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The textile industry has extremely strict requirements for the temperature, humidity and cleanliness of the production environment. Its dedicated air conditioning system, through the coordinated operation of multiple modules, creates a stable air environment for textile processes such as spinning, weaving and dyeing. The following is a comprehensive analysis of the composition structure and technical characteristics of air conditioners in the textile industry from six system dimensions:
I. Air Handling System: The core of cleanliness and temperature and humidity control
Multi-stage filtration unit
Primary filter: Made of chemical fiber non-woven fabric or metal mesh, it intercepts fibers, dust and large particle impurities larger than 5μm. It is commonly found at the fresh air inlet, with a filtration efficiency of 80% to 90% (by weight method).
Medium-efficiency filters: Mostly bag-type or plate-type structures, they filter out fine particles of 1 to 5μm, and are used in conjunction with primary filters to achieve the cleanliness of the workshop air (for example, the dust particle concentration in a cotton spinning workshop should be ≤ 300,000 particles per cubic meter).
High-efficiency filter (optional) : In high-end fabric or chemical fiber production workshops, HEPA filters are configured with a filtration efficiency of ≥99.97% (0.3μm particles) to prevent fiber contamination from affecting product quality.
2. Thermal and humidity treatment equipment cluster
Heater
Steam heater: With saturated steam of 0.3 to 0.8MPa as the heat source, it has a high heat exchange efficiency and is often used for heating in winter (such as heating air from 5℃ to 20℃).
Hot water heater: Utilizing hot water circulation at 60 to 80 degrees Celsius, it is suitable for matching with centralized heating systems, providing more stable temperature control.
Electric heater: As an auxiliary heat source, it is used in scenarios with small air volume or for precise heating supplementation. The power is designed based on the heat load of the workshop (such as 100kW of heating supplementation per hour).
Cooling and dehumidification equipment
Surface cooler: Through the circulation of cold water at 7 to 12℃, it reduces the air temperature from 35℃ to 25℃ in summer, while condensing and dehumidifying (for example, reducing the air moisture content from 18g/kg to 12g/kg).
Rotary dehumidifier: It uses silica gel or molecular sieve rotors. In humid areas (such as the rainy season in the south), it can reduce the humidity to below 40% RH, preventing the yarn from getting damp and breaking.
Humidifier
Steam humidifier: It directly sprays dry saturated steam, with a fast humidification speed (increasing humidity by 5% RH per minute), suitable for cotton spinning workshops (humidity needs to be maintained at 55% to 65% RH).
Ultrasonic humidifier: It atomizes water through high-frequency oscillation, with a particle size of ≤5μm. It is suitable for precision weaving workshops with high requirements for humidity uniformity.
Ii. Ventilation System: The power network for air circulation
1. Fan unit configuration
Centrifugal fan
Main supply fan: The air volume reaches 100,000 to 300,000 m/h, and the air pressure is 1000 to 2000Pa. It adopts variable frequency control (such as a 150kW motor, the frequency can be adjusted from 20 to 50Hz), meeting the air supply requirements of large-area workshops.
Exhaust fan: Installed on the top or side walls of the workshop, it expelling hot and humid air as well as fiber dust. The air volume is 80% to 90% of the supply air volume, preventing the positive pressure in the workshop from being too high.
Axial flow fan
It is used for local ventilation (such as heat dissipation near the machine) or air flow guidance within the air cabinet, with an air volume of 20,000 to 50,000 m/h, a wind pressure of ≤500Pa, and low noise (≤75dB).
2. Design of air ducts and airflow distribution
Material of air duct
Galvanized steel plate (thickness 0.8-1.2mm), with surface anti-corrosion treatment, suitable for main air supply ducts;
Phenolic composite air ducts (insulation and sound insulation integrated) are used for the branch pipes inside the workshop ceiling to reduce cold loss (thermal conductivity ≤0.03W/m · K).
Wind outlet form:
Strip diffusers: Arranged along the long axis of the workshop, with a wind speed of 2 to 3m/s, ensuring uniformity of temperature and humidity (temperature difference ≤±1℃, humidity difference ≤±5% RH).
Swirl air outlet: It is used in large Spaces (such as weaving workshops with a height of over 8 meters) to enhance the diffusion distance of the airflow (up to 10 meters).
