Steam system for residual cigarette processor in cigarette factory and preparation method
By using waste heat generated by the water ring vacuum pump to prepare steam, the energy waste problem caused by steam consumption of the residual smoke treatment machine is solved, and energy saving and consumption reduction of the steam system and the recycling of high-temperature condensate water are realized.
Patent Information
- Application Number
- CN202510568437.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-04-30
- Publication Date
- 2025-07-25
AI Technical Summary
The steam consumption of cigarette residual smoke treatment machines in cigarette plants leads to energy waste, including long-distance heat transfer, unrecycled condensate waste heat and low-load operation of boilers, resulting in energy waste.
The waste heat generated by the water ring vacuum pump is heated to 80°C through the carbon dioxide-type water source heat pump, and used as the feed water of the electric steam generator. 5.0 bar steam is prepared for use by the residual smoke treatment machine, and high-temperature condensate is recovered to replace the steam supplied by the original boiler.
It realizes energy saving and consumption reduction of steam system, reduces the heat energy loss of long-distance steam transport and the heat loss of boiler ultra-low load operation, and reduces steam preparation costs and water resources waste.
Smart Images
Figure CN120368274A_ABST
Abstract
Description
Technical Field
[0001] The present invention belongs to the technical field of waste heat utilization in cigarette factories, and particularly relates to a steam system and a preparation method for a residual cigarette processor in a cigarette factory. Background Art
[0002] During the cigarette production process in a cigarette factory, there will inevitably be defective products. These defective products are peeled by a residual cigarette processor to separate the cigarette rod into tobacco shreds and cigarette paper, and then the tobacco shreds are recycled. During the operation of the residual cigarette machine, in order to reduce the breakage of tobacco shreds, before peeling the cigarette rod, it is necessary to spray and moisten the cigarette rod with steam.
[0003] For the existing residual cigarette processors used in cigarette factories, the steam consumption is usually 60 kg / hour, and the rated steam pressure is 5.0 bar. Although the steam consumption of the residual cigarette machine itself is small, it causes a large amount of energy loss in the cigarette factory for three reasons: (1) Residual cigarette treatment is the end process section of cigarette production in the cigarette factory. The location of the residual cigarette processor is often far from the boiler room in the power workshop. Long-distance steam transmission leads to serious heat energy loss; (2) The high-temperature condensate water generated after the steam used by the residual cigarette processor is depressurized is not easy to recover due to the long distance and is directly discharged into the sewer, resulting in waste heat loss; (3) Since residual cigarette treatment is the end process of cigarette production, even if steam is no longer used in other places in the whole factory, due to the need for steam in the residual cigarette processor, the boiler (rated evaporation capacity of 20 tons / hour) has to operate under an extremely low load condition, with extremely low efficiency and a large amount of energy waste.
[0004] On the other hand, during the cigarette production process, a cigarette machine needs to use vacuum negative pressure air. Currently, most of the vacuum units used in cigarette factories are water ring vacuum pumps. A large amount of heat sources are generated during the operation of the water ring vacuum pump. These heat sources exist in the working fluid of the water ring vacuum pump and are then transferred to the coolant through a shell and tube heat exchanger. Even in winter, the coolant temperature reaches above 30°C, and it is necessary to work through a cooling tower to dissipate the heat into the atmosphere, resulting in energy waste. Summary of the Invention
[0005] The purpose of the present invention is to provide a steam system and a preparation method for a residual cigarette processor in a cigarette factory, which reuse the waste heat generated by the water ring vacuum unit in the cigarette factory to replace the steam supplied by the original boiler, achieve energy conservation and consumption reduction, and can recycle and reuse the high-temperature condensate water of the residual cigarette processor to solve the problems existing in the above background art.
