Steam module based on steam heat pump technology and control method thereof

Abstract

The invention relates to the technical field of steam heat pumps, and discloses a steam module based on the steam heat pump technology and a control method thereof.The steam module comprises a preheater, one end of the primary side of the preheater is connected with a waste heat side water pump outlet, the other end is connected with an evaporator inlet, one end of the secondary side is connected with a tap water supplementing inlet, and the other end is connected with an open type water tank; the primary side of the open water tank is connected with the gas-liquid separator through a drain valve, and the secondary side is connected with one end of the primary side of the condenser through a use side water pump; the primary side of the gas-liquid separator is a steam outlet, and the secondary side is connected with the other end of the primary side of the condenser; one end of the condenser secondary side is connected with one end of the evaporator primary side through an electronic expansion valve, and the other end of the condenser secondary side is connected with the other end of the evaporator primary side through an inverter compressor. The other side of the waste heat side water pump is connected with the other end of the heat source water tank. According to the module, an all-around safety guarantee system is constructed, the energy utilization rate is remarkably increased, and differentiated requirements of users are met.

Description

Technical Field

[0001] This invention relates to the field of steam heat pump technology, specifically to a steam module based on steam heat pump technology and its control method. Background Technology

[0002] Against the backdrop of energy efficiency and low-carbon transformation, traditional steam generation equipment (such as coal-fired boilers and electric heating boilers) is gradually becoming unable to meet the needs of modern industrial and commercial sectors due to high energy consumption and large carbon emissions. Steam modules based on steam heat pumps, as a new type of high-efficiency steam generation technology, have become an important direction for replacing traditional equipment due to their core advantage of "driving with a small amount of high-grade energy to recover heat from low-grade heat sources." Essentially, a steam module based on a steam heat pump is a combination of steam heat pump technology and modular design. Its core logic is to utilize the heat pump's "heat transport" capability to recover heat from low-grade heat sources (such as waste heat from industrial wastewater, ambient air heat, and low-temperature heat energy discharged from other processes), and then drive the recovered heat with a small amount of electricity or a high-temperature heat source to raise the temperature and pressure required for steam generation, ultimately producing saturated steam or superheated steam that meets the demand.

[0003] With the advancement of energy transition and the "dual carbon" goal, steam heat pump steam modules, a new type of steam generation technology integrating "energy saving, low carbon, and flexibility," solve the pain points of high energy consumption and pollution of traditional steam equipment by recovering low-grade heat sources and amplifying energy utilization efficiency. From waste heat recovery in the industrial sector to heating and steam supply in the commercial sector, and production support in the agricultural sector, the modules have shown broad application prospects. Although facing challenges such as high initial investment and heat source stability, with continuous technological advancements (such as high-temperature and high-pressure processing and intelligentization) and policy support, steam heat pump steam modules will inevitably become the mainstream direction of future steam supply, providing important support for achieving the "dual carbon" goal and sustainable energy development.

[0004] Existing steam modules are insufficient to meet different needs, thus failing to match the diverse and high-precision steam requirements of various industries. Furthermore, pressure fluctuations can cause abnormal operation of steam-using equipment, making it difficult to meet users' differentiated needs and indirectly leading to increased costs. Summary of the Invention

[0005] (a) Technical problems to be solved

[0006] To address the shortcomings of existing technologies, this invention provides a steam module and its control method based on steam heat pump technology. It features a comprehensive safety assurance system built through multiple hardware designs and intelligent interlocking control, effectively avoiding operational risks and ensuring stable output. Through efficient heat recovery and precise load regulation, it significantly improves energy utilization, reduces operating costs, and meets the diverse needs of users.

[0007] (II) Technical Solution

[0008] To achieve the above objectives, the present invention provides the following technical solution: a steam module based on steam heat pump technology, including a preheater, wherein one end of the primary side of the preheater is connected to the outlet of the waste heat side water pump and the other end is connected to the inlet of the evaporator, and one end of the secondary side is connected to the tap water supply inlet and the other end is connected to an open water tank.

[0009] The primary side of the open water tank is connected to the gas-liquid separator via a drain valve, and the secondary side is connected to one end of the primary side of the condenser via a side water pump.

[0010] The primary side of the gas-liquid separator is a steam outlet, and the secondary side is connected to the other end of the primary side of the condenser.

