在工業(yè)生產(chǎn)中，大量尾氣余壓往往被白白浪費(fèi)，成為能源利用的“隱形缺口”。中拓針對(duì)山東某生物發(fā)酵企業(yè)發(fā)酵罐尾氣處理需求，量身打造余壓發(fā)電解決方案，將余壓轉(zhuǎn)化為穩(wěn)定綠電，既實(shí)現(xiàn)能源回收，又降低生產(chǎn)成本，成為生物發(fā)酵行業(yè)節(jié)能改造的標(biāo)桿案例。

　　In industrial production, a large amount of exhaust pressure is often wasted, becoming a "hidden gap" in energy utilization. Zhongtuo has tailored a residual pressure power generation solution to meet the tail gas treatment needs of a biological fermentation enterprise in Shandong. The solution converts residual pressure into stable green electricity, achieving energy recovery and reducing production costs. It has become a benchmark case for energy-saving transformation in the biological fermentation industry.

　　01項(xiàng)目背景：尾氣余壓的“能源潛力”待釋放

　　01 Project Background: The "energy potential" of exhaust residual pressure to be released

　　山東某生物發(fā)酵企業(yè)的發(fā)酵罐尾氣中，蘊(yùn)含著未被充分利用的壓力能與熱能。傳統(tǒng)處理模式下，這些能源未經(jīng)過回收便直接排放，不僅造成能源浪費(fèi)，還增加了企業(yè)環(huán)保與能耗成本壓力。

　　The exhaust gas from the fermentation tank of a biological fermentation enterprise in Shandong contains underutilized pressure energy and heat energy. Under the traditional processing mode, these energy sources are directly discharged without being recovered, which not only causes energy waste but also increases the pressure on environmental protection and energy consumption costs for enterprises.

　　為破解這一痛點(diǎn)，中拓提供“渦輪機(jī)組+永磁直驅(qū)發(fā)電機(jī)+驅(qū)控一體電機(jī)+直流微網(wǎng)”一體化解決方案，在保障原有生產(chǎn)工藝穩(wěn)定的前提下，實(shí)現(xiàn)尾氣余壓的高效回收與發(fā)電，讓“閑置能源”成為企業(yè)降本增效的新助力。

　　To solve this pain point, Zhongtuo provides an integrated solution of "turbine unit+permanent magnet direct drive generator+integrated drive control motor+DC microgrid", which achieves efficient recovery and power generation of exhaust gas residual pressure while ensuring the stability of the original production process, making "idle energy" a new help for enterprises to reduce costs and increase efficiency.

　　02核心技術(shù)：四大亮點(diǎn)筑牢高效發(fā)電根基

　　02 Core Technology: Four Highlights Build a Strong Foundation for Efficient Power Generation

　　中拓憑借十幾年永磁電機(jī)研發(fā)積累，為該項(xiàng)目配備多項(xiàng)核心技術(shù)，兼顧發(fā)電效率與系統(tǒng)穩(wěn)定性，適配生物發(fā)酵行業(yè)的復(fù)雜工況：

　　Based on more than a decade of research and development experience in permanent magnet motors, Zhongtuo has equipped the project with multiple core technologies, balancing power generation efficiency and system stability, and adapting to the complex working conditions of the biological fermentation industry

　　永磁直驅(qū)設(shè)計(jì)：無需增速齒輪箱，全功率、全轉(zhuǎn)速范圍保持最高發(fā)電效率，發(fā)電機(jī)效率達(dá)97%，減少機(jī)械損耗；

　　Permanent magnet direct drive design: No need for a speed increasing gearbox, maintaining the highest power generation efficiency across the full power and speed range, with a generator efficiency of 97%, reducing mechanical losses;

　　抗波動(dòng)葉輪技術(shù)：采用耐腐蝕合金材質(zhì)打造核心葉輪，葉片經(jīng)三元流優(yōu)化設(shè)計(jì)，可適配尾氣流量±20%的波動(dòng)場(chǎng)景，同時(shí)耐受濕空氣環(huán)境侵蝕，確保機(jī)組長期穩(wěn)定運(yùn)行；

　　Anti fluctuation impeller technology: The core impeller is made of corrosion-resistant alloy material, and the blades are optimized with a ternary flow design, which can adapt to fluctuation scenarios with exhaust flow rate of ± 20%. At the same time, it can withstand the erosion of humid air environment, ensuring the long-term stable operation of the unit;

　　驅(qū)控一體電機(jī)：集成“驅(qū)動(dòng)+控制”雙功能，無需額外配置獨(dú)立控制器，簡(jiǎn)化系統(tǒng)架構(gòu)的同時(shí)降低信號(hào)傳輸損耗；支持直接接入直流微網(wǎng)，省去交直流轉(zhuǎn)換環(huán)節(jié)，且具備高防護(hù)等級(jí)，抗沖擊、防水防潮，完美適配生物發(fā)酵行業(yè)各種惡劣工況；

