High temperature heat pump steam generation system

Abstract

The application discloses a high-temperature heat pump steam generation system, which comprises a first tank body, a second tank body, a first coil pipe, a second coil pipe, a third coil pipe and a connecting pipeline. The first coil pipe utilizes waste heat of lubricating oil of an air compressor to heat water in the first tank body to generate steam, which is sent into a lower cavity spherical tank of the second tank body through the connecting pipeline; the second coil pipe further heats the steam; a large-arc-shaped cover at the top of the lower cavity spherical tank realizes gas-liquid separation; after the separation, the steam enters an upper cavity spherical tank and is heated into superheated steam through the third coil pipe and then is sent out. The device fully recovers waste heat of the air compressor, is energy-saving and efficient through the double-tank-body and multi-coil-pipe design and the gas-liquid separation structure, can meet the requirements of multiple scenes and has a good application prospect.

Description

Technical Field

[0001] This application relates to the field of compressed air technology, and in particular to high-temperature heat pump steam generation systems. Background Technology

[0002] In the fields of industrial production and civil heat energy transmission, steam has always played a key role due to its unique energy transmission advantages. As one of the important equipment for steam supply, the application status and problems of high-temperature heat pump steam engines have attracted much attention.

[0003] From the current state of steam usage, various steam parameters directly determine the energy transfer efficiency. Among the hard parameters, pressure is the core element, directly affecting whether steam can quickly and efficiently transfer heat from the generation end to the user end; insufficient pressure will significantly reduce heat transfer efficiency. Regarding non-hard parameters, the flexibility of gas composition provides more possibilities for steam applications in different scenarios. At the same time, the vast differences in characteristics of different heat sources determine that the appropriate steam parameters vary. Heat sources such as nuclear power plants and coal-fired power plants generate extremely high energy, with temperatures reaching hundreds of degrees Celsius and extremely high energy density, capable of rapidly heating water to a high-temperature, high-pressure steam state. This type of steam is suitable for large-scale chemical production, power generation, and other fields with stringent parameter requirements, meeting the needs of high-energy-consuming industrial scenarios. Furthermore, water, as the source and energy carrier of steam, possesses excellent properties; its phase change process involves enormous energy changes. Under standard atmospheric pressure, when water boils at 100°C and turns into a gaseous state, it absorbs about 7 times the amount of heat required for its liquid state to rise to 100°C. Moreover, because of the large intermolecular distance, gaseous water has much less flow resistance in pipes than liquid water, enabling long-distance and efficient transmission with lower energy consumption. Traditional hot steam systems rely on this characteristic to achieve heat transfer.

[0004] However, high-temperature heat pump steam engines currently face numerous challenges in practical applications, severely limiting their promotion and development. The primary problem is insufficient outlet pressure, which directly leads to low heat transfer efficiency, failing to meet the demands for rapid and efficient heat transfer in some scenarios. Simultaneously, the temperature is difficult to meet the requirements of some industrial production scenarios, significantly narrowing its applicability. To address these performance issues, some large enterprises have adopted a steam compressor supplementary solution. While this alleviates the pressure and temperature problems to some extent, it introduces new challenges. This solution not only has a low energy efficiency ratio, resulting in additional energy consumption, but also requires large equipment size and ample space, along with excessive power consumption. This is undoubtedly a heavy burden for small and medium-sized enterprises with limited funds and space, making it difficult for them to bear the cost and space investment of this solution.

[0005] Further analysis reveals that the challenges faced by high-temperature heat pump steam engines are also closely related to the characteristics of air source heat sources. Due to the energy limitations of air source heat pumps, it is difficult to directly heat water to the high-temperature and high-pressure state required for traditional steam. Following conventional thinking, to achieve the same steam parameters as traditional heat sources such as nuclear power plants and coal-fired power plants, air source heat pumps would need to heat water to 400-500 degrees Celsius, which far exceeds the feasibility of current technology. Therefore, unless conventional thinking is broken and the reliance on the traditional model of water boiling and vaporizing at 100°C is changed, high-temperature heat pump steam engines will struggle to overcome application bottlenecks and better adapt to the diverse needs of industrial and civilian applications. In-depth research into the characteristics of steam usage and the exploration of new improvement methods are urgently needed. Summary of the Invention

[0006] The purpose of this invention is to provide a high-temperature heat pump steam generation system. Through innovative structural design, it fully utilizes the waste heat of air compressor lubricating oil to achieve efficient gas-liquid separation and superheated steam generation. This solves the problems of insufficient outlet pressure and temperature that are difficult to meet requirements in existing high-temperature heat pump steam engines, as well as the low energy efficiency and high cost of traditional improvement solutions. It provides energy-saving, efficient, and cost-controllable superheated steam supply equipment for industrial production and civil applications, while also taking into account the compactness and ease of maintenance of the equipment, making it suitable for the needs of enterprises of different sizes.

