A high-efficiency heat exchange air compressor waste heat recovery unit

Abstract

This invention relates to the field of waste heat recovery technology for air compressors, and discloses a high-efficiency heat exchange unit for air compressor waste heat recovery. The frame adopts a multi-hole and detachable modular structure. The air tank assembly and heat exchange assembly can be flexibly adjusted in installation position and heat exchange assembly specifications according to the working environment and power specifications of different air compressors, eliminating the need for customized design. It is adaptable to different models of air compressors and industrial application scenarios, improving the equipment's versatility and applicability, and effectively improving the comprehensive energy utilization rate. Addressing the technical problems of low waste heat recovery efficiency, high installation and maintenance costs, high failure rate, and poor adaptability of customized designs in existing air compressor waste heat recovery units, this invention employs a dual composite heat exchange structure of spiral heat exchange oil pipes and circulating heat exchange plates. The integrally formed heat exchange cone on the heat exchange plate significantly increases the heat exchange contact area. Combined with a micro-circulating pump to accelerate the circulation of the heat exchange medium, this completely solves the problem of low efficiency in traditional single-stage heat exchange, achieving full recovery and utilization of air compressor waste heat.

Description

Technical Field

[0001] This invention relates to the field of air compressor waste heat recovery technology, specifically to a high-efficiency heat exchange air compressor waste heat recovery unit. Background Technology

[0002] In the industrial production sector, air compressors, as core power equipment, are widely used in many industries such as machinery manufacturing, mining, and light industry and textiles. During operation, they convert a large amount of electrical energy into heat energy, with only a small portion of the energy used for air compression. The vast majority of the waste heat is lost through the air compressor cylinder, air tank, and compressed air. This unused waste heat not only causes serious energy waste but also increases the energy consumption costs of enterprises. At the same time, the waste heat emission also increases the heat dissipation pressure on the surrounding environment.

[0003] To recover and utilize the waste heat of air compressors, various waste heat recovery devices for air compressors have emerged in the existing technology. However, these devices still have many technical defects in practical applications and are difficult to meet the needs of efficient, versatile and stable use in industrial production. First, the waste heat recovery efficiency is low. Existing devices mostly use single plate or tube heat exchange structures, with limited heat exchange contact area and a lack of precise control over the circulation speed of the heat exchange medium. This makes it impossible to fully absorb the waste heat generated by various parts of the air compressor, thus hindering the improvement of waste heat recovery utilization. Second, the installation and maintenance costs are high, and the system failure rate is high. Some recovery systems use complex pipeline layouts and multi-connection control equipment. The components are tightly connected and lack modular design, making on-site installation and commissioning procedures cumbersome. Subsequent maintenance requires complete disassembly, and the complex structure also makes the equipment prone to failure, affecting continuous production. Third, the equipment has poor adaptability. Existing waste heat recovery devices are mostly customized designs, bound to specific models and power air compressors. Their frame structures lack standardized installation positions, and the specifications and installation positions of heat exchange components cannot be flexibly adjusted. This makes it difficult to adapt to different working environments and different models of air compressors, hindering large-scale promotion in various industry production scenarios and making it difficult to effectively improve the comprehensive utilization rate of energy in industrial production.

[0004] Therefore, developing an air compressor waste heat recovery unit with high heat exchange efficiency, convenient installation and maintenance, and strong adaptability to solve the pain points of existing technologies and maximize the recovery and utilization of air compressor waste heat has become an urgent technical need in this field. Summary of the Invention

