Condensing micro-superheated steam heating device for cable boiling process and use method

Abstract

This invention discloses a condensation-based micro-superheated steam heating device and its usage method for a cable boiling process, belonging to the field of power cable steam crosslinking technology. It includes a micro-superheated steam generator, a steam distribution cylinder, an insulated water tank, a pure water supply device, and a control device. The micro-superheated steam generator is equipped with a steam outlet and a condensate recovery outlet. The steam outlet is connected to the steam inlet of the steam distribution cylinder via a steam delivery pipe, and the condensate recovery outlet is connected to the pure water supply device via a recovery pipe. The insulated water tank includes an external support frame, an inner tank within the external support frame, an insulation layer between the inner tank and the external support frame, and a heat exchange coil within the inner tank. The inlet of the heat exchange coil is connected to the steam outlet of the steam distribution cylinder via a steam supply branch. This invention, by setting up a micro-superheated steam generator, a steam distribution cylinder, and a steam delivery pipeline, reduces condensation losses during steam transportation, thereby lowering fuel consumption and operating costs.

Description

Technical Field

[0001] This invention relates to a condensing micro-superheated steam heating device and its usage method for a cable boiling process, belonging to the field of steam crosslinking technology for power cables. Background Technology

[0002] In cable manufacturing, the cable boiling process is typically used to heat and insulate cable reels to improve the processing performance of the cable materials and enhance product consistency. This process places high demands on the stability of the heat source output, the accuracy of temperature control, and the continuous heating capacity. It usually requires maintaining a constant water temperature or a set temperature range for an extended period, while also considering equipment safety, energy consumption control, and protection of the cable reels from collisions and compression within the water tank. Therefore, this type of heating equipment must not only possess stable and reliable steam heating capabilities but also have functions such as condensate recovery, pure water replenishment, automatic control, and insulation protection to meet the actual production needs of the cable boiling process.

[0003] Existing cable-based water heating systems mostly employ a traditional boiler combined with a standard water tank. These systems typically generate steam using a gas-fired boiler, steam boiler, or ordinary steam generator, then deliver the steam to heat exchange coils within the water tank or directly heat the water. Some systems also include simple water replenishment devices, temperature control switches, or basic insulation structures to achieve basic heating operation. While some existing technologies use ordinary steam distributors to allocate steam or install fixed coils in the water tank to increase the heat exchange area, overall, these systems still rely heavily on basic heating and manual control, resulting in limited system integration and automation.

[0004] However, existing technologies still have several shortcomings: traditional boilers and ordinary heating equipment have low thermal efficiency, high flue gas temperatures, and insufficient steam quality and output stability, resulting in high fuel consumption and operating costs; conventional boilers generally have high nitrogen oxide emissions, making it difficult to meet low-NOx or ultra-low-NOx emission requirements; traditional boilers have large water capacities, high system safety risks, and strict pressure vessel regulations, causing inconvenience in on-site use; ordinary water tank heat exchange coils and insulation structures are relatively simple, with limited insulation performance and heat exchange efficiency, insufficient temperature control accuracy, and a tendency to cause water temperature fluctuations, affecting the consistency of cable boiling quality; existing equipment lacks a complete pure water recovery and replenishment mechanism, which easily leads to scaling, corrosion, and other problems, shortening equipment lifespan. These limitations make it difficult to meet the requirements of modern cable manufacturing processes for high efficiency, energy saving, safety, and stable operation.

[0005] Therefore, a condensing micro-superheated steam heating device and its usage method for cable boiling process are provided to solve the above problems. Summary of the Invention

[0006] The technical problem to be solved by the present invention is to provide a condensing micro-superheated steam heating device and its usage method for the cable boiling process, which solves the problems of high operating cost, failure to meet low nitrogen requirements, high safety risk, easy water temperature fluctuation and easy corrosion.

[0007] The technical problem to be solved by this invention is achieved by the following technical solution: a condensing micro-superheated steam heating device for cable boiling process. It includes a micro-superheated steam generator, a steam distribution cylinder, an insulated water tank, a pure water supply device, and a control device; The micro-superheated steam generator is equipped with a steam output port and a condensate recovery port. The steam output port is connected to the steam inlet of the steam distributor through a steam delivery pipe, and the condensate recovery port is connected to the pure water supply device through a recovery pipe. The insulated water tank includes an external support frame, an inner liner disposed within the external support frame, an insulation layer disposed between the inner liner and the external support frame, and a heat exchange coil disposed within the inner liner. The inlet of the heat exchange coil is connected to the steam outlet of the steam distribution cylinder via a steam supply branch, and the outlet of the heat exchange coil is connected to the recovery pipe. The pure water supply device is connected to the micro-superheated steam generator or the insulated water tank via a water replenishment pipeline. The control device is electrically connected to the temperature detection element, pressure detection element, and liquid level detection element on the micro-superheated steam generator, the pure water supply device, and the insulated water tank. The insulated water tank is equipped with a limiting groove and a top cover.