[0011] One end of the secondary side of the condenser is connected to one end of the primary side of the evaporator via an electronic expansion valve, and the other end of the secondary side of the condenser is connected to the other end of the primary side of the evaporator via a variable frequency compressor.

[0012] One end of the secondary side of the evaporator is connected to one end of the heat source water tank, and the other end of the waste heat side water pump is connected to the other end of the heat source water tank.

[0013] Preferably, the preheater is a plate heat exchanger, and the primary and secondary sides are completely isolated to avoid cross-contamination of the water circuit.

[0014] Preferably, the open water tank has a built-in two-stage liquid level switch. The first-stage liquid level switch is linked to the water replenishment electric valve. When the liquid level in the open water tank is lower than the liquid level height of the first-stage liquid level switch, the water replenishment electric valve opens to ensure that there is sufficient water in the open water tank and at the same time maintain a constant inlet pressure of the side water pump, so as to ensure stable output of the side water pump. When the liquid level gradually rises to the liquid level height of the other stage liquid level switch, the water replenishment electric valve closes to stop water replenishment and prevent excessive water replenishment from overflowing and causing waste.

[0015] Preferably, the preheater is connected to an electric valve at the connection end with the tap water inlet.

[0016] Preferably, the steam outlet of the gas-liquid separator is equipped with a pressure measuring point.

[0017] Preferably, a temperature measuring point is provided at the midpoint of the connection between the condenser and the side water pump, and a similar temperature measuring point is provided at the midpoint of the connection between the condenser and the gas-liquid separator.

[0018] Preferably, a temperature measuring point is provided at the connection end between the evaporator and the preheater, and a temperature measuring point is also provided at the connection end with the heat source water tank.

[0019] Preferably, the connection end between the preheater and the tap water inlet is also connected to a water softener, and the water dispenser is used to filter the tap water at the tap water inlet.

[0020] Preferably, the preheater, open water tank, condenser, and evaporator together constitute a steam module system. All water pumps and electric valves in the steam module system are interlocked with the control system to issue an alarm and cut off the power supply in case of an abnormality.

[0021] A control method for a steam module based on steam heat pump technology, the steam module based on steam heat pump technology includes the following steps:

[0022] Step 1: Select a plate heat exchanger as the preheater and completely isolate the primary and secondary sides of the preheater to avoid cross-contamination of the water circuit;

[0023] Step 2: Connect one end of the primary side of the preheater to the outlet of the waste heat side water pump and the other end to the inlet of the evaporator. Connect one end of the secondary side to the tap water inlet and the other end to the open water tank.

[0024] Step 3: Connect the primary side of the open water tank to the gas-liquid separator via a drain valve, and connect the secondary side to one end of the primary side of the condenser via a side water pump.

[0025] Step 4: Set the primary side of the gas-liquid separator as the steam outlet, and connect the secondary side to the other end of the primary side of the condenser.

[0026] Step 5: Connect one end of the secondary side of the condenser to one end of the primary side of the evaporator through an electronic expansion valve, and connect the other end of the secondary side of the condenser to the other end of the primary side of the evaporator through a variable frequency compressor.

[0027] Step 6: Connect one end of the secondary side of the evaporator to one end of the heat source water tank, and connect the other end of the waste heat side water pump to the other end of the heat source water tank.

[0028] Compared with the prior art, the present invention provides a steam module and its control method based on steam heat pump technology, which has the following beneficial effects:

[0029] 1. This invention constructs a comprehensive safety assurance system through multiple hardware designs and intelligent interlocking control, effectively avoiding operational risks and ensuring stable output. First, the plate heat exchanger design of the preheater achieves complete isolation between the primary and secondary sides. Combined with a water softener at the tap water supply end, it can prevent cross-contamination of water circuits to ensure water safety, and filter impurities in the water to avoid scaling and clogging inside the equipment, extending the service life of core components such as heat exchangers and water pumps. Second, the two-stage liquid level switch of the open water tank is deeply linked with the control system to ensure sufficient water in the open water tank and maintain stable system operation. Finally, the pressure measurement point at the steam outlet of the gas-liquid separator and the temperature measurement point at the key connection point of the condenser and evaporator can capture pressure and temperature anomalies in real time. Combined with the interlocking protection of the water pumps and electric valves of the whole system, it can promptly alarm and cut off the power supply in the early stage of failure, minimizing the risk of equipment damage and providing a solid guarantee for a continuous and stable steam supply.