　　Drive control integrated motor: integrating "drive+control" dual functions, without the need for additional independent controllers, simplifying the system architecture while reducing signal transmission losses; Supports direct access to DC microgrids, eliminating the need for AC/DC conversion, and has a high level of protection, impact resistance, waterproof and moisture-proof, perfectly adapting to various harsh working conditions in the biological fermentation industry;

　　直流微網(wǎng)配電：采用1000KV直流配電架構(gòu)，減少25%電纜使用量，省去無功補(bǔ)償與諧波抑制的額外投資，系統(tǒng)整體用電效率提升3%-7%，同時(shí)保障電力輸出穩(wěn)定，避免對(duì)生產(chǎn)設(shè)備造成電壓波動(dòng)影響。

　　DC microgrid distribution: adopting a 1000KV DC distribution architecture, reducing cable usage by 25%, eliminating additional investment in reactive power compensation and harmonic suppression, and improving the overall power efficiency of the system by 3% -7%, while ensuring stable power output and avoiding voltage fluctuations on production equipment.

　　此外，PLC+DCS無縫聯(lián)動(dòng)系統(tǒng)實(shí)現(xiàn)精準(zhǔn)調(diào)控，設(shè)備層、控制層、監(jiān)控層數(shù)據(jù)雙向傳輸，故障隔離設(shè)計(jì)降低停機(jī)風(fēng)險(xiǎn)，保障發(fā)電機(jī)組全天候穩(wěn)定運(yùn)行。

　　In addition, the PLC+DCS seamless linkage system achieves precise control, with bidirectional data transmission between the equipment layer, control layer, and monitoring layer. The fault isolation design reduces the risk of shutdown and ensures the stable operation of the generator set 24/7.

　　03發(fā)電規(guī)模：穩(wěn)定輸出，性能達(dá)標(biāo)超預(yù)期

　　03 Power generation scale: Stable output, performance meets standards and exceeds expectations

　　該項(xiàng)目核心設(shè)備配置與性能表現(xiàn)亮眼，完全匹配工業(yè)生產(chǎn)需求： 機(jī)組配置：1套1200kW永磁直驅(qū)發(fā)電機(jī)組，配套直流微網(wǎng)電源、緩沖罐、消聲器等全套設(shè)備，實(shí)現(xiàn)“一站式”能源回收與利用；

　　The core equipment configuration and performance of this project are impressive, fully matching industrial production needs: Unit configuration: 1 set of 1200kW permanent magnet direct drive generator set, matched with a complete set of equipment such as DC microgrid power supply, buffer tank, muffler, etc., to achieve "one-stop" energy recovery and utilization;

　　發(fā)電能力：正常工況下單臺(tái)每小時(shí)發(fā)電量≥800kW，年發(fā)電量達(dá)436800kWh， 項(xiàng)目現(xiàn)場(chǎng)配置三臺(tái)機(jī)組，最大總發(fā)電功率可達(dá)3,6MW，可覆蓋企業(yè)部分生產(chǎn)設(shè)備用電，減少外購電依賴；

　　Power generation capacity: Under normal operating conditions, the hourly power generation of a single unit is ≥ 800kW, and the annual power generation reaches 436800kWh. The project site is equipped with three units, and the maximum total power generation can reach 3.6MW, which can cover the electricity consumption of some production equipment of the enterprise and reduce the dependence on purchased electricity;

　　運(yùn)行穩(wěn)定性：透平轉(zhuǎn)子經(jīng)G1.0級(jí)高速動(dòng)平衡試驗(yàn)，112%額定轉(zhuǎn)速下可穩(wěn)定運(yùn)行；軸系能承受短路、非同期合閘等突發(fā)工況沖擊，驅(qū)控一體電機(jī)的抗波動(dòng)設(shè)計(jì)進(jìn)一步提升系統(tǒng)容錯(cuò)率，適配工業(yè)生產(chǎn)的復(fù)雜場(chǎng)景。

　　Stability of operation: The turbine rotor has undergone G1.0 high-speed dynamic balancing test and can operate stably at 112% rated speed; The shaft system can withstand sudden working conditions such as short circuits and asynchronous closing, and the anti fluctuation design of the drive control integrated motor further improves the system's fault tolerance and adapts to complex industrial production scenarios.

