1Project Background

A petrochemical research and development center laboratory is responsible for the development and testing of new petrochemical materials. During the experimental process, chemical reactions need to be carried out in a precisely controlled temperature environment to ensure the accuracy of experimental data and equipment safety.originalcoolingequipmentThere are problems such as large temperature fluctuations, high energy consumption, and insufficient stability, which make it difficult to meet laboratory needs. For this reason, the laboratoryneedIntroduce efficient chiller units to improve temperature control accuracy and system reliability.

2、 Project requirements

1. Precise Temperature ControlTemperature fluctuations need to be controlled withinWithin ± 0.5 ℃, avoid experimental data distortion caused by temperature deviation.

2. stable operationRequirement for continuous operation capability of chiller unit≥ 96 hours/week, annual failure rate ≤ 1%.

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

4. AdaptableMeet the cooling needs and flow range of different experimental scenarios0.5-5 m3/h， The pressure range is 0.2-0.8 MPa.

5. Safety and Environmental ProtectionCompliant with explosion-proof standards（Exd Ⅱ CT4), using environmentally friendly refrigerant (R-134a).

3、 Solution

1. Equipment selection: SelectionAoxu Zhaochenoffrequency conversionformulahigh and low temperatureUnit (model:AX-FC338）Range of cooling capacity33.8kW， It can be dynamically adjusted according to experimental needs. The unit is equipped with a variable frequency compressor and a PID temperature control system, with a temperature control accuracy of ± 01℃。

2. System Design：

ncirculatory system: Adopting304 stainless steel pipeline, with strong corrosion resistance and a diameter of DN50, reduces cooling loss.

ncontrol module: IntegrationPLC intelligent control system, real-time monitoring of temperature, flow rate, pressure parameters, and equipped with remote monitoring and fault warning functions.

nsecurity configurationEquipped with explosion-proof motors, temperature overload protection, pressure sensors, and automatic pressure relief valves to ensure safe operation in hazardous environments.

3. installation and debugging：

nThe unit is installed in an independent equipment room, away from the core area of the laboratory5Rice, reduce noise interference (running noise)≤65 dB）。

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± 0.2 ℃ (target value ± 0.5 ℃), better than the design requirements.

nInPolymer synthesis experimentIn the middle, the temperature fluctuation of the original cooling system reached± 1.2 ℃, resulting in a fluctuation of 5% -8% in product purity; switch toVariable frequency high and low temperature integrationAfter the crew, the purity remained stable at99.5% ± 0.3%, the repeatability of experimental data has been improved to 98%.

2. operational stability：

nContinuous operation of the unitAfter 12 months, the cumulative failure time was only 8 hours (failure rate 0.6%), far lower than the industry average failure rate (2% -3%).

3. Experimental efficiency improvement：

nCatalytic cracking reaction experimentThe original cooling system needs to cool down to the target temperature3 hours, now shortened to 1.5 hours, efficiency increased by 50%.

nIncrease in annual experimental batches: Due to improved cooling efficiency, the number of annual experiments has increased from120 times increased to 150 times, accelerating the research and development progress by 25%.

5user feedback

Evaluation by the laboratory director:After the unit was put into operation, we solved the long-standing problem of temperature fluctuations. Precise temperature control greatly improved the reliability of experimental data, and the heat recovery function also reduced the overall energy consumption of the laboratory. The intelligent monitoring system reduced the workload of manual inspections, and the system stability also avoided experimental interruptions caused by equipment failures, with an overall satisfaction rate of 95%

VIsummary

Through precise temperature control capability（± 0.2 ℃), high stability (0.6% failure rate), significant energy saving (22%), and efficiency improvement (25% increase in experimental batches),thatThe unit has become a key infrastructure for petrochemical laboratories. This project provides the following references for laboratories of the same type:

1. Key indicators for selectionDynamic adjustment range of refrigeration capacity, frequency conversion technology, explosion-proof rating, intelligent control system.

2. System optimization directionPipeline material selection, heat recovery and utilization, remote monitoring function.

3. Quantitative evaluation of benefitsMultidimensional data comparison of energy consumption, maintenance costs, and experimental efficiency.

Data source：somePetrochemical laboratory operation records, equipment testing reports, and third-party energy efficiency assessment reports.