[0007] To achieve the above-mentioned objectives, the present invention adopts the following technical solution:

[0008] A high-temperature heat pump steam generation system includes a first tank, a second tank, a first coil, a second coil, a third coil, and connecting pipes. The components work together to achieve efficient conversion from water to superheated steam.

[0009] 1. Core component structure.

[0010] The first tank has an elliptical cross-section and is used to hold the water to be heated. It is externally insulated with rock wool or polyurethane insulation layer, 50-80mm thick, which effectively reduces heat loss and improves the heating efficiency of the first coil. The first tank has a water inlet at the top and a drain outlet at the bottom. A flow control valve is installed at the water inlet to automatically adjust the water supply based on the water level. A drain valve is installed at the drain outlet to facilitate the periodic removal of sediment and ensure clean water.

[0011] The second tank has an elliptical cross-section and is internally divided into a lower and upper spherical tank. These two chambers are independent yet connected by a specific channel, enabling staged heating of steam and gas-liquid separation. A drain outlet is located at the bottom of the second tank, connected to a condensate recovery pipe equipped with a check valve and filter to prevent condensate backflow and filter impurities. An inspection port is located at the top of the second tank for easy equipment maintenance and internal cleaning.

[0012] The first coil, located inside the first tank, employs a serpentine tube structure. The tubes are made of 304 stainless steel, with an outer diameter of 20-30mm and a wall thickness of 2-3mm. The serpentine layout increases the contact area between the first coil and the water inside the first tank, thereby improving heat exchange efficiency. Both the inlet and outlet ends of the first coil extend to the outside of the first tank and are connected to the air compressor lubricating oil waste heat recovery pipeline via flange joints to achieve heat transfer.

[0013] The second coil, located inside the lower chamber of the second tank, also employs a serpentine tube structure and is made of copper alloy tubing. The copper alloy material is either brass or copper, with an outer diameter of 18-25mm and a wall thickness of 1.5-2.5mm. This structure allows the second coil to fully contact the steam inside the lower chamber, enhancing the steam heating effect. The inlet and outlet ends of the second coil extend to the outside of the second tank, connecting to the air compressor lubricating oil waste heat recovery system to obtain the heat required for heating.

[0014] The third coil, located inside the upper spherical tank of the second tank, is a serpentine structure made of copper alloy tubing with the same outer diameter as the second coil. The serpentine structure increases the contact area between the third coil and the steam in the upper spherical tank, facilitating thorough heating to generate superheated steam. The inlet pipe of the third coil can be connected to the air compressor lubricating oil waste heat recovery system or the heat supply structure of the auxiliary heat source. Auxiliary heat sources can include electric heaters, gas heaters, etc., and the heat source can be switched via a three-way valve to flexibly obtain the heat required for heating the steam, ensuring stable system operation even when the air compressor waste heat is insufficient.

[0015] Connecting Piping: Stainless steel pipes, specifically 304 or 316L stainless steel, extend from the steam outlet of the first tank to the bottom of the lower chamber spherical tank. This connects the steam outlet of the first tank to the bottom of the lower chamber spherical tank of the second tank, allowing steam generated in the first tank to directly enter the bottom of the lower chamber spherical tank and fully contact the second coil for heat exchange. The connecting piping is equipped with a pressure gauge, a temperature sensor, and a shut-off valve. The pressure gauge monitors the steam pressure, the temperature sensor provides real-time feedback on the steam temperature, and the shut-off valve cuts off the steam passage during equipment maintenance.

[0016] 2. Gas-liquid separation structure.

[0017] Large arc-shaped hood: Fixed above the lower chamber spherical tank of the second tank body, with its opening facing downwards and covering the lower chamber spherical tank, it is made of stainless steel with a thickness of 3-5mm. A ring-shaped gap, 50-80mm wide, is left between the edge of the large arc-shaped hood and the inner wall of the lower chamber spherical tank. This gap provides a channel for steam flow and also provides a channel for liquid droplets above the large arc-shaped hood to flow downwards. The large arc-shaped hood guides the flow direction of steam exiting the lower chamber spherical tank and promotes gas-liquid separation, causing condensate droplets in the steam to drip downwards along the arc-shaped hood wall.