[0005] The purpose of this invention is to provide a high-efficiency heat exchange air compressor waste heat recovery unit to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: A high-efficiency heat exchange air compressor waste heat recovery unit technical solution includes an integrated frame, which is spliced ​​from corner connectors, wide frame beams, high frame beams, and long frame beams, and a handling handle is fixed on the frame; an air tank mounting bracket is mounted on the frame, and an air tank is fixed on the air tank mounting bracket. The air tank is sequentially connected to an air filter, a compressor unit, an exhaust valve, and an exhaust pipe. A thermostat is also mounted on the frame; a heat exchange assembly is installed on the side of the frame, which includes a water tank, a spiral heat exchange oil pipe, a micro circulation pump, a circulation heat exchange plate, and a circulation oil pipe. The circulation heat exchange plate is provided with several heat exchange cones and circulation oil pipe interfaces; the spiral heat exchange oil pipe is placed in the water tank and connected to the circulation heat exchange plate through the circulation oil pipe interface; the micro circulation pump is connected in series to the circulation oil pipe; the circulation oil pipe, the circulation heat exchange plate, and the spiral heat exchange oil pipe form a closed heat exchange circulation loop; an inlet pipe and an outlet pipe are sequentially arranged on the water tank.

[0007] As a preferred technical solution, the corner connector is a metal corner bracket structure, which is detachably connected to the wide frame beam, high frame beam and long frame beam by bolts to form a rectangular frame; at least two handling handles are provided, which are symmetrically welded to the high frame beams on both sides of the frame.

[0008] As a preferred technical solution, the gas tank mounting bracket is a metal welded bracket, which is fixedly connected to the long frame beam of the frame by expansion bolts, and the gas tank is fixed to the gas tank mounting bracket by clamps; the air filter is connected to the air inlet of the compressor unit through a flange, and the air outlet of the compressor unit is sealed to the air inlet of the gas tank through an exhaust valve and an exhaust pipe.

[0009] As a preferred technical solution, the temperature controller is fixed to the wide frame beam of the frame by L-shaped metal bracket bolts. Its detection end is divided into two paths, one extending to the outside of the cavity of the gas storage tank and the other extending to the surface of the circulating heat exchange plate. The temperature controller is electrically connected to the micro circulating pump.

[0010] As a preferred technical solution, the spiral heat exchange oil pipe is a spiral wound metal oil pipe, which is installed in the water tank. Both ends of the oil pipe are sealed and connected to the circulating oil pipe interface through the circulating oil pipe. The water tank is a sealed box structure, which is fixed to the top of the frame by a bracket.

[0011] As a preferred technical solution, the circulating heat exchange plate is a metal plate structure, which is adapted to the heat exchange part of the air compressor and is bonded together with thermally conductive adhesive; the heat exchange cone is a conical metal protrusion, which is evenly distributed on the inner surface of the circulating heat exchange plate and is integrally formed with the heat exchange plate.

[0012] As a preferred technical solution, the micro circulating pump is connected in series with the main circulation oil pipe via a pipe clamp. The circulation oil pipe is a heat-resistant metal oil pipe with a heat insulation layer covering its outer wall. The two ends of the circulation oil pipe are respectively sealed and connected to the circulation oil pipe interface and the spiral heat exchange oil pipe interface flange to form a closed heat exchange medium circulation path.

[0013] As a preferred technical solution, the exhaust valve and exhaust pipe are sealed to the air inlet section of the air tank through a flange, and the exhaust pipe is a bendable corrugated metal pipe; the air tank and the heat exchange components are both independent modular structures, and both are detachably connected to the frame, with standardized installation holes reserved on each beam of the frame.

[0014] Compared with the prior art, the beneficial effects of the present invention are: This invention addresses the technical problems of existing air compressor waste heat recovery units, such as low waste heat recovery efficiency, high installation and maintenance costs, high failure rate, and poor adaptability to customized designs. By adopting a dual composite heat exchange structure of spiral heat exchange oil pipe and circulating heat exchange plate, and with the heat exchange cone head integrally formed on the heat exchange plate significantly increasing the heat exchange contact area, combined with a micro circulating pump to accelerate the circulation of the heat exchange medium, the invention completely solves the problem of low efficiency of traditional single-stage heat exchange, and achieves full recovery and utilization of waste heat from air compressors.