[0006] To achieve the above purpose, the present application is realized through the following technical solutions:
[0007] A steam system for a residual cigarette processor in a cigarette factory includes a shell and tube heat exchanger, a first water pump, a water source heat pump assembly, a second water pump, a hot water tank, a third water pump, and an electric steam generator;
[0008] The water source heat pump assembly includes an evaporator, a compressor, an expansion valve and a condenser;
[0009] The working fluid outlet of the water ring vacuum pump is connected to the first inlet of the shell and tube heat exchanger through a pipeline, and the working fluid inlet of the water ring vacuum pump is connected to the first outlet of the shell and tube heat exchanger through a pipeline;
[0010] The second outlet of the shell and tube heat exchanger is connected to the inlet of the first water pump through a pipeline, the outlet of the first water pump is connected to the first inlet of the evaporator through a pipeline, and the second inlet of the shell and tube heat exchanger is connected to the first outlet of the evaporator through a pipeline;
[0011] The second outlet of the evaporator is connected to the inlet of the compressor through a pipeline, the outlet of the compressor is connected to the first inlet of the condenser through a pipeline, the second inlet of the evaporator is connected to the outlet of the expansion valve through a pipeline, and the inlet of the expansion valve is connected to the first outlet of the condenser through a pipeline;
[0012] The second outlet of the condenser is connected to the inlet of the second water pump through a pipeline, the outlet of the second water pump is connected to the first inlet of the hot water tank through a pipeline, and the first outlet of the hot water tank is connected to the second inlet of the condenser through a pipeline;
[0013] The second outlet of the hot water tank is connected to the inlet of the third water pump through a pipeline, and the outlet of the third water pump is connected to the inlet of the electric steam generator through a pipeline;
[0014] The outlet of the electric steam generator is connected to the residual smoke treatment machine through a pipeline.
[0015] Further, a softened water make-up port is provided on the hot water tank. The softened water make-up port is connected to the softened water source through a pipeline, and a softened water make-up valve is provided on the pipeline.
[0016] Further, a one-way check valve is provided on the pipeline between the third water pump and the inlet of the electric steam generator.
[0017] Further, a sewage discharge port is provided at the lower side of the electric steam generator, and a sewage discharge valve is provided on the pipeline connected to the sewage discharge port.
[0018] Further, a steam valve is provided on the pipeline near the outlet of the electric steam generator.
[0019] Further, on the pipeline between the outlet of the electric steam generator and the residual smoke treatment machine, and near the side of the residual smoke treatment machine, a condensate water pipe is connected. The condensate water pipe is connected to the hot water tank.
[0020] Further, a steam trap and a Y-type filter are provided in the condensate water pipe.
[0021] A method for preparing steam used in a residual cigarette processor in a cigarette factory, using the steam system of any one of the above, includes the following steps:
[0022] S1. The working fluid of the water-ring vacuum pump transfers heat energy to the first coolant entering the shell-and-tube heat exchanger through the shell-and-tube heat exchanger;
[0023] S2. The heated first coolant is sent into the evaporator through the first water pump;
[0024] S3. The second coolant circulates between the evaporator and the condenser through the compressor, bringing heat into the condenser;
[0025] S4. After the water entering the condenser is heated to the set temperature, it is injected into the hot water tank through the second water pump;
[0026] S5. The hot water in the hot water tank is sent into the electric steam generator through the third water pump, and the steam generated by the electric steam generator is sent into the residual cigarette processor.
[0027] Further, the controller detects the change in the steam consumption of the residual cigarette processor. If the steam consumption of the residual cigarette processor is within the set range, the controller does not send adjustment signals to the electric steam generator and the third water pump;
[0028] If the steam consumption of the residual cigarette processor exceeds the maximum value of the set range, the controller controls the electric steam generator to increase the steam output and simultaneously increases the power of the third water pump;
[0029] If the steam consumption of the residual cigarette processor is lower than the minimum value of the set range, the controller controls the electric steam generator to reduce the steam output and simultaneously reduces the power of the third water pump.
[0030] The beneficial effects of the present invention are:
[0031] In this technical solution, the waste heat generated by the water-ring vacuum unit in the cigarette factory is reused to replace the steam supplied by the original boiler, achieving energy conservation and consumption reduction, and the high-temperature condensate water of the residual cigarette processor can be recycled.