Iii. Cold and Heat Source System: The core hub of energy supply
Refrigeration system
Screw-type chiller
The cooling capacity ranges from 500 to 2000kW, with a COP (energy efficiency ratio) of ≥3.5. It adopts the environmentally friendly refrigerant R134a and provides 7℃ chilled water for the surface cooler. It is suitable for textile factories with a capacity of over 10,000 spints.
Cooling tower
The circular counter-flow structure has a water treatment capacity of 50 to 200m/h and an outlet water temperature of ≤32℃. It is equipped with a water collector (drift rate ≤0.01%) to reduce water loss.
2. Heating system
Steam boiler
Gas boiler (thermal efficiency ≥95%), evaporation capacity 2-10t/h, providing 0.5MPa steam, simultaneously meeting the requirements of heating and humidification;
Plate heat exchanger
Using the waste heat from factories (such as the waste heat from printing and dyeing wastewater) or hot water from centralized heating networks (90℃) as the heat source, the heat exchange efficiency is ≥90%, reducing energy consumption costs (saving more than 60% compared to electric heating).
Iv. Intelligent Control System: The nerve center for Precise regulation
Sensor network
Temperature and humidity sensor
Platinum resistance (PT100) and capacitive humidity chips are adopted, with measurement accuracy of ±0.5℃ and ± 3%RH. One monitoring point is arranged every 500 square meters in the workshop.
Pressure sensor
Monitor the static pressure of the air duct (range -500 to 500Pa), automatically adjust the fan frequency, and maintain a stable supply air pressure (for example, the static pressure of the main air duct is controlled at 150Pa±10Pa).
2. PLC control and frequency conversion technology
Central controller
Siemens S7-1200 or Mitsubishi FX series PLC is adopted, integrating PID control algorithm. According to the set values of temperature and humidity in the workshop (such as temperature 24±1℃, humidity 60± 2%RH), the opening degree of cold and hot water valves, fan speed and humidification capacity are automatically adjusted.
Human-machine Interface (HMI)
The 10-inch touch screen displays the system operation parameters and energy consumption data in real time (such as daily power consumption and steam usage), and supports historical data query and fault alarm (such as filter clogging alarm and cold water low-temperature protection).
V. Auxiliary Systems: The Guarantee for Efficient Operation
Water supply and drainage as well as water quality treatment
Water softening device
Ion exchange resin is adopted to remove calcium and magnesium ions in water (hardness ≤0.03mmol/L), preventing scaling in humidifiers and heat exchangers (scaling can lead to a decrease of more than 30% in heat exchange efficiency).
Condensate water recovery system
The condensate water from the surface cooler is recovered through the water collection tray and pipeline (with a daily recovery volume of 5 to 20 cubic meters), and after treatment, it is used to replenish water for the humidifier, achieving a water-saving rate of 30%.
2. Heat Recovery and Energy Saving Module
Rotary heat exchanger
Installed between the fresh air and exhaust air channels, the sensible heat recovery efficiency is ≥70%. In winter, the exhaust air heat is utilized to preheat the fresh air (such as preheating the fresh air from -5 ℃ to 10℃), reducing the heating energy consumption.
Variable frequency energy-saving control
The fan and water pump adopt variable frequency motors (power factor ≥0.95), which automatically adjust the rotational speed according to the load. The energy-saving rate can reach 40% at partial loads (for example, when operating at low load at night, the fan power drops from 100kW to 60kW).
3. Noise reduction and vibration damping design
Muffler
Impedance composite mufflers are installed at the inlet and outlet of the fan, with an insertion loss of ≥30dB, ensuring that the noise in the workshop is ≤85dB (meeting the noise standards for industrial sites).
Vibration-reducing base
Spring vibration isolators (with a natural frequency of 2 to 5Hz) are installed on the chiller and the fan to reduce the transmission of vibration to the building structure.
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Jiangsu Jincheng Air Conditioning Engineering Co., Ltd. is a comprehensive manufacturer of special air-conditioning equipment design, production, installation, and commissioning of clean room, electricity, tobacco, civil air defense engineering, medical clean room, clean room, electricity, tobacco, civil air defense engineering, medical clean room. Mainly produce JCZK combined air conditioning unit, cooling tower, glass steel ventilated galvanized sheet pipe, stainless steel pipe, polyurethane ventilation pipe and air conditioning accessories, Jincheng air conditioner is wide, the type, the unique model, superior performance, and user Favused.