[0018] Small arc-shaped cover: Located above the lower chamber spherical tank of the second tank body, between the large arc-shaped cover and the lower chamber spherical tank, with its opening facing downwards and covering the lower chamber spherical tank, it is also made of stainless steel. The arc length of the small arc-shaped cover is smaller than that of the large arc-shaped cover, with an arc length ratio of 1:2-1:3. The small arc-shaped cover is fixed to the lower chamber spherical tank by support rods, and the large arc-shaped cover is fixed to the small arc-shaped cover by support rods, thus indirectly fixing it to the lower chamber spherical tank. The small arc-shaped cover is used to initially guide the flow direction of the steam, performing preliminary gas-liquid separation. The large arc-shaped cover is used to guide the flow direction of the steam a second time, further separating water droplets from the steam. The double arc-shaped cover design significantly improves the gas-liquid separation efficiency.

[0019] 3. Connecting chamber structure.

[0020] A connecting hole is formed at the top of the lower chamber spherical tank. This connecting hole is used to connect the inner cavity of the lower chamber spherical tank and the inner cavity of the second tank. The diameter of the connecting hole is 80-120mm, and it is coaxially set with the second tank to ensure that the steam flows out evenly.

[0021] The bottom of the upper chamber spherical tank has multiple through holes, with a number of 4-8 holes, evenly distributed on the circumference centered on the tank axis. The diameter of the through holes is 30-50mm, and the opening direction is downward to avoid excessive moisture entering the upper chamber spherical tank and to ensure that the moisture content of the steam entering the upper chamber spherical tank is at a low level.

[0022] The top of the upper chamber spherical tank is fixedly connected to the top of the inner wall of the second tank via 3-4 evenly distributed support rods, allowing the upper chamber spherical tank to hang on the second tank. Similarly, the bottom of the lower chamber spherical tank is fixedly connected to the bottom of the inner wall of the second tank via 3-4 evenly distributed support rods, ensuring the lower chamber spherical tank is stably placed on the second tank. The second tank, upper chamber spherical tank, lower chamber spherical tank, large arc-shaped cover, and small arc-shaped cover are coaxially arranged to ensure smooth steam flow and reduce flow resistance.

[0023] 4. Superheated steam output structure

[0024] The superheated steam outlet pipes pass through both the second tank and the upper spherical tank. The outlet pipes are made of stainless steel, with an outer diameter of 30-40 mm and a wall thickness of 3-4 mm. The portion of the outlet pipe inside the upper spherical tank has multiple steam inlet holes to ensure that the superheated steam from the upper spherical tank can enter the outlet pipe evenly. The portion of the outlet pipe extending outside the second tank is equipped with a pressure regulating valve, a temperature display, and a flow meter. The pressure regulating valve allows adjustment of the output steam pressure according to user needs, the temperature display shows the superheated steam temperature in real time, and the flow meter is used to calculate steam usage, facilitating energy consumption accounting for the user.

[0025] 5. Auxiliary systems.

[0026] Control system: Includes a PLC controller, temperature sensors, pressure sensors, and level sensors. Temperature sensors are installed in the first tank, the lower chamber spherical tank, the upper chamber spherical tank, and the superheated steam outlet pipe. Pressure sensors are installed in the connecting pipes and the superheated steam outlet pipe. Level sensors are installed inside the first tank. Each sensor transmits the collected temperature, pressure, and level signals to the PLC controller. The PLC controller automatically adjusts the heat transfer fluid flow in the first and second coils, as well as the heat source switching in the third coil, according to preset parameters. Simultaneously, it controls the opening and closing of the water supply valve, drain valve, and drain valve, achieving automated system operation.

[0027] Safety protection system: Both the first and second tanks are equipped with safety valves. The opening pressure of the safety valves is set to 1.2 times the system working pressure. When the pressure inside the tank exceeds the set value, the safety valve will automatically release pressure to ensure equipment safety. The system is also equipped with an over-temperature protection device. When the steam temperature exceeds the preset upper limit, the PLC controller will automatically cut off the heat source supply to prevent equipment damage. In addition, the bottom of the first and second tanks is equipped with support feet, and shock-absorbing pads are installed on the support feet to reduce vibration during equipment operation and facilitate equipment installation and fixation.