[0008] Preferably, the micro-superheated steam generator includes a water-cooled fully premixed combustion component, a heat exchange component, and a steam superheating component, wherein the water-cooled fully premixed combustion component, the heat exchange component, and the steam superheating component are connected sequentially along the steam flow direction.

[0009] Preferably, the water-cooled fully premixed combustion assembly includes a gas input pipeline, a combustion air input pipeline, a proportioner, a burner body, a water-cooled combustion chamber, an ignition device, and a flame detection device. The gas input pipeline and the combustion air input pipeline are both connected to the proportioner, the output end of the proportioner is connected to the burner body, the burner body is disposed in the water-cooled combustion chamber, and the ignition device and the flame detection device are respectively disposed on the burner body. The heat exchange assembly includes a heat exchange shell, a heat exchange tube bundle, a water inlet, a steam outlet, and a flue gas discharge channel. The heat exchange shell is sleeved on the outside of the water-cooled combustion chamber, and a heat exchange channel is formed between the water-cooled combustion chamber and the heat exchange shell. The water inlet is connected to an external water source, and the steam outlet is connected to the steam superheating assembly. The steam superheating assembly includes a superheating cavity, a superheating coil, and a steam outlet. The steam outlet is connected to the superheating cavity, the superheating coil is disposed in the superheating cavity, the inlet of the superheating coil is connected to the steam outlet, and the outlet of the superheating coil forms the steam outlet. In this process, the fuel gas and combustion air are premixed by the proportioning mixer and then enter the burner body for combustion. The combustion heat is transferred sequentially through the water-cooled combustion chamber and the heat exchange shell to the water in the heat exchange tube bundle, so that the water is vaporized to form steam. The formed steam then enters the steam superheating assembly for further heating and is output as slightly superheated steam.

[0010] Preferably, the insulation layer is a polyurethane foam insulation layer; the external support frame is made of galvanized channel steel; and the heat exchange coil is fixed by a support structure located inside the inner liner.

[0011] Preferably, the support structure is made of 304 stainless steel channel steel, and at least two of the support structures are spaced apart along the length of the inner liner.

[0012] Preferably, the top cover is rotatably connected to the insulated water tank, the top cover is provided with a handle, and the inside of the top cover is provided with a hook.

[0013] Preferably, a bearing connector is provided between the top cover and the insulated water tank, and lifting rings are provided on both the front and back of the insulated water tank.

[0014] Preferably, the pure water supply device includes a reverse osmosis pure water equipment and an insulated pure water tank. The outlet of the reverse osmosis pure water equipment is connected to the inlet of the insulated pure water tank, and the outlet of the insulated pure water tank is connected to both the micro-superheated steam generator and the insulated water tank. The control device includes a PLC controller and a frequency conversion adjustment module. The signal output terminals of the temperature detection element, pressure detection element, and liquid level detection element are electrically connected to the PLC controller, and the control output terminal of the PLC controller is electrically connected to the micro-superheated steam generator and the pure water supply device, respectively.

[0015] A method of using a condensing micro-superheated steam heating device for a cable boiling process, preferably comprising: S1. System initialization: Start the control device to perform self-checks on the micro-superheated steam generator, pure water supply device, steam separator and heat preservation water tank. When the temperature, pressure, liquid level and flame status meet the start-up conditions, it enters the standby state. S2, Pure water supply: Control the pure water supply device to supply water to the micro-superheated steam generator or the insulated water tank so that the system liquid level reaches the set initial liquid level; S3, Micro-superheated steam generation: Control the micro-superheated steam generator to start the combustion and heat exchange process, generate micro-superheated steam and deliver it to the steam distribution cylinder; S4. Steam distribution and heat exchange: The control steam distributor distributes the slightly superheated steam to the heat exchange coil in the heat-insulating water tank. After the slightly superheated steam releases heat in the heat exchange coil, it forms condensate. The condensate is then recovered through the recovery pipe. S5. Temperature closed-loop regulation: Real-time acquisition of water temperature in the insulated water tank, and proportional adjustment of steam output power according to the set temperature to maintain stable water temperature. S6. Shutdown and Reset: After the process is completed, combustion is stopped and steam output is shut off. The system is then drained or replenished with water to reset it, and then enters standby mode.

[0016] Preferably, in step S2, water is automatically replenished when the liquid level is below the lower limit and water replenishment stops when the liquid level reaches the upper limit.

[0017] Preferably, in step S5, when the detected water temperature is lower than the set temperature, the steam output power is increased or the steam supply time is extended; when the detected water temperature reaches the set temperature, the steam output power is reduced.

[0018] The beneficial effects of this invention are: This invention, by setting up a micro-superheated steam generator, a steam distributor, and a steam delivery pipeline, allows the heat generated by combustion to be vaporized through heat exchange and further superheated to form micro-superheated steam. This steam is then stably distributed by the steam distributor to the insulated water tank for heat exchange. This results in a more stable steam output temperature and higher dryness, reducing condensation losses during steam delivery, thereby improving overall thermal efficiency, reducing fuel consumption and operating costs, and solving the problems of low thermal efficiency, high flue gas temperature, and insufficient steam quality and output stability in traditional boilers and ordinary heating equipment.

