How can Dalian blown film units achieve energy conservation and consumption reduction?

As a key equipment for plastic film production, the energy consumption of Dalian blown film unit has always been a focus of attention for enterprises. With the increasing environmental requirements and rising energy costs, how to achieve energy conservation and consumption reduction of blown film units has become an important means for enterprises to enhance their competitiveness.

1、 Equipment optimization

Efficient motor and frequency conversion technology. The motor is the main energy consuming equipment of the blown film unit, and using high-efficiency motors can significantly reduce energy consumption. Efficient motors have higher energy conversion efficiency and can reduce electrical energy loss at the same power. In addition, the application of frequency conversion technology can adjust the motor speed in real time according to production needs, avoiding the motor from running under high load for a long time, thereby achieving energy-saving effects.

Optimize screw design. The screw is the core component of the blown film unit, and its design directly affects energy consumption. By optimizing parameters such as the aspect ratio, groove depth, and pitch of the screw, the melting efficiency can be improved and energy loss can be reduced. For example, using a screw with a large aspect ratio can increase the residence time of materials in the screw, improve melting uniformity, and thus reduce energy consumption.

Efficient heating system. The traditional resistance heating method has the problems of low thermal efficiency and high energy consumption. The use of efficient heating technologies such as electromagnetic induction heating and infrared heating can significantly improve heating efficiency and reduce heat loss. In addition, arranging heating coils reasonably to ensure uniform heating can also effectively reduce energy consumption.

Optimization of cooling system. The cooling system is an important component of the blown film unit, and its energy consumption cannot be ignored. The use of efficient cooling fans and optimized cooling water circulation systems can improve cooling efficiency and reduce energy consumption. For example, using a variable frequency cooling fan can adjust the air volume according to production needs, avoiding unnecessary energy waste.

2、 Process improvement

Accurately control the temperature. Temperature control is the key to the blown film process. Accurately controlling the temperature of each heating zone can avoid overheating or undercooling and reduce energy waste. Adopting advanced temperature control systems, such as PID control, can achieve precise temperature regulation, improve production efficiency, and reduce energy consumption.

Optimize the inflation ratio. The inflation ratio is an important parameter that affects the performance of thin films. Reasonable selection of the inflation ratio can improve the mechanical properties of thin films and reduce raw material consumption. By conducting experiments and data analysis, a better inflation ratio can be determined, which can reduce energy consumption while ensuring product quality.

Reduce waste generation. The generation of waste not only increases the consumption of raw materials, but also increases energy consumption. By optimizing production processes and reducing waste generation, energy consumption can be significantly reduced. For example, using an automatic cutting system to precisely control the cutting length and reduce the production of scraps.

Improve production speed. Improving production speed can produce more products per unit of time, thereby reducing energy consumption per unit of product. By optimizing production processes and improving equipment operating efficiency, production speed can be increased, achieving the goal of energy conservation and consumption reduction.

3、 Energy Management

Energy monitoring and analysis. Establishing a comprehensive energy monitoring system to monitor the energy consumption of the blown film unit in real-time is the foundation of energy conservation and consumption reduction. Through data analysis, identify areas with high energy consumption and develop targeted energy-saving measures. For example, by using smart meters and energy consumption monitoring software, real-time monitoring of equipment energy consumption can be achieved, and problems can be discovered and solved in a timely manner.

Energy audit. Regularly conduct energy audits to comprehensively evaluate the energy consumption status of the blown film unit and identify energy-saving potential. Through energy audits, issues such as equipment aging and unreasonable processes can be identified, and improvement measures can be developed to reduce energy consumption.

Energy saving training. Improving the energy-saving awareness of operators is an important link in energy conservation and consumption reduction. Through energy-saving training, operators can master energy-saving operation skills and reduce unnecessary energy waste. For example, training operators on how to adjust equipment parameters reasonably to avoid prolonged idling of equipment.

Energy management system. Establishing an energy management system to achieve centralized management and optimized scheduling of energy can improve energy utilization efficiency and reduce energy consumption. For example, using energy management software can achieve real-time monitoring, analysis, and optimization of energy, achieving the goal of energy conservation and consumption reduction.

4、 Other measures

Use energy-saving materials. Choosing energy-saving raw materials can reduce energy consumption during the production process. For example, using plastic materials with high fluidity and low melting point can reduce energy consumption during heating and cooling processes.

Equipment maintenance. Regular maintenance of the blown film unit can ensure that the equipment is in better operating condition and reduce energy consumption. For example, regularly cleaning screws and replacing worn parts can improve equipment operating efficiency and reduce energy consumption.

Waste heat recovery. The blown film unit generates a large amount of waste heat during the production process. Through waste heat recovery technology, this heat energy can be used in other production processes to improve energy utilization efficiency. For example, using a heat exchanger to use waste heat for preheating raw materials or heating water can reduce energy consumption.

The energy conservation and consumption reduction of blown film units is a systematic project that requires multiple aspects such as equipment optimization, process improvement, and energy management. By adopting efficient motors, optimizing screw design, precise temperature control, and improving production speed, energy consumption can be significantly reduced. Meanwhile, establishing a comprehensive energy monitoring system, conducting regular energy audits, and enhancing the energy-saving awareness of operators are also important means to achieve energy conservation and consumption reduction. Enterprises should develop practical and feasible energy-saving and consumption reduction plans based on their own situation, improve energy utilization efficiency, reduce production costs, and enhance market competitiveness.