[0030] 2. This invention significantly improves energy utilization and reduces operating costs through efficient heat recovery and precise load regulation. Firstly, the preheater fully recovers heat from the heat source tank supplied by the waste heat pump, preheating the tap water before it enters the open water tank. This avoids energy waste caused by cold water directly entering the system. Simultaneously, it increases the water temperature in the open water tank, thereby raising the condenser inlet water temperature, reducing refrigerant heat exchange temperature difference losses, and indirectly improving the overall energy efficiency of the unit. Then, the liquid water separated by the gas-liquid separator undergoes secondary separation via a drain valve, and the hot water flows directly back to the open water tank, realizing the heat recovery process. By recycling heat, heat loss is further reduced, lowering the energy consumption required for unit heating. Meanwhile, the coordinated operation of the condenser and the variable frequency compressor can precisely adjust the compressor's operating status based on pressure changes fed back from the steam outlet pressure measurement point of the gas-liquid separator. When the user's steam consumption increases, the compressor is loaded to increase steam production; when the consumption decreases, the compressor is unloaded to reduce energy consumption, avoiding energy waste. The temperature measurement points at the key connection points of the evaporator can assist in monitoring the heat output of the heat source water tank, providing data support for optimizing waste heat recovery efficiency, effectively reducing the energy consumption cost per unit of steam production, and bringing significant economic benefits to users. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the module flow of the present invention;

[0032] Figure 2 This is a flowchart illustrating the module control method of the present invention. Detailed Implementation

[0033] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0034] Please see Figures 1-2 A steam module based on steam heat pump technology includes a preheater. One end of the primary side of the preheater is connected to the outlet of the waste heat side water pump, and the other end is connected to the inlet of the evaporator. One end of the secondary side is connected to the tap water inlet, and the other end is connected to an open water tank. The preheater uses a plate heat exchanger, and the primary and secondary sides are completely isolated to avoid cross-contamination of water circuits. An electric valve is connected to the connection end between the preheater and the tap water inlet. A water softener is also connected to the connection end between the preheater and the tap water inlet. A water dispenser is used to filter the tap water at the tap water inlet.

[0035] The electric valve precisely controls the water supply, and the liquid level switch enables automatic pressure stabilization and water supply. The water softener effectively removes impurities and ions from the water, preventing scale buildup that clogs the heat exchanger channels and avoiding impurities from entering steam-using equipment and affecting quality. It also fully recovers waste heat to preheat the water supply, raising the base water temperature of the open water tank and reducing subsequent heating energy consumption. At the same time, the water purification system ensures clean operation, extends equipment life, and forms an efficient, stable, and safe energy recycling system.

[0036] The primary side of the open water tank is connected to the gas-liquid separator via a drain valve, while the secondary side is connected to one end of the primary side of the condenser via a side water pump. The open water tank has a built-in two-stage liquid level switch. The first-stage liquid level switch is linked to the water supply electric valve. When the liquid level in the open water tank is lower than the liquid level height of the first-stage liquid level switch, the water supply electric valve opens to ensure that there is sufficient water in the open water tank and at the same time maintain a constant inlet pressure of the side water pump, so as to ensure stable output of the side water pump. When the liquid level gradually rises to the liquid level height of the other stage liquid level switch, the water supply electric valve closes to stop water supply and prevent excessive water supply from overflowing and causing waste.

[0037] The open water tank forms a heat recovery loop with the gas-liquid separator through a drain valve, enabling the high-temperature condensate after separation to be returned to the system for reuse. The secondary side supplies water to the condenser stably via a side water pump. With the help of a built-in two-stage liquid level switch, intelligent control is achieved. The first stage is linked to the water supply electric valve to dynamically maintain the water level and ensure that the inlet pressure of the side water pump is constant to ensure stable flow output. The second stage closes the water supply electric valve to avoid waste, which significantly improves the stability and reliability of the equipment operation, while reducing energy consumption and maintenance costs.

[0038] The primary side of the gas-liquid separator is the steam outlet, and the secondary side is connected to the other end of the primary side of the condenser. A pressure measuring point is set at the steam outlet of the gas-liquid separator.