[0028] Compared with the prior art, the high-temperature heat pump steam generation system of the present invention has the following significant advantages:

[0029] 1) Significant energy-saving advantages

[0030] This device innovatively utilizes the waste heat of the air compressor's lubricating oil, recovering previously wasted low-grade heat for steam generation, thus achieving energy reuse and breaking the dependence of traditional steam generators on high-grade energy. Compared with traditional electric or gas-fired steam generators, this system can save 30%-50% of energy. It requires no additional consumption of large amounts of electricity or fossil fuels during operation, reducing users' energy costs and carbon emissions, complying with national energy conservation and emission reduction policies, and demonstrating significant environmental benefits. Simultaneously, the third coil allows for flexible switching of auxiliary heat sources, ensuring system operation even when air compressor waste heat is insufficient, further optimizing energy utilization efficiency.

[0031] 2) High efficiency in heat exchange and steam generation

[0032] Through a dual-tank structure and a three-coil staged heating design, steam gradually absorbs heat during generation, resulting in a thorough and efficient heat exchange process. The first, second, and third coils all employ a serpentine tube structure, significantly increasing the contact area with water or steam and improving the heat exchange coefficient. The double-arc shroud's gas-liquid separation design effectively removes water droplets from the steam, preventing them from affecting heat exchange efficiency and ensuring the quality of the superheated steam. The entire system boasts high heat exchange efficiency, rapidly and efficiently generating sufficient superheated steam to meet demand. Compared to traditional high-temperature heat pump steam engines, the increased steam generation speed better meets the continuous and stable steam supply requirements of industrial production.

[0033] 3) Outstanding cost advantage

[0034] Low initial investment cost: For small and medium-sized enterprises, this device does not require a large and expensive steam compressor supplementation scheme. The overall cost of the equipment is only more than half of that of the traditional steam compressor supplementation scheme, which greatly reduces the initial investment cost of the equipment and makes it affordable for small and medium-sized enterprises.

[0035] Low operating costs: By primarily utilizing waste heat from the air compressor, the consumption of expensive energy sources such as electricity and natural gas is reduced, resulting in lower energy costs compared to existing technologies. Simultaneously, the condensate recovery system recycles and reuses the separated condensate, further reducing water resource consumption costs.

[0036] Low maintenance cost: The device has a simple structural design, and the core components are made of high-quality materials that are corrosion-resistant and high-temperature resistant, resulting in a long service life. The layout of each component is reasonable, the inspection ports are conveniently located, and maintenance is relatively simple. No professional maintenance team is required, and the annual maintenance cost is low, far lower than that of traditional steam generators.

[0037] 4) Wide range of applications

[0038] Adjustable parameters to meet diverse needs: The superheated steam generated by this device can be adjusted between 120-180℃ in temperature and between 0.8-1.6MPa in pressure, meeting the needs of different fields. Whether it is the high-temperature, high-pressure steam required in chemical production, the medium-temperature, medium-pressure steam required in food processing and medical sterilization, or the low-temperature, low-pressure steam required for civil heating, this system can achieve precise adaptation by adjusting parameters.

[0039] Compact size and low site requirements: The device adopts a double-tank elliptical design, which is compact in structure and occupies only 2 / 3 of the area of ​​traditional steam generators. It does not have high requirements for site space and can be flexibly installed in workshops of large factories or small spaces of small enterprises.

[0040] Adaptable to businesses of different sizes: This system can be designed with different specifications and models according to the user's steam demand, ranging from 0.5 tons to 5 tons of steam per hour. It is suitable for large industrial enterprises with large-scale steam demand, as well as small and medium-sized enterprises with medium-scale steam demand. It can also meet the steam supply needs of civilian places such as hospitals, schools, and hotels, making it extremely widely applicable.

[0041] 5) Stable and reliable operation advantages

[0042] The system boasts a rational structural design and stable operation: its dual-tank, multi-coil, and dual gas-liquid separation structure ensures the stability of the steam generation process, avoiding common problems in existing equipment such as pressure fluctuations and temperature instability. The insulation structure reduces heat loss, guaranteeing system stability; and the safety protection system effectively prevents overpressure, overtemperature, and other safety risks, ensuring long-term stable operation.