[0032] This technical solution closes the original boiler steam pipeline, avoiding the heat loss caused by the long-distance transmission of steam and the heat loss of the boiler operating at ultra-low load after the whole factory production ends; the waste heat of the water-ring vacuum pump is recycled by means of a carbon dioxide type water source heat pump unit; the COP value of the carbon dioxide type water source heat pump unit reaches more than 4.0, and the inlet water temperature of the electric heating steam generator is high, reducing the steam preparation cost; since the coolant temperature of the water-ring vacuum pump is reduced, the cooling tower operation can be shut down, eliminating the power consumption of the cooling tower fan operation and the water pump operation; after the cooling tower stops operating, for a cooling tower with a flow rate of 200 tons per hour, 0.2 tons per hour of softened water evaporated can be saved; the high-temperature condensate water of the residual cigarette processor can be recycled on-site, further reducing the steam preparation cost. Description of the Drawings
[0033] Figure 1 This is the process flow diagram of the steam system used in the residual cigarette processor of the cigarette factory of the present invention.
[0034] Description of the reference numerals in the drawings:
[0035] 1. Tube heat exchanger; 2. First water pump; 3. Water source heat pump assembly; 301. Evaporator; 302. Compressor; 303. Expansion valve; 304. Condenser; 4. Second water pump; 5. Hot water tank; 6. Soft water make-up valve; 7. Third water pump; 8. Check valve; 9. Drain valve; 10. Electric steam generator; 11. Steam valve; 12. Original boiler steam stop valve; 13. Residual cigarette processor; 14. Steam trap; 15. Y-type filter. Detailed implementation manners
[0036] The technical solution of the present invention will be described in detail below with reference to the accompanying drawings. The following embodiments are merely exemplary and can only be used to explain and illustrate the technical solution of the present invention, rather than being construed as a limitation to the technical solution of the present invention.
[0037] During the cigarette production process, the cigarette machine needs to use vacuum negative pressure air, and the residual cigarette processor is often close to the vacuum pump room. At present, most of the vacuum units used in cigarette factories are water ring vacuum pumps. A large amount of heat sources are generated during the operation of the water ring vacuum pump. These heat sources exist in the working fluid of the water ring vacuum pump and are then transferred to the coolant through the tube heat exchanger. Even in winter, the coolant temperature reaches above 30°C, and the heat needs to be dissipated to the atmosphere through the operation of the cooling tower.
[0038] The idea of this technical solution is: close the original boiler steam pipeline, send the waste heat generated by the water ring vacuum pump into the carbon dioxide type water source heat pump unit to produce hot water at 80°C, which is used as the inlet water of the small electric steam generator. The electric steam generator locally prepares steam at 5.0 bar as the steam source of the residual cigarette processor, and the high-temperature condensate water of the residual cigarette processor is locally recovered and filtered to be used as the inlet water of the electric steam generator.
[0039] As Figure 1 shown, the present application provides a steam system used in a residual cigarette processor of a cigarette factory, including a tube heat exchanger 1, a first water pump 2, a water source heat pump assembly 3, a second water pump 4, a hot water tank 5, a third water pump 7, and an electric steam generator 10; the water source heat pump assembly 3 includes an evaporator 301, a compressor 302, an expansion valve 303, and a condenser 304.
[0040] The outlet of the working fluid of the water ring vacuum pump is connected to the first inlet of the tube heat exchanger through a pipeline, and the inlet of the working fluid of the water ring vacuum pump is connected to the first outlet of the tube heat exchanger through a pipeline.
[0041] The second outlet of the shell-and-tube heat exchanger is connected to the inlet of the first water pump through a pipeline, the outlet of the first water pump is connected to the first inlet of the evaporator through a pipeline, and the second inlet of the shell-and-tube heat exchanger is connected to the first outlet of the evaporator through a pipeline.
[0042] The second outlet of the evaporator is connected to the inlet of the compressor through a pipeline, the outlet of the compressor is connected to the first inlet of the condenser through a pipeline, the second inlet of the evaporator is connected to the outlet of the expansion valve through a pipeline, and the inlet of the expansion valve is connected to the first outlet of the condenser through a pipeline.
[0043] The second outlet of the condenser is connected to the inlet of the second water pump through a pipeline, the outlet of the second water pump is connected to the first inlet of the hot water tank through a pipeline, and the first outlet of the hot water tank is connected to the second inlet of the condenser through a pipeline.
[0044] The second outlet of the hot water tank is connected to the inlet of the third water pump through a pipeline, and the outlet of the third water pump is connected to the inlet of the electric steam generator through a pipeline.