[0015] The entire system adopts an integrated frame structure, with each functional component modularly assembled on the frame. The piping layout is simple and there are no complex control devices. The corner connectors are bolt-on and detachable. Installation only requires completing the module splicing and pipe flange connection, making operation convenient. At the same time, the modular design allows the equipment to be maintained by only disassembling the faulty module, which greatly reduces maintenance costs, reduces the system failure rate, and ensures the stable and continuous operation of the unit.

[0016] The frame adopts a multi-hole and detachable modular structure. The installation position and heat exchanger specifications of the air tank assembly and heat exchanger assembly can be flexibly adjusted according to the working environment and power specifications of different air compressors. No customized design is required, which can adapt to different models of air compressors and industrial application scenarios, improve the versatility and applicability of the equipment, and effectively improve the comprehensive energy utilization rate. Attached Figure Description

[0017] Figure 1 A schematic diagram of the front structure of a high-efficiency heat exchange air compressor waste heat recovery unit; Figure 2 A three-dimensional structural diagram of a high-efficiency heat exchange air compressor waste heat recovery unit; Figure 3 A schematic diagram of the disassembly structure of a high-efficiency heat exchange air compressor waste heat recovery unit; Figure 4 A schematic diagram of the air storage tank structure of a high-efficiency heat exchange air compressor waste heat recovery unit; Figure 5 This is a schematic diagram of the heat exchange structure of a high-efficiency air compressor waste heat recovery unit. Figure 6 This is a schematic diagram of the frame disassembly structure of a high-efficiency heat exchange air compressor waste heat recovery unit.

[0018] In the attached diagram, the following are the reference numerals: 1. Frame; 11. Corner connector; 12. Wide frame beam; 13. High frame beam; 14. Long frame beam; 15. Handle; 21. Air tank; 22. Air tank mounting bracket; 23. Air filter; 24. Compressor unit; 25. Exhaust valve and exhaust pipe; 26. Thermostat; 31. Water tank; 32. Spiral heat exchange oil pipe; 33. Miniature circulating pump; 34. Circulating heat exchange plate; 341. Heat exchange cone; 342. Circulating oil pipe interface; 35. Circulating oil pipe; 36. Water inlet pipe; 37. Water outlet pipe. Detailed Implementation

[0019] The features and exemplary embodiments of various aspects of the present invention will now be described in detail. To make the objectives, technical solutions, and advantages of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. For those skilled in the art, the present invention can be practiced without some of these specific details. The following description of the embodiments is merely to provide a better understanding of the present invention by illustrating examples of the invention.

[0020] like Figures 1-6As shown, this invention provides a high-efficiency heat exchange air compressor waste heat recovery unit technical solution: It includes an integrated frame 1, which is assembled from corner connectors 11, wide frame beams 12, high frame beams 13, and long frame beams 14. This assembly structure makes the frame 1 more flexible and convenient to assemble and disassemble, facilitating transportation and installation. A handling handle 15 is fixed on the frame 1 for easy handling and movement of the entire unit. An air tank mounting bracket 22 is mounted on the frame 1, providing a stable support structure for the air tank 21. The air tank 21 is sequentially connected to an air filter 23, a compressor unit 24, and an exhaust valve and exhaust pipe 25. The air filter 23 filters the air entering the compressor unit 24, ensuring the quality of the compressed air; the compressor unit 24 compresses the air and delivers it to the air tank 21 for storage through the exhaust valve and exhaust pipe 25. A thermostat 26 is also mounted on the frame 1 for monitoring and controlling the unit's temperature. A heat exchange assembly is installed on the side of frame 1. The heat exchange assembly includes a water tank 31, a spiral heat exchange oil pipe 32, a micro circulating pump 33, a circulating heat exchange plate 34, and a circulating oil pipe 35. The circulating heat exchange plate 34 is provided with several heat exchange cones 341 and circulating oil pipe interfaces 342. The heat exchange cones 341 increase the heat exchange area and improve the heat exchange efficiency. The spiral heat exchange oil pipe 32 is placed inside the water tank 31 and is connected to the circulating heat exchange plate 34 through the circulating oil pipe interface 342. The micro circulating pump 33 is connected in series to the circulating oil pipe 35. The circulating oil pipe 35, the circulating heat exchange plate 34, and the spiral heat exchange oil pipe 32 form a closed heat exchange circulation loop, allowing the heat exchange medium to circulate in the loop and achieve heat transfer. The water tank 31 is provided with an inlet pipe 36 and an outlet pipe 37. The inlet pipe 36 is used to inject cold water into the water tank 31, and the outlet pipe 37 is used to discharge heated hot water, thus supplying hot water.