[0043] High steam quality: Through dual gas-liquid separation and three-stage heating, the superheated steam generated by this system has low water content, high purity, and is free of oil and pollution. It can meet the needs of scenarios with high requirements for steam quality, such as food processing and medical sterilization, and avoid the impact of poor steam quality on product quality.

[0044] Long service life: The core components are made of high-quality materials such as 304 stainless steel and copper alloy, which have good corrosion resistance and high temperature resistance, and can withstand long-term high temperature and high pressure operating environment; all connection parts adopt flange joints or welding connections, which have good sealing performance, reduce the risk of leakage, and extend the service life of the equipment. The normal service life of the equipment can reach several years.

[0045] To better understand and implement this application, the following detailed description is provided in conjunction with the accompanying drawings. Attached Figure Description

[0046] Figure 1This is a schematic diagram of the structural principle of a high-temperature heat pump steam generation system exemplified in this application;

[0047] Figure 2 This is a schematic diagram illustrating the working principle of an exemplary high-temperature heat pump steam generation system of this application;

[0048] Figure 3 This is a schematic diagram illustrating the assembly relationship of the various support rods in the second tank body, which is an example of this application.

[0049] Figure 4 This is a three-dimensional structural diagram of the second tank body, which is an example of this application;

[0050] Figure 5 This is a front view of an exemplary second tank body of this application;

[0051] Figure 6 This is a cross-sectional view of a second tank body that is an example of this application. Detailed Implementation

[0052] In the description of this application, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, are used only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on this application. In the description of this application, unless otherwise stated, "a plurality of" means two or more.

[0053] Combination Figure 1-6 The present invention will now be described in further detail.

[0054] A high-temperature heat pump steam generation system includes a first tank 10, a second tank 20, a first coil 31, a second coil 32, a third coil 33, and a connecting pipe 40. The components work together to achieve efficient conversion from water to superheated steam.

[0055] (a) The equipment assembly of the present invention.

[0056] The assembly process for this high-temperature heat pump steam generation system is as follows, and must be carried out strictly in accordance with design requirements and assembly specifications to ensure that the equipment performance meets the standards:

[0057] 1. Component preparation: According to the material and size requirements of the equipment in the technical solution of the instruction manual, configure the first tank 10, the second tank 20, the first coil 31, the second coil 32, the third coil 33, the connecting pipe 40, the large arc cover 51, the small arc cover 52, the support rod, valves, sensors and other components, and conduct quality inspection to ensure that each component meets the design standards and is free from cracks, corrosion, dimensional deviations and other problems.

[0058] 2. Assembly of the first tank body:

[0059] Install the first coil inside the first tank and fix it inside the tank with a bracket, ensuring that there is sufficient gap between the coil and the tank wall to avoid affecting heat exchange.

[0060] Weld the inlet and outlet ends of the first coil to ensure a good seal and no leakage; install flange joints for easy connection to external pipelines.

[0061] An insulation layer is wrapped around the outside of the first tank body. The insulation layer is made of rock wool and is 60mm thick. A waterproof and moisture-proof layer is wrapped around the insulation layer to prevent the insulation material from becoming damp and failing.

[0062] Install the flow control valve at the water inlet, the drain valve at the drain outlet, and the liquid level sensor inside the tank, ensuring that all components are securely installed and functioning properly.

[0063] 3. Assembly of the second tank:

[0064] A support rod is welded to the bottom of the lower chamber spherical tank, and the lower chamber spherical tank is fixed to the inner wall of the bottom of the second tank through the support rod to ensure that the lower chamber spherical tank is coaxial with the second tank.

[0065] Install the second coil, fix it inside the lower chamber spherical tank, weld the inlet and outlet ends, install the flange joint, and ensure a good seal.

[0066] Weld a support rod for the small arc-shaped cover to the top of the lower chamber spherical tank, install the small arc-shaped cover, ensuring that the opening of the small arc-shaped cover faces downward and is coaxial with the lower chamber spherical tank; then install a large arc-shaped cover above the small arc-shaped cover using the support rod, adjust the distance between the large arc-shaped cover and the small arc-shaped cover, and ensure that the circumferential distance between the edge and the inner wall of the lower chamber spherical tank is 10-90mm.

[0067] A support rod is welded to the top of the upper spherical tank, and the upper spherical tank is suspended on the inner wall of the top of the second tank, ensuring that the upper spherical tank and the second tank are coaxial, and that the through hole at the bottom of the upper spherical tank is directly above the large arc-shaped cover.