[0045] The outlet of the electric steam generator is connected to the residual smoke treatment machine through a pipeline.
[0046] In this application, a softened water make-up port is provided on the hot water tank 5, the softened water make-up port is connected to the softened water source through a pipeline, and a softened water make-up valve 6 is provided on the pipeline.
[0047] In this application, a one-way check valve 8 is provided on the pipeline between the third water pump 7 and the inlet of the electric steam generator 10.
[0048] In this application, a blowdown port is provided on the lower side of the electric steam generator 10, and a blowdown valve 9 is provided on the pipeline connected to the blowdown port.
[0049] In this application, a steam valve 11 is provided on the pipeline near the outlet of the electric steam generator.
[0050] In this application, on the pipeline between the outlet of the electric steam generator and the residual smoke treatment machine, and on the side close to the residual smoke treatment machine, a condensate water pipe is connected, and the condensate water pipe is connected to the hot water tank.
[0051] In this application, a steam trap 14 and a Y-type filter 15 are provided in the condensate water pipe.
[0052] The specific working process is as follows:
[0053] The working fluid of the water-ring vacuum pump transfers heat energy to the coolant (temperature above 30°C) through a shell-and-tube heat exchanger. The coolant is sent to the evaporator of the carbon dioxide water-source heat pump through the first water pump, and high-temperature hot water at 80°C is output through the condenser in the water-source heat pump assembly. It is injected into the hot water tank through the second water pump. The hot water tank can supplement softened water to the tank through a softened water makeup valve. The water in the hot water tank is sent to the electric steam generator through the third water pump and a one-way check valve, where it is heated to steam at 5 bar (about 158°C), and is sent to the residual smoke treatment machine through a steam valve. The boiler steam originally used by the residual smoke treatment machine is closed through the original boiler steam stop valve 12, and at the same time, it is sent to the steam bypass of the residual smoke treatment machine, where it is converted into condensed water through a steam trap, and then through a Y-type filter, and is injected into the hot water tank through a pipeline to recycle the high-temperature condensed water.
[0054] This application also provides a method for preparing steam used in a residual smoke treatment machine in a cigarette factory. Using the steam system of any one of the above, it includes the following steps:
[0055] S1. The working fluid of the water-ring vacuum pump transfers heat energy to the first coolant entering the shell-and-tube heat exchanger through the shell-and-tube heat exchanger.
[0056] S2. The heated first coolant is sent into the evaporator through the first water pump.
[0057] S3. The second coolant circulates between the evaporator and the condenser through a compressor, bringing heat into the condenser.
[0058] S4. After the water entering the condenser is heated to the set temperature, it is injected into the hot water tank through the second water pump.
[0059] S5. The hot water in the hot water tank is sent into the electric steam generator through the third water pump, and the steam generated by the electric steam generator is sent into the residual smoke treatment machine.
[0060] In this application, the controller detects the change in the steam consumption of the residual smoke treatment machine. If the steam consumption of the residual smoke treatment machine is within the set range, the controller does not send adjustment signals to the electric steam generator and the third water pump.
[0061] If the steam consumption of the residual smoke treatment machine exceeds the maximum value of the set range, the controller controls the electric steam generator to increase the steam output, and at the same time increases the power of the third water pump.
[0062] If the steam consumption of the residual smoke treatment machine is lower than the minimum value of the set range, the controller controls the electric steam generator to reduce the steam output, and at the same time reduces the power of the third water pump.
[0063] Since the amount of steam used by the residual smoke treatment machine is very small (60 kg / hour), and because the waste heat of the vacuum pump is utilized and the feed water temperature of the steam generator is relatively high (80°C), a heating furnace chamber of the steam generator less than 29 L can meet the requirements.
[0064] The water source heat pump unit of this application is a carbon dioxide heat pump unit with R744 as the working medium. When the inlet water temperature is 30°C, the outlet water temperature of 80°C can be generated.
[0065] Although the embodiments of the present invention have been shown and described, those of ordinary skill in the art can understand that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.
