Gas steam boiler energy utilization and material recycling device

Abstract

The application relates to a gas-steam boiler energy utilization and material recycling device, which comprises a condensing economizer, a spraying recycler, a heat exchange water tank and a water supplement tank. The gas inlet of the condensing economizer is connected with the smoke outlet of the steam boiler, and the gas outlet of the condensing economizer is connected with the gas inlet of the spraying recycler. The water inlet of the condensing economizer is connected with the first water outlet of the water supplement tank, and the water outlet of the condensing economizer is connected with the water inlet of the steam boiler. The first water inlet of the water supplement tank is connected with external water supply. The spraying recycler is provided with multiple spraying pipes, the water inlets of the multiple spraying pipes are connected with the water outlet of the heat exchange water tank to connect with low-temperature water and spray the high-temperature smoke gas in the spraying recycler. The first water outlet of the spraying recycler is connected with the water inlet of the heat exchange water tank. The smoke outlet of the spraying recycler is used for discharging low-temperature smoke gas. The coil inlet of the heat exchange water tank is connected with the second water outlet of the water supplement tank, and the coil outlet of the heat exchange water tank is connected with the second water inlet of the water supplement tank.

Description

Technical Field

[0001] This application relates to the field of steam boiler energy utilization technology, and in particular to a gas-fired steam boiler energy utilization and material recovery device. Background Technology

[0002] Natural gas is a highly efficient, clean, and convenient energy source. With the vigorous promotion of natural gas and the advancement of the national "coal-to-gas" conversion program, the proportion of gas-fired heating in northern China is gradually increasing. The burner mixes natural gas and air in a specific ratio and ignites it, generating a high-temperature flame and flue gas in the boiler furnace. The high-temperature flue gas efficiently transfers heat to the boiler water, which absorbs the heat, rises to its boiling point, and vaporizes, producing saturated steam. However, the flue gas produced after natural gas combustion needs to be discharged. Due to the excessively high temperature of the flue gas, currently, condensing economizers are often used alone to cool and utilize the flue gas. Even after temperature recovery, a large amount of residual heat remains unrecovered. This unused residual heat is directly released into the environment, not only wasting energy but also further exacerbating thermal pollution, affecting the temperature balance of the surrounding ecosystem, and potentially destroying habitats.

[0003] Therefore, optimizing the waste heat recovery system of steam boiler exhaust gas and further recovering the heat in the steam boiler exhaust gas has become an urgent problem to be solved. Summary of the Invention

[0004] In view of this, this application proposes an energy utilization and material recovery device for a gas-fired steam boiler.

[0005] According to one aspect of this application, a gas-fired steam boiler energy utilization and material recovery device is provided, characterized in that it includes: a condenser economizer, a spray recovery device, a hot water exchange tank and a makeup water tank; The air inlet of the condensing energy-saving device is suitable for connection with the flue gas outlet of the steam boiler, and the air outlet of the condensing energy-saving device is connected with the air inlet of the spray recovery device to send the high-temperature flue gas discharged from the steam boiler into the spray recovery device for cooling; the water inlet of the condensing energy-saving device is connected with the first water outlet of the water supply tank, and the water outlet of the condensing energy-saving device is suitable for connection with the water inlet of the steam boiler so that the water in the water supply tank exchanges heat with the high-temperature flue gas and then enters the steam boiler. The first inlet of the water tank is suitable for introducing external water supply; The spray recovery unit is equipped with multiple spray pipes. The inlet of each spray pipe is connected to the outlet of the hot water exchange tank to receive low-temperature water and spray it out into the high-temperature flue gas inside the spray recovery unit. The first outlet of the spray recovery unit is connected to the inlet of the hot water exchange tank. The flue gas outlet of the spray recovery unit is suitable for discharging low-temperature flue gas. The coil inlet of the hot water exchange tank is connected to the second outlet of the water supply tank to draw in water from the water supply tank and exchange heat with the water in the hot water exchange tank. The coil outlet of the hot water exchange tank is connected to the second inlet of the water supply tank.

[0006] In one possible implementation, it also includes: a water softening device; the water softening device is installed on the pipeline connected to the first inlet of the water supply tank, and is suitable for softening the water supplied to the water supply tank.