[0068] Install the third coil, fix it inside the upper chamber spherical tank, weld the inlet and outlet ends, and install a three-way valve to connect it to the air compressor waste heat recovery system and auxiliary heat source.

[0069] Install the drain valve, check valve, and filter at the bottom of the second tank, the inspection port at the top, and the temperature and pressure sensors inside the tank.

[0070] 4. Piping assembly:

[0071] 304 stainless steel connecting pipes are used to connect the steam outlet of the first tank to the bottom of the lower chamber of the second tank, ensuring that the pipes are installed firmly, with a reasonable slope, to facilitate steam flow.

[0072] Install pressure gauges, temperature sensors, and shut-off valves on the connecting pipelines, and adjust the valve positions for easy operation and maintenance.

[0073] 5. Assembly of control and safety protection systems:

[0074] Install the PLC controller and electrically connect the temperature sensor, pressure sensor, liquid level sensor, flow control valve, drain valve, drain valve, three-way valve, safety valve, over-temperature protection device, etc. to the PLC controller to ensure smooth signal transmission.

[0075] Adjust the parameter settings of the control system, preset parameters such as steam temperature, pressure, and water level to ensure that the system can automatically adjust its operation.

[0076] Install shock-absorbing pads on the supports of the first and second tanks, adjust the equipment level, and ensure that the equipment vibrates less during operation.

[0077] 6. Overall debugging:

[0078] Perform an airtightness test on the entire system by introducing compressed air into the tank at a pressure 1.5 times the system's working pressure and maintaining this pressure for 24 hours. Check for leaks at all welded joints, flange connections, valves, and other parts to ensure the system is properly sealed.

[0079] Perform cold-state commissioning, start the control system, and check whether the functions of each valve, sensor, and controller are normal to ensure smooth automated operation.

[0080] Perform hot commissioning, connect to the air compressor lubricating oil waste heat recovery system, start the system, monitor parameters such as steam temperature, pressure, and moisture content, and adjust the heat source switching of the third coil to ensure that the system can stably generate superheated steam that meets the requirements.

[0081] (II) Working principle of the present invention.

[0082] The working process of this high-temperature heat pump steam generation system is as follows: water is gradually converted into superheated steam through three-stage heating and gas-liquid separation:

[0083] 1) Primary Heating Stage: Waste heat from the air compressor lubricating oil is transferred to the first coil via a heat exchange device. The heat transfer medium circulates within the first coil, transferring heat to the water in the first tank. Thanks to the insulation structure, the water in the first tank loses little heat and quickly absorbs heat, heating up to approximately 50°C saturated steam. During this process, a level sensor monitors the water level in the first tank in real time. When the water level falls below a preset value, the PLC controller opens the water supply valve to automatically replenish water; when the water level reaches the set value, the water supply valve closes, ensuring that the first tank always maintains a sufficient water level.

[0084] 2) Secondary Heating Stage: Saturated steam at approximately 50°C generated in the first tank enters directly into the bottom of the lower chamber of the second tank via connecting pipes. During its ascent, the steam comes into full contact with the second coil. The heat transfer medium in the second coil also originates from the waste heat of the air compressor lubricating oil. After absorbing heat, the steam's temperature rises to 80-90°C, and its pressure increases accordingly. Pressure gauges and temperature sensors on the connecting pipes provide real-time feedback on the steam's pressure and temperature data. The PLC controller adjusts the heat transfer medium flow rate based on this data to ensure stable steam parameters.

[0085] 3) Gas-Liquid Separation Stage: Steam heated to 80-90℃ flows out from the connection hole at the top of the lower chamber spherical tank, first contacting the small arc-shaped shroud below. The small arc-shaped shroud initially guides the steam, changing its flow direction. The steam collides with the surface of the small arc-shaped shroud, and some of the steam condenses into water droplets due to the temperature drop. These water droplets drip down the wall of the small arc-shaped shroud to the bottom of the second tank. The steam that has undergone initial separation continues to rise, contacting the large arc-shaped shroud above. The large arc-shaped shroud guides and separates the steam a second time, further removing water droplets from the steam, ensuring that the water content of the steam subsequently entering the upper chamber spherical tank is less than 5%. The separated condensate collects at the bottom of the second tank, where a drain pipe 60 is installed. The condensate is discharged through the drain pipe 60 and recycled through a condensate recovery pipeline, improving water resource utilization.