　　04投資回報(bào)：1.8年回本，多重收益超可觀

　　04 Investment return: Return on investment in 1.8 years, multiple returns are considerable

　　該項(xiàng)目的經(jīng)濟(jì)性與環(huán)保效益顯著，為該企業(yè)帶來實(shí)打?qū)嵉幕貓?bào)： 回本周期短：項(xiàng)目投資回報(bào)周期僅1.8年，遠(yuǎn)低于行業(yè)平均水平，資金周轉(zhuǎn)效率高，快速實(shí)現(xiàn)“投入-盈利”閉環(huán)；

　　The economic and environmental benefits of this project are significant, bringing tangible returns to the enterprise: the payback period is short: the investment return period of the project is only 1.8 years, far below the industry average, the capital turnover efficiency is high, and the "input-output" loop is quickly achieved;

　　節(jié)能收益豐：依托發(fā)電系統(tǒng)、直流微網(wǎng)與驅(qū)控一體電機(jī)的協(xié)同作用，可實(shí)現(xiàn)系統(tǒng)總電耗降低70%，節(jié)能效果遠(yuǎn)超行業(yè)常規(guī)水平；同時(shí)直流微網(wǎng)設(shè)計(jì)能進(jìn)一步降低電網(wǎng)容量費(fèi)用與日常運(yùn)行成本，長期電費(fèi)節(jié)省效益極為顯著；

　　Energy saving benefits are abundant: relying on the synergistic effect of power generation system, DC microgrid and integrated drive control motor, the total power consumption of the system can be reduced by 70%, and the energy-saving effect far exceeds the industry's conventional level; At the same time, the design of DC microgrids can further reduce the capacity and daily operating costs of the power grid, resulting in significant long-term electricity cost savings;

　　長期價(jià)值高：機(jī)組設(shè)計(jì)壽命長，且支持多直流網(wǎng)互聯(lián)擴(kuò)展，后續(xù)可根據(jù)生產(chǎn)規(guī)模靈活擴(kuò)容，持續(xù)挖掘能源回收潛力；驅(qū)控一體電機(jī)的高可靠性還能減少設(shè)備維護(hù)頻次，降低運(yùn)維成本；

　　High long-term value: The unit has a long design life and supports the interconnection and expansion of multiple DC networks. In the future, it can be flexibly expanded according to production scale, continuously exploring the potential of energy recovery; The high reliability of the integrated drive control motor can also reduce equipment maintenance frequency and lower operation and maintenance costs;

　　附加成本?。簻p少國家電網(wǎng)配電容量投入，省去諧波抑制、無功補(bǔ)償?shù)阮~外投資，電纜使用量降低25%，全生命周期成本優(yōu)勢(shì)突出。

　　Additional cost savings: Reduce the investment in national power grid distribution capacity, eliminate additional investments in harmonic suppression, reactive power compensation, etc., reduce cable usage by 25%, and highlight the advantage of full lifecycle cost.

　　05場(chǎng)景復(fù)用：同類工況可直接適配，快速落地

　　05 Scenario Reuse: Similar working conditions can be directly adapted and quickly implemented

　　山東某生物發(fā)酵企業(yè)的成功案例，并非個(gè)例！在生物發(fā)酵、化工、尿素合成、磷肥生產(chǎn)等行業(yè)，只要存在可回收的尾氣余壓、蒸汽壓差，均可直接適配中拓的“余壓回收+驅(qū)控一體”解決方案。

　　The successful case of a biological fermentation enterprise in Shandong is not an isolated case! In industries such as biological fermentation, chemical engineering, urea synthesis, and phosphate fertilizer production, as long as there is a recoverable tail gas residual pressure and steam pressure difference, it can be directly adapted to Zhongtuo's "residual pressure recovery+drive control integrated" solution.

　　無需復(fù)雜改造，中拓提供“交鑰匙”工程服務(wù)，從設(shè)計(jì)、制造、安裝到調(diào)試，全流程把控，合同生效后90個(gè)工作日即可交貨，6-8個(gè)月實(shí)現(xiàn)并網(wǎng)發(fā)電。投資回報(bào)快、運(yùn)行穩(wěn)定、節(jié)能效果顯著，是工業(yè)企業(yè)降本增效、綠色轉(zhuǎn)型的優(yōu)選方案。

　　No need for complex renovation, Zhongtuo provides "turnkey" engineering services, from design, manufacturing, installation to commissioning, with full process control. Delivery can be made within 90 working days after the contract takes effect, and grid connected power generation can be achieved within 6-8 months. Fast investment return, stable operation, and significant energy-saving effects make it the preferred solution for industrial enterprises to reduce costs, increase efficiency, and achieve green transformation.

　　如果你的企業(yè)也存在尾氣余壓、蒸汽壓差等未被利用的能源，歡迎聯(lián)系中拓，獲取量身定制的節(jié)能發(fā)電方案，讓“閑置能源”快速變現(xiàn)，共贏綠色未來！

　　If your company also has unused energy sources such as exhaust residual pressure and steam pressure difference, please feel free to contact Zhongtuo for customized energy-saving power generation solutions, so that "idle energy" can be quickly realized and a green future can be achieved!

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