[0019] This invention employs a staged heat exchange structure that combines a water-cooled fully premixed combustion assembly, a heat exchange assembly, and a steam superheating assembly. This allows the fuel gas and combustion air to be fully combusted after being mixed in a specific ratio. The combustion heat is first absorbed by the water-cooled combustion chamber, then vaporized through the heat exchange tube bundle, and finally further heated by the steam superheating assembly. This significantly reduces heat loss from high-temperature flue gas and facilitates low-NOx combustion and efficient heat exchange, reducing the generation of nitrogen oxides. It solves the problem of high nitrogen oxide emissions from conventional boilers, which makes it difficult to meet low-NOx or ultra-low-NOx emission requirements.

[0020] This invention utilizes a separate heating structure with small water capacity, slightly superheated steam heating, and an insulated water tank to separate the high heat source generation end from the water boiling process end. The system does not require a traditional large-capacity boiler as the main heat source, resulting in lower operating pressure and less safety risk. At the same time, the control device interlocks the temperature, pressure, liquid level, and flame status, enabling timely shutdown protection in abnormal conditions. This reduces reliance on pressure vessel supervision and on-site operational risks, solving the problems of large water capacity, high system safety risks, and stringent pressure vessel supervision requirements associated with traditional boilers.

[0021] This invention provides an insulated water tank with an external support frame, an inner tank, an insulation layer, and a heat exchange coil inside the inner tank. The heat exchange coil is fixed by the support structure, which reduces heat loss while ensuring structural strength and improves the heat exchange efficiency between the heat exchange coil and the water. Combined with a closed top cover structure, it further reduces water temperature fluctuations, improves insulation performance and temperature control accuracy, and makes the temperature more stable during the cable boiling process. This invention solves the problems of ordinary water tanks having simple heat exchange coils and insulation structures, limited insulation performance and heat exchange efficiency, insufficient temperature control accuracy, and a tendency to cause water temperature fluctuations.

[0022] By incorporating a pure water supply device, a condensate recovery port, and a recovery pipeline, this invention enables the condensate generated by the micro-superheated steam generator and the insulated water tank to be recovered into the pure water system for reuse. Simultaneously, the pure water supply device filters and purifies the makeup water before sending it into the system, which reduces the entry of impurities and hardness ions into the heat exchange tube bundle and heat exchange coil, thereby reducing the risk of scaling, clogging, and corrosion, extending the service life of the equipment, and solving the problems of existing equipment lacking a complete pure water recovery and replenishment mechanism and being prone to scaling and corrosion. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the structure of the insulated water tank of the present invention.

[0024] In the diagram: 11-Top cover, 12-Steam inlet, 13-Water inlet, 14-Return water inlet, 15-Overflow outlet, 16-Drain outlet, 17-Limiting groove, 18-Heat exchange coil, 21-Air inlet pipe, 22-Return water pipe. Detailed Implementation

[0025] To facilitate a clear understanding of the technical means, creative features, objectives, and effects of this invention, the invention will be further described below in conjunction with specific embodiments. Example 1

[0026] like Figure 1 As shown, A condensing micro-superheated steam heating device for a cable boiling process includes a micro-superheated steam generator, a steam distribution cylinder, an insulated water tank, a pure water supply device, and a control device.

[0027] The micro-superheated steam generator is equipped with a steam output port and a condensate recovery port. The steam output port is connected to the steam inlet of the steam distributor through a steam delivery pipe, and the condensate recovery port is connected to the pure water supply device through a recovery pipe. The insulated water tank includes an external support frame, an inner liner set inside the external support frame, an insulation layer set between the inner liner and the external support frame, and a heat exchange coil set inside the inner liner. The inlet of the heat exchange coil is connected to the steam outlet of the steam distribution cylinder through a steam supply branch, and the outlet of the heat exchange coil is connected to the recovery pipe.

[0028] The pure water supply device is connected to a micro-superheated steam generator or an insulated water tank via a water replenishment pipeline.

[0029] The control device is electrically connected to the micro-superheated steam generator, the pure water supply device, and the temperature, pressure, and level detection elements on the insulated water tank. The insulated water tank is equipped with a limit groove and a top cover.

[0030] In this embodiment, the micro-superheated steam generator is located at the front end of the system and adopts a vertical box-type unit structure. Inside the unit, a water-cooled fully premixed combustion assembly, a heat exchange assembly, and a steam superheating assembly are arranged sequentially along the steam flow direction. One end of the micro-superheated steam generator is equipped with a steam output port and a condensate recovery port. The steam output port is connected to the steam inlet of the steam distribution cylinder via a steam delivery pipe, and the condensate recovery port is connected to a pure water supply device via a recovery pipe, thus forming a circulation path for steam output and condensate recovery.