[0021] The corner connector 11 is a metal corner bracket structure, which is detachably connected to the wide frame beam 12, the high frame beam 13, and the long frame beam 14 by bolts. This detachable connection method facilitates the assembly and disassembly of the frame 1, and also makes it convenient to maintain the frame 1 and replace parts. The components are spliced ​​together to form a rectangular frame 1. The rectangular frame structure is stable and can provide reliable support for the entire unit. At least two handling handles 15 are provided, symmetrically welded to the high frame beams 13 on both sides of the frame 1. The symmetrical arrangement of the handling handles 15 makes the handling of the unit more balanced and stable, facilitating the operator's handling operations.

[0022] The gas tank mounting bracket 22 is a welded metal support, fixedly connected to the long frame beam 14 of the frame 1 by expansion bolts. This expansion bolt fixing method ensures a firm connection between the gas tank mounting bracket 22 and the frame 1, capable of supporting the weight of the gas tank 21. The gas tank 21 is secured to the gas tank mounting bracket 22 by clamps. This clamp connection facilitates the installation and removal of the gas tank 21 while also ensuring its stability. The air filter 23 is connected to the air inlet of the compressor unit 24 via a flange. The flange connection provides good sealing performance, ensuring a tight connection between the air filter 23 and the compressor unit 24 and preventing air leakage. The air outlet of the compressor unit 24 is sealed to the air inlet of the gas tank 21 via an exhaust valve and exhaust pipe 25. This sealed connection ensures that compressed air can smoothly enter the gas tank 21 while preventing compressed air leakage, thus improving the unit's operating efficiency.

[0023] The thermostat 26 is fixed to the wide frame beam 12 of the frame 1 using L-shaped metal bracket bolts. This bolt fixing method ensures a secure installation of the thermostat 26 and facilitates disassembly and maintenance. Its detection end is divided into two paths: one extends to the outside of the cavity of the gas storage tank 21 to monitor the temperature of the gas storage tank 21; the other extends to the surface of the circulating heat exchange plate 34 to monitor the temperature of the circulating heat exchange plate 34. The thermostat 26 is electrically connected to the micro circulating pump 33. When the thermostat 26 detects an abnormal temperature, it can promptly control the operation of the micro circulating pump 33 to ensure that the unit's temperature remains within the normal range, thus improving the unit's safety and stability.

[0024] The spiral heat exchange oil pipe 32 is a spirally wound metal oil pipe installed inside the water tank 31. The spiral winding method increases the contact area between the oil pipe and the water in the water tank 31, improving heat exchange efficiency. Both ends of the oil pipe are sealed to the circulating oil pipe interface 342 via the circulating oil pipe 35. The sealed connection ensures that the heat exchange medium will not leak during circulation, improving the heat exchange effect. The water tank 31 is a sealed box structure, fixed to the top of the frame 1 by a bracket. The sealed box structure prevents water leakage from the water tank 31, and the bracket fixing method ensures stable installation of the water tank 31 and facilitates connection with other components.

