-ballasted high pressure mercury lamp and metal halide lamp
2. 2 lamp arrangement
The layout of the lamps in the electrolysis plant is arranged by the original two lines, and the transformation design is arranged in a "Z" shape, as shown in Figure 1. The distance between each lamp in the electrolysis cell of the electrolysis plant is 19 m, and two lamps are installed at the channel of the electrolysis plant, so that the number of lamps in the two electrolysis plants is reduced to 244 ç›, which is 399 较 less than the original. However, due to the proper selection of lamps and reasonable layout, although the number of lamps in the electrolysis plant is reduced and the power is reduced, the illumination of the working face of the plant is increased. After the manufacturer's technicians use the relevant software to calculate, after using the above lighting renovation plan in the electrolysis workshop, the average illumination of the working face of the plant can reach 77 lux (Luke), as shown in Figure 2, the illuminance value meets the requirements of the electrolysis workshop. Although the illuminance value is low in the corner, due to the fact that there are 6 ç› 450 W self-ballasted mercury lamps at the crown of the crane for the production of lighting during the actual production of the electrolysing and aluminum extrusion work, it does not affect the operation. Brightness requirements.
2. 3 lighting system control
The lighting adopts two modes of time control/manual control. The time control is to ensure that the illumination is enabled or not according to the intensity of the lighting. It can avoid the premature waste of energy caused by the human participation setting, and the phenomenon that the lighting is affected too late; manual Controlling the inability to properly transmit power to prevent damage to the photosensitive element; adding a set of DL series intelligent lighting sections for inductive fluorescent lamps, electronic ballast fluorescent lamps and energy-saving lamps, high-pressure sodium lamps and other lamps at the front end of the control circuit The electric controller suppresses high-order chopping in the power grid and protects the control circuit.
3 Economic Benefit Analysis after Transformation
3. 1 cost of lamps
It can be seen from Table 1 that the gold halide light flux and lifetime are more than double that of the self-ballasted mercury bulb. The average lighting time of the electrolysis workshop is 12 h per night, 4 380 h a year. The mercury bulb can be used for 0.68 years, and the metal halide lamp can be used for 1.82 years. The mercury bulb (unit price is 55 yuan) is changed twice a year, and the metal halide lamp (unit price is 110 yuan) is calculated twice a year:
The cost of replacing a mercury bulb for two years is:
739 × 2 × 2 × 55 = 162 580 yuan replacement of metal halide lamps for two years is:
292 × 110 = 32 120 yuan two years to save costs 130,000 yuan.
3. 2 annual energy savings
The annual energy savings are:
[(739×0. 45) - (292×0. 40)]×12 h/d×365 d =944 985 kWh.
Calculated by lighting electricity of 0.25 yuan / kWh, annual electricity savings: 944 985 × 0. 25 = 236 246. 25 yuan.
If the above two items are combined, if the plan is reformed, the annual cost savings will be 7.6 million yuan.
4 Conclusion
Since the height of the aluminum electrolysis plant is generally about 12 m, and it belongs to the working environment of high dust and HF-containing gas, there is a major difference in the maintenance of the lamps compared with the usual office or fine-working workplaces. The lighting design should be changed and processed according to the nature and location of the work by the formal lighting design department. It not only emphasizes energy conservation, but also ensures the demand for lighting parameters of aluminum electrolysis to produce multiple light quantities, so as to truly provide a comfortable production environment for production workers and improve people's labor enthusiasm and enthusiasm.
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