[0031] The water-cooled fully premixed combustion assembly includes a gas input pipeline, a combustion air input pipeline, a proportioner, a burner body, a water-cooled combustion chamber, an ignition device, and a flame detection device. The gas input pipeline and the combustion air input pipeline are respectively connected to the proportioner. Gas and air are premixed in the proportioner to form a combustible mixture, which is then delivered to the burner body for combustion. The burner body is located within the water-cooled combustion chamber. The ignition device is used for ignition and start-up, and the flame detection device is used to detect the combustion status. In this embodiment, the water-cooled combustion chamber adopts a surrounding jacketed cavity structure or an enclosed cavity structure. Cooling medium channels or circulating water channels are provided within the cavity, which can absorb heat from the combustion zone and reduce local peak temperatures, thereby stabilizing the combustion state and reducing nitrogen oxide generation.

[0032] The heat exchange assembly includes a heat exchange shell, heat exchange tube bundle, water inlet, steam outlet, and flue gas exhaust channel. The heat exchange shell is fitted outside the water-cooled combustion chamber, forming a heat exchange channel between them. Combustion heat is transferred outwards through the water-cooled combustion chamber and then acts on the water within the heat exchange tube bundle. The heat exchange tube bundle is located inside the heat exchange shell, with the water inlet connected to an external water source. Pure water enters the heat exchange tube bundle through the inlet, absorbs heat, and vaporizes to form steam, which is then output through the steam outlet. The flue gas exhaust channel is located at the rear of the heat exchange shell to discharge the flue gas after heat recovery, preventing high-temperature flue gas from lingering inside the unit and improving heat utilization efficiency.

[0033] The steam superheating assembly includes a superheating chamber, a superheating coil, and a steam outlet. The steam outlet is connected to the superheating chamber, and the superheating coil is located inside the superheating chamber. Steam output from the heat exchange assembly enters the superheating chamber and continues to absorb heat, undergoing further heating by the superheating coil to form slightly superheated steam, which is finally output through the steam outlet. The superheating chamber is preferably a closed-loop structure, and the superheating coil is preferably a serpentine coil, annular coil, or multi-pass coil structure to extend the steam heating path and improve steam dryness. This structure reduces condensation during steam transport, minimizes the risk of water hammer, and ensures stable steam quality entering the insulated water tank.

[0034] In this embodiment, the micro-superheated steam generator can realize the staged utilization of combustion heat, the simultaneous completion of steam vaporization and superheating, and output micro-superheated steam with stable temperature and high dryness to the subsequent steam distribution cylinder and heat preservation water tank, thereby meeting the requirements of cable boiling process for heating stability and energy efficiency.

[0035] The steam distributor is located between the micro-superheated steam generator and the insulated water tank. In this embodiment, the steam distributor is a cylindrical pressure distribution cylinder with a steam inlet at one end and multiple steam outlets around its circumference. One end of the steam delivery pipe is connected to the steam outlet of the micro-superheated steam generator, and the other end is connected to the steam inlet of the steam distributor. Multiple steam supply branches are respectively connected to the steam outlets of the steam distributor and the inlet of the heat exchange coil in the insulated water tank.

[0036] The function of the steam distributor is to stabilize, buffer, and distribute the slightly superheated steam output from a single path. After the steam enters the steam distributor, the flow rate is weakened, pressure fluctuations are buffered, and it is then distributed to each steam supply branch into the heat exchange coil. This ensures uniform steam supply to each branch, avoids excessive or insufficient heating in local coils, and thus improves the uniformity of the temperature field inside the insulated water tank.

[0037] In this embodiment, the steam distributor cylinder can adopt a Φ159mm cylindrical structure and be provided with at least two ports, one of which serves as the steam inlet and the other as the steam outlet, to adapt to single-box heating or multi-box parallel heating scenarios. The cylinder body of the steam distributor cylinder adopts a horizontal cylindrical shape, which facilitates installation, pressure stabilization, and condensate discharge.

[0038] The insulated water tank is located at the rear end of the steam distributor. It features a rectangular box structure, including an external support frame, an inner liner, an insulation layer, heat exchange coils, a limiting groove, and a top cover. The external support frame is located on the outermost side of the insulated water tank and is used to support and bear the load of the entire tank. The external support frame is preferably made of galvanized channel steel welded into a rectangular frame structure. Reinforcing ribs are installed along the length and height of the insulated water tank to improve the overall structural strength and reduce deformation caused by long-term high temperatures and full water conditions.

[0039] The inner tank is located inside the external support frame. The inner tank is constructed from welded stainless steel plates to form a closed box structure, with a water storage chamber inside for the boiling process. An insulation layer, preferably polyurethane foam, is installed between the inner tank and the external support frame, forming an integrated insulation structure. This structure reduces heat loss from the inside of the insulated water tank, minimizes steam consumption, and maintains a stable water temperature inside the tank.

[0040] The heat exchange coil is installed inside the inner tank. The inlet of the heat exchange coil is connected to the steam outlet of the steam distributor via a steam supply branch, and the outlet of the heat exchange coil is connected to the condensate recovery port via a recovery pipe. In this embodiment, the heat exchange coil is preferably made of 316L stainless steel. The coil has a serpentine, spiral, or multi-layered coil structure to increase the flow path and heat exchange area of ​​steam inside the coil. The heat exchange coil is fixed inside the inner tank by a support structure, preferably made of 304 stainless steel channel steel. At least two support structures are spaced apart along the length of the inner tank to support and position the heat exchange coil, preventing sagging, displacement, or deformation at high temperatures.

