Under the dual pressures of energy transformation and stricter environmental regulations, the transformation of old
large generator sets has become a key measure for enterprises to reduce costs, increase efficiency and avoid policy risks. This article analyzes how to give old equipment a new lease of life through systematic transformation from the three dimensions of technology upgrade, compliance adaptation and cost optimization.
1. The urgency of transformation of old units: three core driving factors
1. Environmental regulations force upgrades
The global carbon tax policy coverage has expanded, the EU Industrial Emissions Directive (IED) requires NOx emissions to be lower than 100mg/m³, and the domestic "Air Pollution Prevention and Control Law" has tightened the emission limits of particulate matter and SO₂ year by year, and traditional units are facing the risk of shutdown.
2. Energy efficiency bottlenecks restrict development
The thermal efficiency of units that have been in operation for more than 10 years is generally lower than 38%, and the fuel cost accounts for more than 70%. Taking a 100MW unit as an example, a 5% increase in efficiency can save more than 10 million yuan in fuel costs per year.
3. Impact of the digital wave
In the era of Industry 4.0, units that lack intelligent monitoring and remote operation and maintenance functions are difficult to integrate into the smart grid system, and the operation and maintenance costs are 40% higher than those of new units.
2. Three core paths of technical transformation
1. Deep optimization of the combustion system
Low-nitrogen transformation: Using staged combustion + SCR denitrification technology, NOx emissions can be reduced to below 50mg/m³ (transformation case: the emission of a 300MW unit in a power plant meets EU standards after transformation)
Fuel adaptation: Add a multi-fuel supply system to achieve natural gas/hydrogen mixed combustion, and reduce carbon emissions by 20%-35%
2. Intelligent control system upgrade
AI energy efficiency management: Deploy a predictive maintenance system based on digital twins, optimize combustion parameters in real time, and increase the unit response speed by 300%
Load adaptation: Add a VFD variable frequency drive device, and increase the efficiency by 8%-12% under partial load conditions
3. Material and structural innovation
Blade aerodynamic optimization: 3D printing technology is used to reconstruct the turbine blade flow path, and the compressor efficiency is increased by 5%
Corrosion-resistant coating: Nano-ceramic coating is sprayed on high-temperature components such as superheaters and reheaters, and the service life is extended by 3 times
III. Five-step method for transformation implementation
Current situation diagnosis: Use infrared thermal imaging, vibration analysis and other means to establish equipment health records
Scheme design: Combine the needs of power grid dispatching to formulate the optimal solution of "energy efficiency-emission-cost"
Construction management: Modular transformation technology is used to shorten the single downtime to less than 15 days
Commissioning verification: Complete 168 hours of full-load trial operation and extreme working condition testing
Post-evaluation: Establish a post-transformation KPI tracking system and continuously optimize the operation strategy
Conclusion
Under the dual carbon goals and energy security strategy, the transformation of old units has been upgraded from "optional" to "must-have". Through the combustion technology revolution, intelligent upgrades, and full life cycle compliance management, enterprises can control capital expenditures while creating green assets that meet future needs. It is recommended to give priority to service providers with EPC general contracting capabilities and independent intellectual property rights to ensure the technical foresight and execution reliability of the transformation plan.
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