[0086] 4) Three-stage heating stage: After double gas-liquid separation, the high-temperature steam enters the upper chamber spherical tank through multiple through-holes at the bottom. The downward-facing design of the through-holes further prevents water droplets from entering the upper chamber. The steam entering the upper chamber comes into full contact with the third coil, which is connected to the air compressor lubricating oil waste heat recovery system or an auxiliary heat source according to actual heat demand. Under the heating effect of the third coil, the steam temperature continues to rise, eventually forming superheated steam at 120-180℃ and a pressure of 0.8-1.6MPa.

[0087] 5) Steam Output Stage: The generated superheated steam is sent out through the superheated steam outlet pipe 70 at the top of the upper chamber spherical tank. The pressure regulating valve and temperature display on the outlet pipe can adjust and display the steam parameters in real time to meet the needs of different users. The flow meter records the steam output, which is convenient for users to perform energy consumption statistics and cost accounting.

[0088] Throughout the entire operation, the control system operates automatically, and the safety protection system monitors the equipment's operating status in real time to ensure stable, safe, and efficient operation.

[0089] (III) Equipment operation and maintenance.

[0090] 1. Run the operation.

[0091] Pre-start checks: Before starting the machine, check that all components are securely connected, valves are in the correct position, insulation is intact, and sensors and controllers are working properly. Only start the system after ensuring there are no abnormalities.

[0092] Start-up and Operation: The system is started via the PLC controller. The system automatically replenishes water to the set level in the first tank. Waste heat from the air compressor lubricating oil enters the first and second coils to heat the water and generate steam. During operation, the temperature, pressure, and liquid level parameters displayed on the PLC controller are monitored in real time to ensure they remain within the set range.

[0093] Parameter adjustment: According to user needs, the steam pressure is adjusted by the pressure regulating valve on the superheated steam outlet pipe, and the steam temperature is set by the PLC controller. The system automatically adjusts the heat source supply of the third coil to achieve precise parameter control.

[0094] Shutdown procedure: When shutting down, first disconnect the heat source supply. After the system temperature drops below 80℃ and the pressure drops to normal pressure, close the control system, open the drain valve and drain valve to drain the water and impurities from the tank, ensuring that the inside of the equipment is dry and clean.

[0095] 2. Maintenance and upkeep.

[0096] Routine maintenance: Check system operating parameters daily and record data such as steam output and energy consumption; check for leaks at valves and pipe connections; clean dust and debris from equipment surfaces and keep equipment clean.

[0097] Regular maintenance: Check the insulation layer weekly for integrity and repair any damage promptly; check the accuracy of sensors and controllers monthly and calibrate them; open the drain valve and drain valve quarterly to thoroughly drain sediment and condensate from the tank; clean the first, second, and third coils every six months to remove scale and dirt and improve heat exchange efficiency.

[0098] Annual overhaul: A comprehensive overhaul of the equipment is carried out once a year, checking the wear and tear of each component, replacing aging valves, seals, etc.; non-destructive testing is performed on welded joints to ensure the structural safety of the equipment; and the control system and safety protection system are fully debugged to ensure stable and reliable system operation.

[0099] This high-temperature heat pump steam generation system overcomes many shortcomings of existing technologies through innovative structural design and energy utilization methods. It has significant energy-saving, high efficiency, economy and wide applicability, and can provide a stable and reliable steam supply for industrial production and civil use. It has good market promotion prospects and application value.

[0100] The embodiments described above are merely examples of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these modifications and improvements all fall within the protection scope of this application.

Claims

1. A high-temperature heat pump steam generation system, characterized in that, The system includes a first tank, a second tank, a first coil, a second coil, a third coil, and connecting pipes. The first tank contains water, and the first coil is installed inside the first tank to heat the water, with the heat source being waste heat recovery from the air compressor lubricating oil. The second tank contains a lower spherical tank and an upper spherical tank. The second coil is installed in the lower spherical tank of the second tank to heat the steam entering the lower spherical tank, with the heat source being waste heat recovery from the air compressor lubricating oil. The third coil is installed in the upper spherical tank of the second tank to heat the steam entering the upper spherical tank. The connecting pipes connect the first tank and the second tank, allowing the steam generated in the first tank to enter the lower spherical tank of the second tank. The top of the lower cavity spherical tank has a connecting hole for connecting the inner cavity of the lower cavity spherical tank and the inner cavity of the second tank body; The bottom of the upper cavity spherical tank has a through hole, which is used to connect the inner cavity of the upper cavity spherical tank and the inner cavity of the second tank. The superheated steam outlet pipes pass through the second tank body and the upper spherical tank, respectively.