[0041] Slightly superheated steam is distributed by the steam distributor and flows into the heat exchange coil. It releases heat to the water in the inner tank through the heat exchange coil, forming condensate, which is then recovered to the pure water supply device via the recovery pipe. Because the heat exchange coil uses a multi-pass winding structure, it can extend the steam heat exchange time and improve heat utilization efficiency, thereby increasing the heating rate and temperature stability of the water inside the insulated water tank.

[0042] The top cover 11 is located on top of the insulated water tank and is rotatably connected to the tank. The top cover 11 preferably uses a metal cover plate structure, and a bearing connector is provided between the top cover 11 and the insulated water tank, allowing the top cover 11 to open and close around a rotation axis. A handle is provided on the top cover 11 for manual opening; hooks are provided on the inner side of the top cover 11 for hanging wires or assisting in fixing workpieces. When closed, the top cover 11 forms a sealed space inside the insulated water tank, thereby reducing heat loss and steam leakage.

[0043] The top of the insulated water tank is equipped with a steam inlet 12 and a tap water inlet 13. The steam inlet 12 is connected to the steam supply branch and is used to supply slightly superheated steam to the heat exchange coils. The tap water inlet 13 is used to replenish process water into the insulated water tank. The side of the insulated water tank is equipped with a return water inlet 14, which is connected to the condensate recovery system through a recovery pipe for recovering condensate after heat exchange. The top of the insulated water tank is equipped with an overflow outlet 15 for discharging excess liquid when the liquid level is too high. The bottom of the insulated water tank is equipped with a drain outlet 16 for discharging deposited impurities and wastewater from inside the tank.

[0044] Multiple limiting grooves 17 are provided inside the inner tank, and the limiting grooves 17 are arranged at intervals along the length of the insulated water tank. The limiting grooves 17 are preferably groove-shaped positioning structures or frame-shaped positioning structures, used to limit and fix the cable roll. After the cable roll is placed inside the limiting grooves 17, it can limit the lateral movement and mutual collision of the cable roll during the boiling process, thereby reducing the risk of damage to the outer wall of the cable roll and improving the uniformity of heating of the cable during the boiling process.

[0045] The heat exchange coil 18 is located inside the inner tank and between or below the limiting grooves 17, so that the heat released by the heat exchange coil 18 can be evenly transferred to the water inside the insulated water tank. The air inlet pipe 21 is connected to the micro-superheated steam generator and is used to deliver micro-superheated steam into the heat exchange coil 18; the water return pipe 22 is connected to the water return port 14 and is used to discharge and recover the condensate after heat exchange, thereby forming a complete steam heat exchange circulation path.

[0046] The pure water supply system is used to replenish pure water for the micro-superheated steam generator and the insulated water tank, and to receive the recovered condensate. The pure water supply system includes a reverse osmosis pure water unit and an insulated pure water tank. The outlet of the reverse osmosis pure water unit is connected to the inlet of the insulated pure water tank, and the outlet of the insulated pure water tank is connected to both the micro-superheated steam generator and the insulated water tank. A recovery pipe returns the condensate generated by the steam generator and the insulated water tank to the pure water supply system, enabling condensate reuse.

[0047] In this embodiment, the reverse osmosis pure water equipment adopts a combined structure of two-stage pretreatment and reverse osmosis membrane to filter, soften, and desalinate tap water, reducing the content of calcium and magnesium ions, suspended solids, and impurities in the water, and preventing scaling on the heat exchange tube bundle and heat exchange coil. The raw water inlet of the reverse osmosis pure water equipment is connected to an external tap water source, and the outlet is connected to the inlet of the insulated pure water tank through a pure water delivery pipe. A filter assembly and a one-way valve can be installed on the pure water delivery pipe to prevent impurities from entering the insulated pure water tank and to prevent backflow. The insulated pure water tank preferably uses a 304 stainless steel inner liner and a 201 stainless steel outer shell, with an insulation layer in between. The shape can be a vertical or horizontal rounded cuboid structure, which facilitates the storage of pure water and can reduce water temperature fluctuations.

[0048] The pure water supply unit is connected to the micro-superheated steam generator or the insulated water tank via a water replenishment pipeline. This pipeline connects to the water inlet of both the micro-superheated steam generator and the insulated water tank. The pipeline is equipped with a solenoid valve, a check valve, and a filter assembly. The solenoid valve controls the start and stop of the water replenishment, the check valve prevents backflow, and the filter assembly further removes impurities from the water. This system continuously supplies water to the steam generator and replenishes the insulated water tank, ensuring the continuity of steam generation and process heating. Condensate is recovered and re-enters the pure water system, reducing the amount of fresh water needed and lowering operating costs.