[0007] One possible implementation also includes: a boiler feedwater pump; The boiler feedwater pump is installed on the pipeline between the inlet of the condenser economizer and the first outlet of the makeup water tank.

[0008] One possible implementation also includes: a water tank circulation pump; the water tank circulation pump is installed on the pipeline between the coil inlet of the hot water exchange tank and the second outlet of the makeup water tank.

[0009] One possible implementation also includes: a spray water pump; The spray water supply pump is installed on the pipeline between the inlet of multiple spray pipes and the outlet of the hot water tank.

[0010] One possible implementation also includes: water purification equipment; The second outlet of the spray recovery unit is connected to the inlet of the water purification equipment; the outlet of the water purification equipment is connected to the third inlet of the water replenishment tank so that the condensate generated by the high-temperature flue gas condensation recovery is purified and stored in the water replenishment tank.

[0011] One possible implementation also includes: a booster pump; The booster pump is installed on the pipeline between the second outlet of the spray recovery unit and the inlet of the water purification equipment.

[0012] Beneficial Effects: This application optimizes the waste heat recovery system for steam boiler exhaust gas by dividing the waste heat recovery process into two steps to achieve deep extraction of heat from the flue gas. Specifically, the first step uses a condenser to initially recover the sensible heat of the high-temperature flue gas, while the second step utilizes spray condensation technology to further recover the latent heat of the flue gas, thus forming a temperature gradient for recovery and utilization. This design can significantly improve overall energy utilization efficiency; at the same time, the exhaust gas temperature is greatly reduced, thermal pollution is decreased, and the thermal load and emission burden on the environment are effectively reduced.

[0013] Other features and aspects of this application will become clear from the following detailed description of exemplary embodiments with reference to the accompanying drawings. Attached Figure Description

[0014] The accompanying drawings, which are included in and form part of this specification, illustrate exemplary embodiments, features, and aspects of this application together with the specification and serve to explain the principles of this application.

[0015] Figure 1 This invention relates to a structural connection diagram of a gas-fired steam boiler energy utilization and material recovery device according to an embodiment of this application. Figure 2 Show Figure 1 A partial structural diagram; Figure 3 Show Figure 1 A partial structural diagram; Figure 4 A main structural diagram of a gas-fired steam boiler energy utilization and material recovery device according to one embodiment is shown; Figure 5 A main structural diagram of a gas-fired steam boiler energy utilization and material recovery device according to one embodiment is shown; Figure 6 A main structural diagram of a gas-fired steam boiler energy utilization and material recovery device according to one embodiment is shown; Figure 7 A partial structural diagram of a gas-fired steam boiler energy utilization and material recovery device according to one embodiment is shown; Figure 8 A cross-sectional view of one embodiment of the spray recovery unit is shown; Figure 9 A cross-sectional view of one embodiment of the spray recovery unit is shown.

[0016] Steam boiler 100, condenser energy saver 200, spray recovery unit 300, hot water exchange tank 500, water replenishment tank 600, spray pipe 400, water softening equipment 700, first liquid level sensor 640, second liquid level sensor 310, water purification equipment 800, connecting chimney 210, spray box 350, water collection tank 360, second water softening equipment 830. Detailed Implementation

[0017] Various exemplary embodiments, features, and aspects of this application will now be described in detail with reference to the accompanying drawings. The same reference numerals in the drawings denote elements that have the same or similar functions. Although various aspects of the embodiments are shown in the drawings, they are not necessarily drawn to scale unless specifically indicated otherwise.

[0018] It should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this application or to simplify 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 limitations on this application.

[0019] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0020] The term “exemplary” as used herein means “serving as an example, embodiment, or illustration.” Any embodiment illustrated herein as “exemplary” is not necessarily to be construed as superior to or better than other embodiments.

[0021] Furthermore, to better illustrate this application, numerous specific details are provided in the following detailed embodiments. Those skilled in the art should understand that this application can be implemented without certain specific details. In some instances, methods, means, components, and circuits well-known to those skilled in the art have not been described in detail in order to highlight the main points of this application.

