英威腾GD800变频器在有色行业氧化铝隔膜泵应用案例

<p style="line-height:150%"><strong><span style=";font-family:宋体;line-height:150%;font-size:14px">一、引言</span></strong></p><p style="text-indent:28px;line-height:150%"><span style=";font-family:宋体;line-height:150%;font-size:14px">隔膜泵是借助薄膜将被输液体与活柱和泵缸隔开，从而保护活柱和泵缸，是一种新型输送机械，是目前国内较新颖的一种泵类。对于各种腐蚀性液体，带颗粒的液体，高粘度、易挥发、易燃、剧毒的液体，均能予以抽光吸尽。隔膜泵有四种材质：</span><span style=";font-family:&#39;Times New Roman&#39;;line-height:150%;font-size:14px"><span style="font-family:宋体">塑料、铝合金、铸铁、不锈钢。隔膜泵膜片根据不同液体介质分别采用</span></span><a href="https://baike.baidu.com/item/%E4%B8%81%E8%85%88%E6%A9%A1%E8%83%B6?fromModule=lemma_inlink"><span style=";font-family:&#39;Times New Roman&#39;;line-height:150%;font-size:14px"><span style="font-family:宋体">丁腈橡胶</span></span></a><span style=";font-family:&#39;Times New Roman&#39;;line-height:150%;font-size:14px"><span style="font-family:宋体">、</span></span><a href="https://baike.baidu.com/item/%E6%B0%AF%E4%B8%81%E6%A9%A1%E8%83%B6?fromModule=lemma_inlink"><span style=";font-family:&#39;Times New Roman&#39;;line-height:150%;font-size:14px"><span style="font-family:宋体">氯丁橡胶</span></span></a><span style=";font-family:&#39;Times New Roman&#39;;line-height:150%;font-size:14px"><span style="font-family:宋体">、</span></span><a href="https://baike.baidu.com/item/%E6%B0%9F%E6%A9%A1%E8%83%B6?fromModule=lemma_inlink"><span style=";font-family:&#39;Times New Roman&#39;;line-height:150%;font-size:14px"><span style="font-family:宋体">氟橡胶</span></span></a><span style=";font-family:&#39;Times New Roman&#39;;line-height:150%;font-size:14px"><span style="font-family:宋体">、</span></span><a href="https://baike.baidu.com/item/%E8%81%9A%E5%9B%9B%E6%B0%9F%E4%B9%99%E7%83%AF?fromModule=lemma_inlink"><span style=";font-family:&#39;Times New Roman&#39;;line-height:150%;font-size:14px"><span style="font-family:宋体">聚四氟乙烯</span></span></a><span style=";font-family:&#39;Times New Roman&#39;;line-height:150%;font-size:14px"><span style="font-family:宋体">、聚四六乙烯等安置在各种特殊场合，用来抽送各种介质以满足需要。</span></span><span style=";font-family:宋体;line-height:150%;font-size:14px">隔膜泵既能抽送流动的液体，又能输送一些不易流动的介质，具有自吸泵、潜水泵、屏蔽泵、泥浆泵和杂质泵等输送机械的许多优点。</span></p><p style="margin-top:9px;margin-right:5px;margin-bottom:9px;margin-left:5px;text-indent:27px;padding:0 0 0 0 ;text-align:justify;text-justify:inter-ideograph;line-height:25px;background:rgb(255,255,255)"><span style="font-family: &#39;Microsoft YaHei UI&#39;;letter-spacing: 1px;font-size: 12px">&nbsp;&nbsp;&nbsp;</span><span style=";font-family:宋体;font-size:14px">氧化铝生产的前端工序是先将铝矾土粉碎制成原矿浆，再将合格的原矿浆通过隔膜泵送至高压溶出器，在一定的外部条件作用下，溶出铝土矿中的氧化铝得到铝酸钠。当溶出时间一定时，溶出速度越快，氧化铝的溶出率就越高，产能越大。但溶出反应需在一定条件下进行，要保证氧化铝的高溶出率，就要保证各种物料的相对平衡，在其他条件相对变化的情况下，要求料浆泵的喂料量进行相应的调整，这样才能优化生产工艺指标，进而优化氧化铝生产的技术经济指标。为实现生产工艺过程的优化进行，隔膜泵是采用拜尔法生产氧化铝，尤其是采用管道化溶出工艺的氧化铝厂的重要设备，被誉为拜尔法氧化铝厂的心脏部位，其运转率直接代表着氧化铝厂的投矿运转率。</span></p><p style="line-height:150%"><strong><span style=";font-family:宋体;line-height:150%;font-size:14px">二、控制要求</span></strong></p><p style="text-indent: 28px;line-height: 150%"><span style=";font-family:宋体;line-height:150%;font-size:14px">2022年</span><span style=";font-family:宋体;line-height:150%;font-size:14px">山东某</span><span style=";font-family:宋体;line-height:150%;font-size:14px"><span style="font-family:宋体">氧化铝有限公司</span><span style="font-family:宋体">4套隔膜泵技改项目，原变频器采用西门子6SE70系列变频器，已使用15年以上，</span></span><span style=";font-family:宋体;line-height:150%;font-size:14px">因使用年限长，产品停产备品备件采购周期较长，导致设备</span><span style=";font-family:宋体;line-height:150%;font-size:14px">故障维修时间长</span><span style=";font-family:宋体;line-height:150%;font-size:14px">，</span><span style=";font-family:宋体;line-height:150%;font-size:14px">对生产造成重大隐患</span><span style=";font-family:宋体;line-height:150%;font-size:14px">。