[0025] The circulating heat exchange plate 34 is a metal plate structure, adapted to the heat exchange parts of the air compressor and connected by thermally conductive adhesive. This adhesive bonding method ensures close contact between the circulating heat exchange plate 34 and the air compressor's heat exchange parts, improving heat transfer efficiency. The heat exchange cones 341 are conical metal protrusions, evenly distributed on the inner surface of the circulating heat exchange plate 34, and are integrally formed with the heat exchange plate. This integral structure ensures a firm connection between the heat exchange cones 341 and the circulating heat exchange plate 34, while the evenly distributed cones increase the heat exchange area, further improving heat exchange efficiency.

[0026] The miniature circulating pump 33 is connected in series with the main circuit of the circulating oil pipe 35 via a pipe clamp. This pipe clamp connection facilitates the installation and disassembly of the miniature circulating pump 33 while ensuring the sealing of the circulating oil pipe 35. The circulating oil pipe 35 is a high-temperature resistant metal pipe with an outer wall covered by a heat insulation layer. The high-temperature resistant metal pipe can withstand high temperatures, ensuring the normal operation of the circulating oil pipe 35 in high-temperature environments. The heat insulation layer reduces heat loss and improves heat exchange efficiency. Both ends of the circulating oil pipe 35 are respectively sealed and connected to the circulating oil pipe interface 342 and the spiral heat exchange oil pipe interface 32 flange, forming a closed heat exchange medium circulation path. The flange sealing connection ensures a tight connection between the circulating oil pipe 35 and other components, preventing heat exchange medium leakage and ensuring the normal operation of the heat exchange cycle.

[0027] The exhaust valve and exhaust pipe 25 are sealed to the air inlet section of the air tank 21 via a flange. This flange sealing connection ensures a tight connection between the exhaust valve and exhaust pipe 25 and the air tank 21, preventing compressed air leakage. The exhaust pipe is a flexible corrugated metal pipe, which makes the exhaust pipe more flexible during installation and use, adapting to different installation environments. Both the air tank 21 and the heat exchange components are independent modular structures, and both are detachably connected to the frame 1. Standardized installation holes are pre-drilled on each beam of the frame 1. The independent modular structure makes the installation and maintenance of the air tank 21 and the heat exchange components more convenient, and the standardized installation holes ensure more accurate and standardized installation of each component, improving the installation efficiency and quality of the unit.

[0028] The working principle and usage process of this invention: After assembling the various components of this solution in sequence, the above implementation methods are followed according to actual needs to complete all working steps.

[0029] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

[0030] In the description of this invention, it should be understood that the terms "coaxial," "bottom," "one end," "top," "middle," "other end," "upper," "side," "top," "inner," "front," "center," "both ends," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention 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. Therefore, they should not be construed as limiting this invention.

[0031] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "setting," "connection," "fixing," "screw connection," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal connection of two components or the interaction between two components. Unless otherwise explicitly limited, those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0032] The embodiments described above are not exhaustive and do not limit the invention to specific implementations. Clearly, many modifications and variations can be made based on the above description. These embodiments are selected and specifically described in this specification to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to effectively utilize the invention and its modifications. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the invention should be included within the scope of protection of the invention.

Claims

1. A high-efficiency heat exchange air compressor waste heat recovery unit, characterized in that, The system includes an integrated frame (1), which is assembled from corner connectors (11), wide frame beams (12), high frame beams (13), and long frame beams (14). A handling handle (15) is fixed on the frame (1). A gas tank mounting bracket (22) is mounted on the frame (1), and a gas tank (21) is fixed on the gas tank mounting bracket (22). The gas tank (21) is connected in sequence to an air filter (23), a compressor unit (24), an exhaust valve, and an exhaust pipe (25). A thermostat (26) is also mounted on the frame (1). A heat exchange assembly is installed on the side of the frame (1), which includes a water tank (31), a screw... The system includes a spiral heat exchange oil pipe (32), a micro circulating pump (33), a circulating heat exchange plate (34), and a circulating oil pipe (35). The circulating heat exchange plate (34) is provided with several heat exchange cones (341) and a circulating oil pipe interface (342). The spiral heat exchange oil pipe (32) is placed in a water tank (31) and is connected to the circulating heat exchange plate (34) through the circulating oil pipe interface (342). The micro circulating pump (33) is connected in series to the circulating oil pipe (35). The circulating oil pipe (35), the circulating heat exchange plate (34), and the spiral heat exchange oil pipe (32) form a closed heat exchange circulation loop. The water tank (31) is provided with an inlet pipe (36) and an outlet pipe (37) in sequence.