[0039] The primary side of the gas-liquid separator is the steam outlet, enabling direct steam supply and achieving the goal of direct steam output. The secondary side precisely guides the separated liquid water into the other port of the condenser for heat exchange. The pressure measuring point located at the steam outlet monitors pressure changes in real time, providing key parameter data for the control system. This ensures that qualified saturated steam is stably delivered to the steam-using equipment. It can also dynamically adjust the subsequent process through pressure feedback to prevent wet steam from damaging process quality or equipment safety. At the same time, it optimizes energy transfer efficiency, significantly improving the thermal balance and operational reliability of the entire system, and achieving efficient separation of steam and condensate.

[0040] One end of the secondary side of the condenser is connected to one end of the primary side of the evaporator through an electronic expansion valve, and the other end of the secondary side of the condenser is connected to the other end of the primary side of the evaporator through a variable frequency compressor. A temperature measuring point is set at the middle of the connection between the condenser and the side water pump, and a temperature measuring point is also set at the middle of the connection between the condenser and the gas-liquid separator.

[0041] One end of the secondary side of the condenser is equipped with an electronic expansion valve to precisely match the refrigerant flow to the evaporator inlet, while the other end is equipped with a variable frequency compressor to synchronously regulate the power output, forming a closed-loop refrigeration cycle system. Temperature measurement points are set up to monitor the medium temperature at the connection with the gas-liquid separator and the side water pump in real time, enabling the control system to dynamically optimize the superheat and subcooling parameters, ensuring that the heat pump unit operates in the optimal energy efficiency range, significantly improving system reliability, energy saving and response speed, and achieving flexible adaptation of steam supply and efficient heat energy conversion;

[0042] One end of the secondary side of the evaporator is connected to one end of the heat source water tank, and the other end of the waste heat side water pump is connected to the other end of the heat source water tank. Temperature measuring points are set at the connection end between the evaporator and the preheater, and also at the connection end with the heat source water tank.

[0043] The evaporator and waste heat side water pump form a closed-loop circulation system by connecting to the heat source water tank at both ends, forming a stable water flow path. The deployed temperature measuring points monitor the water temperature changes at the inlet and outlet of the evaporator in real time. One temperature measuring point is located at the connection end of the preheater to accurately capture the waste heat recovery efficiency, and the other temperature measuring point is set at the interface of the heat source water tank to dynamically track the temperature gradient of the main circulation. Through the bidirectional temperature control layout, the system can evaluate the heat transfer efficiency in real time, automatically balance the waste heat utilization rate and the heating demand, and ensure that the heat pump unit always operates in the optimal operating range, realizing energy cascade utilization and long-term stable operation of the equipment.

[0044] The preheater, open water tank, condenser, and evaporator together constitute the steam module system. All water pumps and electric valves in the steam module system are interlocked with the control system to issue an alarm and cut off the power supply in case of an abnormality.

[0045] The integrated preheater, open water tank, condenser, and evaporator form a steam module system, realizing a deep interlock protection mechanism for all water pumps and electric valves in the same control system. When abnormal operating conditions are detected, the system issues an alarm and cuts off the power supply, effectively avoiding the risk of equipment overload or medium leakage. It builds multiple protection barriers to ensure the safety of personnel and equipment, can accurately locate the source of the fault and accelerate the troubleshooting process, and at the same time, through linkage control, it ensures that each unit shuts down in a coordinated manner to prevent secondary damage, significantly improving system reliability and operation and maintenance efficiency, and providing all-weather safety guarantee for industrial-grade steam supply.

[0046] The specific control method for the above-mentioned steam module is as follows, including the following steps:

[0047] Step 1: Select a plate heat exchanger as the preheater and completely isolate the primary and secondary sides of the preheater to avoid cross-contamination of the water circuit;

[0048] Step 2: Connect one end of the primary side of the preheater to the outlet of the waste heat side water pump and the other end to the inlet of the evaporator. Connect one end of the secondary side to the tap water inlet and the other end to the open water tank.

[0049] Step 3: Connect the primary side of the open water tank to the gas-liquid separator via a drain valve, and connect the secondary side to one end of the primary side of the condenser via a side water pump.

[0050] Step 4: Set the primary side of the gas-liquid separator as the steam outlet, and connect the secondary side to the other end of the primary side of the condenser.

[0051] Step 5: Connect one end of the secondary side of the condenser to one end of the primary side of the evaporator through an electronic expansion valve, and connect the other end of the secondary side of the condenser to the other end of the primary side of the evaporator through a variable frequency compressor.

