1Project Background

someBiopharmaceutical technology enterprise production base，Mainly used for synthetic production.In the synthesis process, the main use isThe 1000L glass lined reaction kettle serves as a monomer unit, with a total of 20 monomer units in the overall production line. synthesisDuring the process,The highest temperature inside the kettle is150 ℃, with a low temperature of -15 ℃, it is necessary to stabilize the temperature inside the kettle at -10 ℃ to ensure the stability of synthesis and the safety of production.The factory is located in Xinjiang, China, and originallycoolingequipmentThere are problems such as large temperature fluctuations, high energy consumption, and insufficient stability,Therefore, it is necessary to upgrade and introduce a new set of cooling and temperature control equipment.

2、 Project requirements

1. Precise Temperature ControlTemperature fluctuations need to be controlled within±1Within ℃

2. High temperature drop：The temperature inside the kettle isAt 150 ℃, it has a direct drop function and can lower the temperature to the required range within the specified time.

3. High Efficiency and Energy SavingCompared to the original cooling system, energy consumption has been reduced≥ 20%, reducing operating costs.

4. AdaptableSatisfy different needsUnder environmental conditionsThe cooling demand,ambient temperature0~40℃。

5. Smart Remote：It is required to be able to switch between remote and local control in a timely manner, and to be able to independently develop temperature control operation programs that can record temperature curves.

3、 Solution

1. Equipment selection: SelectionAoxu Zhaochenofair coolingformulaTCUUnit (model:AX-TCU023）Range of cooling capacity23kW@-20℃，Temperature control range:-25~150℃Unit configurationAir cooling heat exchange module, intelligent switching of cooling mode.

2. System Design：

ncirculatory system: Adopting304 stainless steel pipeline, strong corrosion resistance, pipeline diameter DN25Reduce cooling loss.High temperature oil pump is selected for the circulating coolant pump.

nRefrigeration system:Choose a grain wheelZF series compressors adopt direct cooling design. Can meet the direct cooling requirements at full temperature.

ncontrol module: IntegrationPLC intelligent control system, real-time monitoring of temperature, flow rate, pressure parameters, and equipped with remote monitoring and fault warning functions.Can develop operating temperature operating proceduresSequence; Can store temperature and curves.

nenergy savingconfiguration：Air cooling combined temperature control: The high-temperature section is cooled by air cooling, and the low-temperature section is cooled by the compressor through intelligent monitoring and program switching. Energy conservation and emission reduction, saving overall energy consumption costs.

3. installation and debugging：

nThe unit is installed inReserved space in the workshop，Unified configuration of upper computer control interface，Easy to remotely monitor and regulate settings.

nConducted during the debugging phase72 hour continuous operation test to verify temperature stability, pressure fluctuations, and energy consumption data.

4、 Implementation effect

1. Accurate temperature control:

nIn actual operation, the cooling temperature fluctuation of the reaction kettle remains stable at±1℃ (target value ±)2℃), better than the design requirements.

2. Operational stability:

ncrewcurrentlycontinuousrun6month，No fault alarm or other prompts have appeared yet. The temperature control is in good condition.

3. Reduced operating costs：

nDuring the operation of the unit6 monthsIn the original cooling systemThe average monthly electricity consumption is1 million 50 thousandkWhCurrentlyreduceto73kWh，Reduce electricity costs by approximately30

4. Production efficiency improvement:

nproductionBatch increase: Due to improved cooling efficiency,productionAccelerate progress25%.

5user feedback

Workshop Planning SupervisorEvaluation:After the unit was put into operation, it solved the long-standing problem of temperature fluctuationsLarge and slow cooling rateproblem The intelligent monitoring system reduces the workload of manual inspection, and the system stability also avoids the problems caused by equipment failuresproductionInterruption, overall satisfaction reached95%. ”

VIsummary

Through in-depth understanding and communication of project requirements in the early stages, Provide practical solutions to pain points that meet the actual needs of customers and set long-term goals for cost reduction and efficiency improvement.Through precise temperature control capability, high stability, significant energy saving, and efficiency improvement,thatcrewIt has now become a production lineCritical infrastructure. This project is of the same typecustomerThe following references are provided:

1. Key indicators for selectionDynamic adjustment range of refrigeration capacityCooling rate requirementIntelligent control system.

2. System optimization direction: Selection of pipeline materialsProgrammable running programRemote monitoring function.

3. Quantitative evaluation of benefitsEnergy consumption, maintenance costsproductionMulti dimensional data comparison of efficiency.