[0049] The control device is used to control the operation of the entire system. The control device includes a PLC controller and a frequency converter module. The signal output terminals of the temperature detection element, pressure detection element, and liquid level detection element are electrically connected to the PLC controller, and the control output terminals of the PLC controller are electrically connected to the micro-superheated steam generator and the pure water supply device, respectively.

[0050] The PLC controller uses real-time data to coordinate the steam generation power and water replenishment. The frequency converter module can work with fans, pumps, or other actuators to adjust their speeds, resulting in more stable heating. Through the intervention of the control device, the system can increase steam output when the temperature is low, reduce output or provide intermittent steam supply once the set temperature is reached, automatically replenish water when the liquid level is too low, and stop water replenishment when the liquid level is too high. This enables constant temperature control and continuous heating, reducing manual intervention.

[0051] The control device can be configured with a remote monitoring module, a safety interlock module, and an automatic sewage discharge module. The remote monitoring module can be used to upload operating data, the safety interlock module can be used for interlock shutdown under conditions such as over-temperature, over-pressure, low water level, abnormal gas pressure, abnormal wind pressure, and abnormal flame, and the automatic sewage discharge module is used to periodically discharge impurities.

[0052] In this embodiment, pure water enters the micro-superheated steam generator through the pure water supply device. The generated micro-superheated steam enters the steam distribution cylinder through the steam delivery pipe. The steam distribution cylinder evenly distributes the steam to the heat exchange coil inside the insulated water tank. After the steam releases heat in the coil, it forms condensate. The condensate returns to the pure water supply device through the recovery pipe. The process water inside the insulated water tank is continuously heated and kept at a constant temperature. The limiting groove positions the cable roll, the top cover reduces heat loss, and the control device performs closed-loop control of the entire process.

[0053] In this embodiment, the external steam pipelines of the micro-superheated steam generator, steam distribution cylinder, insulated water tank, and pure water supply device are all covered with an insulation structure. The insulation structure consists of an inner layer of high-temperature resistant insulation cotton, an outer metal cladding layer, and fixing straps. Insulation layers are also installed on the outer surfaces of the steam delivery pipe, steam supply branches, recovery pipe, and water supply pipe to reduce heat loss during steam transportation and prevent condensation from forming on the outer walls of the pipelines. Removable insulation sleeves are used at bends, valves, and flange connections in each pipeline to facilitate subsequent maintenance and replacement. By insulating the entire steam pipeline, heat loss can be reduced, steam consumption can be decreased, and the overall thermal efficiency of the system can be improved.

[0054] In this embodiment, the control device is electrically interlocked with temperature detection elements, pressure detection elements, liquid level detection elements, over-temperature protection elements, over-pressure protection elements, gas pressure detection elements, wind pressure detection elements, and an emergency stop switch. The over-temperature protection element is located in the middle of the water body or on the outlet side of the insulated water tank to detect whether the water temperature exceeds a preset safe temperature; the over-pressure protection element is located on the steam side of the micro-superheated steam generator or on the steam distribution cylinder to detect whether the steam pressure exceeds a preset upper limit; the gas pressure detection element is located on the gas input pipeline to detect whether the gas supply pressure is stable; the wind pressure detection element is located on the combustion air input pipeline or on the fan outlet side to detect the combustion air delivery status; and the emergency stop switch is located on the operating side of the equipment for manually shutting off the system in an emergency. The control device forms an interlock protection logic based on the signals fed back from each detection element. When any abnormal situation occurs, such as over-temperature, over-pressure, low water level, abnormal gas pressure, abnormal wind pressure, flame extinguishing, or emergency stop triggering, the control device immediately stops the burner, shuts off the gas input, and stops the steam output, while issuing an alarm signal to avoid the equipment from continuing to operate and causing safety risks.

[0055] In this embodiment, the flame detection device and the ignition device are installed together on the burner body. The flame detection device is used to identify the combustion state in real time. When no stable flame is detected after ignition, the control device determines that ignition has failed and executes shutdown protection. When the flame is accidentally extinguished during operation, the control device immediately cuts off the gas input and stops ignition to restart, preventing gas accumulation and potential safety hazards. An electromagnetic shut-off valve can be installed on the gas input pipeline. The control device uses the electromagnetic shut-off valve to quickly control the gas supply and demand, forming a rapid interlock protection system in conjunction with the flame detection.

[0056] In this embodiment, the insulated water tank and the micro-superheated steam generator are equipped with a reserved temperature port, a pressure switch interface, and a blind pipe monitoring position. The reserved temperature port is located on the side wall or top of the insulated water tank for future installation of temperature detection probes or calibration of temperature signals. The pressure switch interface is located on the steam-side pipeline or steam distribution cylinder for installing a mechanical pressure switch to improve the reliability of pressure protection. The blind pipe monitoring position is located at the end of the pipeline or at a reserved port on the equipment for future pressure testing, temperature testing, venting and drainage, or installation of backup monitoring elements. By providing these reserved interfaces, the future expandability and maintenance convenience of the equipment can be improved, and it is also convenient to add monitoring and protection functions according to different process requirements.

