Research On Pump Energy Saving Strategy Of Dyeing Solution Circular System Of High Temperature High Pressrue Jet Overflow Dyeing Machine

High temperature high pressure jet overflow dyeing machines are widely usedin print and dyeing factories. The electricity consumption, which comes from thepump of the dyeing solution circular system in dyeing process, has a greatproportion in the whole energy consumption. The pump keeps working at powerfrequency even when the dyeing machine dyes different kinds of fabric. But if theflow rate could be changed according to the variation of the fabric, there would begreat energy saving potential.As to this problem, the author goes to a textile, print and dyeing factory toobtain parameters of the equipments, and has an overall view and comprehensiveunderstanding of the high temperature high pressure jet overflow dyeing machine,technological requirements of dyeing, and production process, along with referenceto relevant literature. The paper summarizes the information of field research,analyses the energy saving potential of dyeing process, and provides thepreliminarily estimated energy-saving outcome.The consumption reduction of the pump of the dyeing solution circular systemof dyeing machine can be achieved by reducing the flow rate, which needs to satisfythe demands of the dyeing quality. Thus at first the feasibility of reducing the flowrate is analyzed from the perspective of technology and the flow rate range isidentified qualitatively according to the heavy, normal and light types of the fabric.Then with theory of pump frequency conversion, the paper analyses the operatingpoint and its movement while different kinds of fabric are processed, applicablecondition of single pump when used similarity principle, and the performanceconversion of similar conditions, which function as a basis for further analysis andcomputing of energy saving.Each flow rate range of different fabric is discussed quantificationally based onthe pump samples of the three dyeing machines. The energy saving rate formulationof pump frequency conversion is deduced by using similarity principle. And bydiscussion, the energy saving rate is mainly affected by total efficiency of pumpfrequency conversion system and flow rate ratio. Finally, the paper presents theenergy saving rate of each kind of fabric by an example of calculation: the energysaving rate of heavy type fabric is18.9%~26.9%, the one of normal type is26.6%~38.8%, and the light type34.3%~48.9%. The energy saving rate is used forthe total energy consumption of the pump’s original operating point of pumpfrequency conversion system. In order to realize the energy saving effect, an automation system is needed.The core part of the automation system is the flow rate control program of the fabric.Automation technicians need to coordinate with factory workers to obtain the flowrate of dyeing solution after frequency conversion, which satisfies the dyeingrequirement, of each kind of fabric and those which have special needs for theirflow rate. The program is downloaded from the central automation system to theend-flowmeter which equips with a controller. The energy can be saved by adjustingthe variation frequency device in order to change the flow rate according to theprogram.