2. The high-temperature heat pump steam generation system according to claim 1, characterized in that, A large arc-shaped cover is fixed above the lower cavity spherical tank of the second tank body. The opening of the large arc-shaped cover faces downward and covers the lower cavity spherical tank. The bottom of the second tank is provided with a drain outlet; The large arc-shaped hood is used to guide the flow direction of the steam flowing out of the lower spherical tank and promote gas-liquid separation, while the drain outlet is used to discharge the condensate at the bottom of the second tank. An annular gap is left between the edge of the large arc-shaped cover and the inner wall of the lower cavity spherical tank. This gap provides a channel for the flow of steam and also provides a channel for the droplets above the large arc-shaped cover to flow downward.

3. The high-temperature heat pump steam generation system according to claim 2, characterized in that, A small arc-shaped cover is also fixed above the lower cavity spherical tank of the second tank body. The opening of the small arc-shaped cover faces downward and covers the lower cavity spherical tank. The arc length of the cross section of the small arc-shaped cover is smaller than the arc length of the cross section of the large arc-shaped cover. The small arc-shaped cover is installed between the large arc-shaped cover and the lower cavity spherical tank; and the small arc-shaped cover is fixed to the lower cavity spherical tank by a support rod; The large arc-shaped cover is fixed to the small arc-shaped cover by a support rod, thereby indirectly fixing it to the lower cavity spherical tank; The small arc-shaped hood is used to guide the flow direction of steam initially, and the large arc-shaped hood is used to guide the flow direction of steam secondaryly.

4. The high-temperature heat pump steam generation system according to claim 3, characterized in that, The second tank body, the upper cavity spherical tank, the lower cavity spherical tank, the large arc-shaped cover, and the small arc-shaped cover are coaxial; Furthermore, the connecting hole of the lower spherical tank is coaxial with the second tank body.

5. The high-temperature heat pump steam generation system according to claim 3, characterized in that, The bottom of the upper cavity spherical tank has multiple through holes, and the openings of the multiple through holes face downwards to prevent excessive water from entering the upper cavity spherical tank; The top of the upper spherical tank is fixedly connected to the top of the inner wall of the second tank by a support rod, so that the upper spherical tank is suspended on the second tank. The bottom of the lower chamber spherical tank is fixedly connected to the bottom of the inner wall of the second tank by a support rod, so that the lower chamber spherical tank is placed on the second tank.

6. The high-temperature heat pump steam generation system according to any one of claims 1-5, characterized in that, The first coil has a serpentine structure. This serpentine layout increases the contact area between the first coil and the water in the first tank, thereby improving the heat exchange effect. The second coil has a serpentine structure, which allows the second coil to fully contact the steam in the lower chamber spherical tank, thereby improving the heating effect on the steam. The third coil has a serpentine structure, which increases the contact area between the third coil and the steam in the upper spherical tank, thus facilitating the full heating of the steam to generate superheated steam. The inlet pipe of the third coil can be connected to the heat medium supply structure of the air compressor lubricating oil waste heat recovery system or auxiliary heat source to flexibly obtain the heat required for heating steam.

7. The high-temperature heat pump steam generation system according to claim 1, characterized in that, The first tank has an elliptical cross-section and is equipped with an external heat insulation structure to reduce heat loss from the tank and improve the heating efficiency of the first coil. The cross-section of the second tank is elliptical.

8. The high-temperature heat pump steam generation system according to claim 1, characterized in that, The connecting pipe is used to connect the steam outlet of the first tank to the bottom of the lower chamber spherical tank of the second tank, so that the steam generated in the first tank can directly enter the bottom of the lower chamber spherical tank and fully contact the second coil for heat exchange.

9. The high-temperature heat pump steam generation system according to any one of claims 1-8, characterized in that, The large arc-shaped cover and the small arc-shaped cover are both made of stainless steel; The second coil has a serpentine structure and is made of copper alloy tubing; The third coil has a serpentine structure and is made of copper alloy tubing; The connecting pipe is a stainless steel pipe that extends from the steam outlet of the first tank to the bottom of the lower spherical tank.

10. The high-temperature heat pump steam generation system according to claim 9, characterized in that, Safety valves are respectively installed on the first tank and the second tank; It also includes a controller, which serves as the main control unit of the device.

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