In high-load industrial scenarios such as chemical engineering, iron and steel production, and electronic manufacturing, the production process has extremely strict requirements for temperature control. Screw chillers are required to provide continuous and stable refrigeration capacity to ensure the smooth progress of production processes and product quality. Any interruption in refrigeration may lead to product scrapping, equipment damage, and even safety accidents. Therefore, how to ensure that screw chillers achieve continuous refrigeration under high-load working conditions has become a core concern for industrial enterprises.
In high-load industrial scenarios, refrigeration demand is large and fluctuates frequently. When selecting equipment, it is necessary to accurately calculate the refrigeration capacity. Based on factors such as the heat load of the production process and environmental heat dissipation, determine the rated refrigeration capacity of the screw chiller, and reserve a certain margin to cope with peak loads. For example, in the cooling of chemical reaction kettles, a large amount of heat is released during the reaction process, and there is a significant difference in heat load between the initial stage and the stable stage of the reaction. Therefore, it is necessary to select a screw chiller with a wide refrigeration capacity range and flexible adjustment capabilities. At the same time, consider the parallel operation scheme of multiple units: some units can be shut down during low-load periods, and all units can be put into operation during peak-load periods. This not only meets the refrigeration demand but also avoids long-term high-load operation of a single unit, thereby extending the service life of the equipment.
The compressor is the core component of a screw chiller, and its performance directly determines the refrigeration capacity and stability of the chiller. Under high-load working conditions, priority should be given to compressors with high compression ratio, large displacement, and high efficiency. For instance, compressors with an asymmetric double-screw rotor design, combined with nanoscale surface coating technology, can reduce internal leakage and friction losses, increasing compression efficiency by 12-18%. Moreover, they can withstand higher pressure and adapt to high-load operation. Some high-end compressors also have an adaptive adjustment function: when the ambient temperature or load changes, they automatically adjust the compression ratio to maintain stable output of refrigeration capacity.
An efficient heat exchange system is crucial for ensuring continuous refrigeration. The condenser and evaporator should adopt high-efficiency heat transfer materials and advanced structural designs to improve heat exchange efficiency. For example, the use of new high-efficiency heat exchange tubes can increase the heat exchange area and reduce thermal resistance; optimizing the cooling water flow channel of the condenser and the refrigerant distribution method of the evaporator ensures uniform heat exchange and reduces local overheating or supercooling. At the same time, add redundant design to the heat exchange system, such as backup condensers or evaporators. When the main heat exchange equipment fails, the backup equipment can be quickly put into use to avoid refrigeration interruption.
Intelligent control systems collect real-time operating parameters of screw chillers (such as temperature, pressure, and flow rate) through sensors, enabling comprehensive monitoring of the equipment's operating status. Based on these data, the system uses PID closed-loop control technology to precisely adjust key components such as compressor speed, expansion valve opening, and water pump flow rate. This ensures that the equipment always operates under optimal working conditions and that the refrigeration capacity accurately matches the actual load. In electronic chip manufacturing workshops, the production process is extremely sensitive to temperature fluctuations. The intelligent control system is connected to multiple sets of temperature sensors, which can respond to load changes within milliseconds and control the temperature deviation within ±0.3℃, meeting the high-precision requirements of chip production.
With the help of the Internet of Things (IoT) and big data analysis technology, the intelligent control system conducts in-depth mining of the equipment's operating data and establishes an equipment performance model. By comparing the actual operating parameters with the model data, potential fault risks (such as predicting scaling of heat exchangers and wear of compressor bearings) are identified in advance, and early warnings are issued in a timely manner. At the same time, the system presets multiple fault handling plans. When a fault occurs, it automatically executes corresponding operations (such as switching to backup equipment and adjusting the operating mode), minimizing the impact of the fault on refrigeration continuity. After a chemical enterprise applied the intelligent control system, the unplanned downtime was reduced by 58%, effectively ensuring production continuity.
Strict implementation of a regular maintenance plan is the foundation for ensuring the stable operation of screw chillers. Regularly clean the condenser and evaporator to remove dirt and impurities and maintain heat exchange efficiency; check the refrigerant charge and purity, and supplement or replace the refrigerant in a timely manner; replace the lubricating oil to ensure good lubrication of moving parts such as the compressor. In summer, focus on cleaning the air filter (it needs to be replaced when the pressure difference > 150Pa); in autumn, calibrate the temperature sensor (with an error of ±0.5℃); in winter, detect the refrigerant charge (superheat controlled at 3-5℃) and the efficiency of the oil separator (required to be > 98%), etc. Through regular maintenance, the energy efficiency of the equipment can be improved by 25-30%, and the annual operation and maintenance cost can be reduced by 18%.
The professional quality of operators and maintenance personnel is crucial to the stable operation of the equipment. Enterprises need to organize regular personnel training to help them familiarize themselves with the working principle, operation process, and maintenance key points of screw chillers, and master the methods for troubleshooting and handling common faults. At the same time, develop a complete emergency plan and conduct regular emergency drills to simulate emergency situations such as refrigeration interruption. This improves the personnel's emergency response capabilities and coordination skills, ensuring that effective measures can be taken quickly to restore refrigeration and reduce losses in emergency situations.
In high-load industrial scenarios, through scientific and reasonable equipment selection, in-depth application of intelligent control systems, and refined operation and maintenance management, screw chillers can reliably ensure continuous refrigeration, providing solid support for the stable operation of industrial production.
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