2. The high-efficiency heat exchange air compressor waste heat recovery unit according to claim 1, characterized in that: The corner connector (11) is a metal corner bracket structure, which is detachably connected to the wide frame beam (12), the high frame beam (13), and the long frame beam (14) by bolts to form a rectangular frame (1); at least two handling handles (15) are provided, which are symmetrically welded to the high frame beams (13) on both sides of the frame (1).

3. The high-efficiency heat exchange air compressor waste heat recovery unit according to claim 2, characterized in that: The gas tank mounting bracket (22) is a metal welded bracket, which is fixedly connected to the long frame beam (14) of the frame (1) by expansion bolts. The gas tank (21) is fixed on the gas tank mounting bracket (22) by clamping. The air filter (23) is connected to the air inlet of the compressor unit (24) through a flange. The air outlet of the compressor unit (24) is sealed to the air inlet of the gas tank (21) through an exhaust valve and an exhaust pipe (25).

4. The high-efficiency heat exchange air compressor waste heat recovery unit according to claim 3, characterized in that: The temperature controller (26) is fixed to the wide frame beam (12) of the frame (1) by L-shaped metal bracket bolts. Its detection end is divided into two paths, one extending to the outside of the cavity of the gas storage tank (21) and the other extending to the surface of the circulating heat exchange plate (34). The temperature controller (26) is electrically connected to the micro circulating pump (33).

5. The high-efficiency heat exchange air compressor waste heat recovery unit according to claim 4, characterized in that: The spiral heat exchange oil pipe (32) is a spiral wound metal oil pipe, which is installed in the water tank (31). Both ends of the oil pipe are sealed and connected to the circulating oil pipe interface (342) through the circulating oil pipe (35). The water tank (31) is a sealed box structure, which is fixed to the top of the frame (1) by a bracket.

6. The high-efficiency heat exchange air compressor waste heat recovery unit according to claim 5, characterized in that: The circulating heat exchange plate (34) is a metal plate structure, which is adapted to the heat exchange part of the air compressor and is bonded together with thermally conductive adhesive; the heat exchange cone (341) is a conical metal protrusion, which is evenly distributed on the inner surface of the circulating heat exchange plate (34) and is integrally formed with the heat exchange plate.

7. The high-efficiency heat exchange air compressor waste heat recovery unit according to claim 6, characterized in that: The micro circulating pump (33) is connected in series with the main circuit of the circulating oil pipe (35) through a pipe clamp. The circulating oil pipe (35) is a heat-resistant metal oil pipe with a heat insulation layer covering its outer wall. The two ends of the circulating oil pipe (35) are respectively sealed and connected to the circulating oil pipe interface (342) and the spiral heat exchange oil pipe (32) interface flange to form a closed heat exchange medium circulation passage.

8. The high-efficiency heat exchange air compressor waste heat recovery unit according to claim 7, characterized in that: The exhaust valve and exhaust pipe (25) are sealed to the air inlet section of the gas storage tank (21) through a flange. The exhaust pipe is a bendable metal corrugated pipe. The gas storage tank (21) and the heat exchange components are both independent modular structures. Both are detachably connected to the frame (1). Standardized installation holes are reserved on each frame beam of the frame (1).

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