[0052] Step 6: Connect one end of the secondary side of the evaporator to one end of the heat source water tank, and connect the other end of the waste heat side water pump to the other end of the heat source water tank.

[0053] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A steam module based on steam heat pump technology, characterized in that, The preheater has one end connected with the outlet of the waste heat side water pump and the other end connected with the inlet of the evaporator, one end of the secondary side is connected with the tap water supplement inlet and the other end is connected with the open water tank; The one side of the open water tank is connected with the gas-liquid separator through the drain valve and the other side is connected with the one end of the primary side of the condenser through the use side water pump; The one side of the gas-liquid separator is the steam outlet and the other side is connected with the other end of the primary side of the condenser; The one end of the secondary side of the condenser is connected with the one end of the primary side of the evaporator through the electronic expansion valve and the other end is connected with the other end of the primary side of the evaporator through the variable frequency compressor; The one end of the secondary side of the evaporator is connected with one end of the heat source water tank and the other end of the waste heat side water pump is connected with the other end of the heat source water tank.

2. A steam module based on steam heat pump technology and a control method thereof according to claim 1, characterized in that: The preheater is a plate heat exchanger and the primary side and the secondary side are completely isolated to avoid cross contamination of waterways.

3. A steam module based on steam heat pump technology and a control method thereof according to claim 2, characterized in that: The open water tank is provided with two-stage liquid level switches, the first stage liquid level switch is linked with the water supplement electric valve, when the liquid level in the open water tank is lower than the liquid level of the first stage liquid level switch, the water supplement electric valve is opened, when the liquid level gradually rises to the liquid level of the other stage liquid level switch, the water supplement electric valve is closed.

4. The steam module based on vapor heat pump technology and the control method thereof according to claim 2, characterized in that: The connection end of the preheater and the tap water supplement inlet is connected with an electric valve.

5. The steam module based on vapor heat pump technology and the control method thereof according to claim 4, characterized in that: The steam outlet of the gas-liquid separator is provided with a pressure measuring point.

6. The steam module based on vapor heat pump technology and the control method thereof according to claim 5, characterized in that: The middle end of the condenser connected with the side water pump is provided with a temperature measuring point and the middle end connected with the gas-liquid separator is also provided with a temperature measuring point.

7. A steam module based on steam heat pump technology and a control method thereof according to claim 6, characterized in that: The middle end of the evaporator connected with the preheater is provided with a temperature measuring point and the middle end connected with the heat source water tank is also provided with a temperature measuring point.

8. The steam module based on vapor heat pump technology and the control method thereof according to claim 7, characterized in that: The connection end of the preheater and the tap water supplement inlet is also connected with a water softener, the water dispenser is used for filtering and treating the tap water of the tap water supplement inlet.

9. The steam module based on vapor heat pump technology and the control method thereof according to claim 8, characterized in that: The preheater, the open water tank, the condenser and the evaporator jointly constitute a steam module system, all the water pumps and electric valves in the steam module system are interlocked with the control system to send an alarm and cut off the power supply when an abnormality occurs.

10. A method for controlling a steam module based on steam heat pump technology, applied to the steam module based on steam heat pump technology according to any one of claims 1-9, characterized in that, The method comprises the following steps: Step one, a plate heat exchanger is selected as the preheater and the primary side and the secondary side of the preheater are completely isolated to avoid cross contamination of waterways; Step two, one end of the primary side of the preheater is connected with the outlet of the waste heat side water pump, the other end is connected with the inlet of the evaporator, one end of the secondary side is connected with the tap water supplement inlet and the other end is connected with the open water tank; Step three, the one side of the open water tank is connected with the gas-liquid separator through the drain valve and the other side is connected with the one end of the primary side of the condenser through the use side water pump; Step four, the one side of the gas-liquid separator is set as the steam outlet and the other side is connected with the other end of the primary side of the condenser; Step five, the one end of the secondary side of the condenser is connected with the one end of the primary side of the evaporator through the electronic expansion valve and the other end is connected with the other end of the primary side of the evaporator through the variable frequency compressor; Step six, the one end of the secondary side of the evaporator is connected with one end of the heat source water tank and the other end of the waste heat side water pump is connected with the other end of the heat source water tank.

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