[0057] In this embodiment, the top cover of the insulated water tank forms a press-fit seal with the upper edge of the tank body after closing. A sealing strip can be installed on the edge of the top cover to reduce steam escape and heat loss. With the top cover open, the operator can temporarily suspend the workpiece or wire using hooks, facilitating loading, unloading, and process switching. Lifting rings are provided on the front and back of the insulated water tank for easy installation, hoisting, and relocation. Through top cover sealing and full pipeline insulation, the equipment can maintain a stable, safe, and energy-efficient operating state during the cable boiling process.

[0058] A method of using a condensing micro-superheated steam heating device for a cable boiling process includes: S1. After starting the control device, perform self-checks on the micro-superheated steam generator, pure water supply device, steam distributor, and insulated water tank to check whether the temperature, pressure, liquid level, and flame status meet the start-up conditions. Simultaneously check whether the steam delivery pipe, steam supply branch, recovery pipe, water replenishment pipe, and drain outlet are unobstructed. Once all conditions meet the requirements, the system enters the standby state.

[0059] S2, Pure Water Supply The pure water supply device replenishes water to the micro-superheated steam generator or the insulated water tank to bring the system level to the set initial level. Water replenishment is automatic when the level falls below the lower limit and stops when the level reaches the upper limit. The preferred source of pure water is pure water produced by a reverse osmosis pure water system to reduce scaling on the steam generator and heat exchange coils.

[0060] S3, Slightly Superheated Steam Generation The micro-superheated steam generator is controlled to start the combustion and heat exchange process. The fuel gas and combustion air are premixed in the proportioner and then enter the burner body for combustion. The combustion heat is first absorbed by the water-cooled combustion chamber and then transferred to the water in the heat exchange tube bundle through the heat exchange shell, causing the water to vaporize and form steam. The steam then enters the steam superheating component for further heating and is finally output as micro-superheated steam and sent to the steam distribution cylinder.

[0061] S4, Steam Distribution and Heat Exchange The steam distributor controls the distribution of slightly superheated steam to the heat exchange coils within the insulated water tank. The slightly superheated steam releases heat within the heat exchange coils, forming condensate, which is then recovered via the return port and recovery pipe. The steam distributor plays a role in equalizing, stabilizing, and distributing steam throughout this process, ensuring uniform steam distribution to the heat exchange coils and preventing localized overheating or insufficient steam supply.

[0062] S5, Temperature Closed-Loop Regulation The system monitors the water temperature in the insulation tank in real time and adjusts the steam output power proportionally according to the set temperature to maintain a stable water temperature. When the detected water temperature is lower than the set temperature, the steam output power is increased or the steam supply time is extended; when the detected water temperature reaches the set temperature, the steam output power is reduced. This ensures that the temperature inside the insulation tank remains within a stable range suitable for cable boiling, improving process consistency.

[0063] S6, Stop and Reset After the process is completed, combustion is stopped and steam output is shut off. The system is then drained or replenished with water to reset it before entering standby mode. During shutdown, residual liquid at the bottom of the tank can be drained through drain port 16, and residual condensate can be recovered through the return water passage to prepare for the next operation.

[0064] In actual use, the cable roll can be placed into the limiting groove 17 before heating begins. The limiting groove 17 positions the cable roll, preventing it from rolling, colliding, or being squeezed during heating, thereby improving the uniformity of boiling and the consistency of the finished product.

[0065] In step S2, water is automatically replenished when the liquid level is below the lower limit and water replenishment stops when the liquid level reaches the upper limit.

[0066] In step S5, when the detected water temperature is lower than the set temperature, the steam output power is increased or the steam supply time is extended; when the detected water temperature reaches the set temperature, the steam output power is reduced.

[0067] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments, and various changes and modifications can be made without departing from the spirit and scope of the invention, all of which fall within the scope of protection claimed by the present invention. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A condensing micro-superheated steam heating device for a cable boiling process, characterized in that: It includes a micro-superheated steam generator, a steam distribution cylinder, an insulated water tank, a pure water supply device, and a control device; The micro-superheated steam generator is equipped with a steam output port and a condensate recovery port. The steam output port is connected to the steam inlet of the steam distributor through a steam delivery pipe, and the condensate recovery port is connected to the pure water supply device through a recovery pipe. The insulated water tank includes an external support frame, an inner liner disposed within the external support frame, an insulation layer disposed between the inner liner and the external support frame, and a heat exchange coil disposed within the inner liner. The inlet of the heat exchange coil is connected to the steam outlet of the steam distribution cylinder via a steam supply branch, and the outlet of the heat exchange coil is connected to the recovery pipe. The pure water supply device is connected to the micro-superheated steam generator or the insulated water tank via a water replenishment pipeline. The control device is electrically connected to the temperature detection element, pressure detection element, and liquid level detection element on the micro-superheated steam generator, the pure water supply device, and the insulated water tank. The insulated water tank is equipped with a limiting groove and a top cover.

2. The condensing micro-superheated steam heating device for cable boiling process according to claim 1, characterized in that: The micro-superheated steam generator includes a water-cooled fully premixed combustion component, a heat exchange component, and a steam superheating component, which are connected sequentially along the steam flow direction.