</span></p><p style="text-indent: 28px;line-height: 150%"><span style="font-family: 宋体; font-size: 14px; text-align: center;">隔膜泵电机参数如下：电机功率</span><span style="font-family: 宋体; font-size: 14px; text-align: center;">770kW、额定电压690V、电流781A、转速990r/min。</span></p><p style="text-indent: 28px;line-height: 150%"><span style=";font-family:宋体;line-height:150%;font-size:14px">客户对电气传动系统提出以下要求：</span></p><p style="line-height: 150%"><span style=";font-family:宋体;line-height:150%;font-size:14px"><span style="font-family:宋体">（</span><span style="font-family:宋体">1）在使用原机械设备的基础上，通过改变电气控制系统的控制方法，使电动机转速在0～990rpm之间连续可调，且能够带载起动隔膜泵；</span></span></p><p style="line-height: 150%"><span style=";font-family:宋体;line-height:150%;font-size:14px"><span style="font-family:宋体">（</span><span style="font-family:宋体">2）设备起动平缓，运行稳定可靠。</span></span></p><p style="line-height: 150%"><span style=";font-family:宋体;line-height:150%;font-size:14px"><span style="font-family:宋体">（</span><span style="font-family:宋体">3）采用三地操作，分别设置在机旁、变频器控制室、仪表室。泵组的开、停在机旁和变频器控制室进行，仪表室只有在管道超压或其他紧急情况下进行设备紧急停车；当进料量给定值确定后，系统能够自动跟踪给定值。</span></span></p><p style="line-height:150%"><span style=";font-family:宋体;line-height:150%;font-size:14px">（</span><span style=";font-family:宋体;line-height:150%;font-size:14px">4</span><span style=";font-family:宋体;line-height:150%;font-size:14px">）</span><span style=";font-family:宋体;line-height:150%;font-size:14px"><span style="font-family:宋体">采用</span><span style="font-family:宋体">Profibus-DP通讯，需要实现无缝替换</span></span><span style=";font-family:宋体;line-height:150%;font-size:14px"><span style="font-family:宋体">西门子</span><span style="font-family:宋体">6SE70系列变频器</span></span><span style=";font-family:宋体;line-height:150%;font-size:14px">。</span></p><p style="line-height:150%"><span style="font-family:宋体;font-size:14px">三、</span><strong><span style=";font-family:宋体;line-height:150%;font-size:14px">英威腾</span></strong><strong><span style=";font-family:宋体;line-height:150%;font-size:14px">方案</span></strong></p><p style="text-indent:28px;text-align:justify;text-justify:inter-ideograph;line-height:150%"><span style=";font-family:宋体;line-height:150%;font-size:14px"><span style="font-family:宋体">针对现场客户需求，采用英威腾</span><span style="font-family:Times New Roman">GD800</span><span style="font-family:宋体">系列变频器，变频器选型为单传柜机</span><span style="font-family:Times New Roman">GD800-16-0800-6</span><span style="font-family:宋体">，控制盒与单元之间采用光纤通讯；输入侧配置输入电抗器；为了降低变频器对电网的谐波干扰，每个变频器单元输入侧还配置有输入滤波器；变频器单元输出侧配置输出电抗器。</span><span style="font-family:Times New Roman">PLC</span><span style="font-family:宋体">为西门子</span><span style="font-family:Times New Roman">300</span><span style="font-family:宋体">系列，采用</span><span style="font-family:Times New Roman">DP</span><span style="font-family:宋体">通讯，现场无需更换</span><span style="font-family:Times New Roman">PLC</span><span style="font-family:宋体">以及控制逻辑方式，实现无缝替换。系统图如下：</span></span></p><p style=";text-align:justify;text-justify:inter-ideograph;line-height:150%"><img width="553" height="463" src="/upload/article/20240331/1711893734213434.png" style="background:url(https://technology.invt.com.cn/pc/ueditor/lang/zh-cn/images/localimage.png) no-repeat center center;border:1px solid #ddd" title="1711893734213434.png" alt="图片2.png"/></p><p><br/></p>