Claims
1. A steam system used in a residual cigarette processor of a cigarette factory, characterized in that, It includes a shell-and-tube heat exchanger, a first water pump, a water source heat pump assembly, a second water pump, a hot water tank, a third water pump, and an electric steam generator; The water source heat pump assembly includes an evaporator, a compressor, an expansion valve, and a condenser; The working fluid outlet of the water ring vacuum pump is connected to the first inlet of the shell-and-tube heat exchanger through a pipeline, and the working fluid inlet of the water ring vacuum pump is connected to the first outlet of the shell-and-tube heat exchanger through a pipeline; The second outlet of the shell-and-tube heat exchanger is connected to the inlet of the first water pump through a pipeline, the outlet of the first water pump is connected to the first inlet of the evaporator through a pipeline, and the second inlet of the shell-and-tube heat exchanger is connected to the first outlet of the evaporator through a pipeline; The second outlet of the evaporator is connected to the inlet of the compressor through a pipeline, the outlet of the compressor is connected to the first inlet of the condenser through a pipeline, the second inlet of the evaporator is connected to the outlet of the expansion valve through a pipeline, and the inlet of the expansion valve is connected to the first outlet of the condenser through a pipeline; The second outlet of the condenser is connected to the inlet of the second water pump through a pipeline, the outlet of the second water pump is connected to the first inlet of the hot water tank through a pipeline, and the first outlet of the hot water tank is connected to the second inlet of the condenser through a pipeline; The second outlet of the hot water tank is connected to the inlet of the third water pump through a pipeline, and the outlet of the third water pump is connected to the inlet of the electric steam generator through a pipeline; The outlet of the electric steam generator is connected to the residual smoke treatment machine through a pipeline.
2. The steam system for the residual cigarette disposer in a cigarette factory according to claim 1, characterized in that, A softened water make-up port is provided on the hot water tank. The softened water make-up port is connected to the softened water source through a pipeline, and a softened water make-up valve is provided on the pipeline.
3. The steam system used in the residual cigarette processor of a cigarette factory according to claim 1, characterized in that, A one-way check valve is provided on the pipeline between the third water pump and the inlet of the electric steam generator.
4. The steam system used in the residual cigarette processor of a cigarette factory according to claim 1, characterized in that, A blowdown port is provided on the lower side of the electric steam generator, and a blowdown valve is provided on the pipeline connected to the blowdown port.
5. The steam system for the waste cigarette processor in a cigarette factory according to claim 1, wherein A steam valve is provided on the pipeline near the outlet of the electric steam generator.
6. The steam system for the residual cigarette processor in a cigarette factory according to claim 1, characterized in that, On the pipeline between the outlet of the electric steam generator and the residual smoke treatment machine, and on the side close to the residual smoke treatment machine, a condensate pipe is connected. The condensate pipe is connected to the hot water tank.
7. The steam system used in the residual cigarette processor of a cigarette factory according to claim 1, characterized in that, A steam trap and a Y-type filter are provided in the condensate pipe.
8. A method for preparing steam used in a residual cigarette processor in a cigarette factory, which utilizes the steam system according to any one of claims 1 to 7 above, characterized in that, It includes the following steps: S1. The working fluid of the water ring vacuum pump transfers heat energy to the first coolant entering the shell-and-tube heat exchanger through the shell-and-tube heat exchanger; S2. The heated first coolant is sent into the evaporator by the first water pump; S3. The second coolant circulates between the evaporator and the condenser through the compressor, and brings heat into the condenser; S4. After the water entering the condenser is heated to the set temperature, it is injected into the hot water tank by the second water pump; S5. The hot water in the hot water tank is sent into the electric steam generator by the third water pump, and the steam generated by the electric steam generator is sent into the residual smoke treatment machine.
9. The method for preparing steam used in the residual cigarette processor of a cigarette factory according to claim 8, characterized in that, The controller detects the change in the steam consumption of the residual smoke treatment machine. If the steam consumption of the residual smoke treatment machine is within the set range, the controller does not send adjustment signals to the electric steam generator and the third water pump; If the steam consumption of the residual smoke treatment machine exceeds the maximum value of the set range, the controller controls the electric steam generator to increase the steam output and simultaneously increase the power of the third water pump; If the steam consumption of the residual smoke treatment machine is lower than the minimum value of the set range, the controller controls the electric steam generator to reduce the steam output and simultaneously reduce the power of the third water pump.