3. The condensing micro-superheated steam heating device for cable boiling process according to claim 2, characterized in that: The water-cooled fully premixed combustion assembly includes a gas input pipeline, a combustion air input pipeline, a proportioner, a burner body, a water-cooled combustion chamber, an ignition device, and a flame detection device. The gas input pipeline and the combustion air input pipeline are both connected to the proportioner. The output end of the proportioner is connected to the burner body. The burner body is disposed in the water-cooled combustion chamber. The ignition device and the flame detection device are respectively disposed on the burner body. The heat exchange assembly includes a heat exchange shell, a heat exchange tube bundle, a water inlet, a steam outlet, and a flue gas discharge channel. The heat exchange shell is sleeved on the outside of the water-cooled combustion chamber, and a heat exchange channel is formed between the water-cooled combustion chamber and the heat exchange shell. The water inlet is connected to an external water source, and the steam outlet is connected to the steam superheating assembly. The steam superheating assembly includes a superheating cavity, a superheating coil, and a steam outlet. The steam outlet is connected to the superheating cavity, the superheating coil is disposed in the superheating cavity, the inlet of the superheating coil is connected to the steam outlet, and the outlet of the superheating coil forms the steam outlet. In this process, the fuel gas and combustion air are premixed by the proportioning mixer and then enter the burner body for combustion. The combustion heat is transferred sequentially through the water-cooled combustion chamber and the heat exchange shell to the water in the heat exchange tube bundle, so that the water is vaporized to form steam. The formed steam then enters the steam superheating assembly for further heating and is output as slightly superheated steam.

4. The condensing micro-superheated steam heating device for cable boiling process according to claim 1, characterized in that: The insulation layer is a polyurethane foam insulation layer; the external support frame is made of galvanized channel steel; the heat exchange coil is fixed by a support structure set inside the inner tank.

5. A condensing micro-superheated steam heating device for a cable boiling process according to claim 4, characterized in that: The support structure is made of 304 stainless steel channel steel, and at least two of the support structures are spaced apart along the length of the inner liner.

6. The condensing micro-superheated steam heating device for cable boiling process according to claim 1, characterized in that: The top cover is rotatably connected to the insulated water tank, and the top cover is provided with a handle and a hook on the inside of the top cover.

7. A condensing micro-superheated steam heating device for a cable boiling process according to claim 6, characterized in that: A bearing connector is provided between the top cover and the insulated water tank, and lifting rings are provided on both the front and back of the insulated water tank.

8. A condensing micro-superheated steam heating device for a cable boiling process according to claim 1, characterized in that: The pure water supply device includes a reverse osmosis pure water equipment and an insulated pure water tank. The outlet of the reverse osmosis pure water equipment is connected to the inlet of the insulated pure water tank, and the outlet of the insulated pure water tank is connected to both the micro-superheated steam generator and the insulated water tank. The control device includes a PLC controller and a frequency conversion adjustment module. The signal output terminals of the temperature detection element, pressure detection element, and liquid level detection element are electrically connected to the PLC controller, and the control output terminal of the PLC controller is electrically connected to the micro-superheated steam generator and the pure water supply device, respectively.

9. A method of using a condensing micro-superheated steam heating device for a cable boiling process, characterized in that: A condensing micro-superheated steam heating device for controlling a cable boiling process as described in any one of claims 1-8, comprising: S1. System initialization: Start the control device to perform self-checks on the micro-superheated steam generator, pure water supply device, steam separator and heat preservation water tank. When the temperature, pressure, liquid level and flame status meet the start-up conditions, it enters the standby state. S2, Pure water supply: Control the pure water supply device to supply water to the micro-superheated steam generator or the insulated water tank so that the system liquid level reaches the set initial liquid level; S3, Micro-superheated steam generation: Control the micro-superheated steam generator to start the combustion and heat exchange process, generate micro-superheated steam and deliver it to the steam distribution cylinder; S4. Steam distribution and heat exchange: The control steam distributor distributes the slightly superheated steam to the heat exchange coil in the heat-insulating water tank. After the slightly superheated steam releases heat in the heat exchange coil, it forms condensate. The condensate is then recovered through the recovery pipe. S5. Temperature closed-loop regulation: Real-time acquisition of water temperature in the insulated water tank, and proportional adjustment of steam output power according to the set temperature to maintain stable water temperature. S6. Shutdown and Reset: After the process is completed, combustion is stopped and steam output is shut off. The system is then drained or replenished with water to reset it, and then enters standby mode.

10. The method of using the condensing micro-superheated steam heating device for the cable boiling process according to claim 9, characterized in that: In step S2, water is automatically replenished when the liquid level is below the lower limit and water replenishment stops when the liquid level reaches the upper limit.

11. The method of using the condensing micro-superheated steam heating device for the cable boiling process according to claim 9, characterized in that: In step S5, when the detected water temperature is lower than the set temperature, the steam output power is increased or the steam supply time is extended; when the detected water temperature reaches the set temperature, the steam output power is reduced.

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