[0022] Figure 1 This invention relates to a structural connection diagram of a gas-fired steam boiler energy utilization and material recovery device according to an embodiment of this application. Figure 2 Show Figure 1 A partial structural diagram; Figure 3 Show Figure 1 A local structural diagram; such as Figure 1The device for energy utilization and material recovery of a gas-fired steam boiler includes: a condenser 200, a spray recovery unit 300, a hot water tank 500, and a makeup water tank 600. The air inlet of the condenser 200 is connected to the exhaust port of the steam boiler 100 to receive the high-temperature flue gas discharged from the steam boiler 100. The air outlet of the condenser 200 is connected to the air inlet of the spray recovery unit 300 to send the high-temperature flue gas discharged from the steam boiler 100 into the spray recovery unit 300 for secondary cooling. The water inlet of the condenser 200 is connected to the first outlet of the makeup water tank 600, and the water outlet of the condenser 200 is connected to the water inlet of the steam boiler 100, so that the water in the makeup water tank 600 reacts with the high-temperature flue gas in the condenser 600. After heat exchange within 200, the water enters the steam boiler 100; the first inlet of the makeup water tank 600 is suitable for introducing external water supply; the spray recovery unit 300 is equipped with multiple spray pipes 400, the inlet of each spray pipe 400 is connected to the outlet of the heat exchange tank 500 to receive low-temperature water and spray it out into the high-temperature flue gas in the spray recovery unit 300; the first outlet of the spray recovery unit 300 is connected to the inlet of the heat exchange tank 500; the flue gas outlet of the spray recovery unit 300 is suitable for discharging low-temperature flue gas; the coil inlet in the heat exchange tank 500 is connected to the second outlet of the makeup water tank 600 to receive water in the makeup water tank 600 and exchange heat with the water in the heat exchange tank 500; the coil outlet in the heat exchange tank 500 is connected to the second inlet of the makeup water tank 600.

[0023] It should be noted that the air inlet of the condenser 200 is designed to connect to the exhaust port of the steam boiler 100, thereby efficiently introducing the high-temperature flue gas generated by natural gas combustion. Inside the condenser 200, the high-temperature flue gas undergoes thorough heat exchange with the cold water supplied from the water supply tank 600. This process significantly reduces the temperature of the flue gas. Simultaneously, the cold water is heated to a suitable temperature and then directly supplied to the steam boiler 100 for use. This achieves the first efficient recovery of heat from the flue gas, ensuring that the waste heat in the flue gas is cooled and exchanged for heat in the first stage, thus improving the overall energy efficiency of the system.

[0024] The air inlet of the spray recovery unit 300 is connected to the air outlet of the condenser energy saver 200 to introduce flue gas into the spray recovery unit 300. Inside the spray recovery unit 300, ice water sprayed from the spray pipe 400 performs a second heat exchange and cooling of the flue gas, reducing its temperature to 15±3℃ (below room temperature). This achieves a second, efficient recovery of flue gas heat. Simultaneously, water vapor in the flue gas is condensed within the spray recovery unit 300. The resulting condensate is collected within the spray recovery unit 300 and sent to the hot water tank 500 for circulating spraying. This application can reduce evaporation... While reducing the temperature of the flue gas discharged from the boiler, it can also significantly reduce the concentration of water vapor carried in the flue gas. The reduction in water vapor content directly avoids the flue gas from becoming supersaturated due to the temperature drop after discharge, thereby preventing water vapor from condensing in the air to form white fog and effectively achieving "white fog elimination". On the other hand, because water vapor condenses and precipitates in advance in the system, the total volume of flue gas finally discharged into the atmosphere is reduced accordingly. The flue gas emission volume can be reduced by about 16% due to water vapor condensation. This not only helps to reduce the thermal and humid impact on the local environment, but also improves the overall system's economy and environmental adaptability.

[0025] It should also be noted that the ice water sprayed from the spray pipe 400 originates from the hot water exchange tank 500. The condensate in the hot water exchange tank 500 originates from the spray recovery unit 300. The condensate collected in the spray recovery unit 300 enters the hot water exchange tank 500 for heat exchange and cooling before entering the spray pipe 400 as spray ice water, thus forming the first water circulation. The water that cools the condensate in the hot water exchange tank 500 comes from the makeup water tank 600. The water in the makeup water tank 600 enters the coil 510 in the hot water exchange tank 500, which takes away the temperature of the condensate in the hot water exchange tank 500 before returning to the makeup water tank 600, thus forming the second water circulation. During the continuous water circulation process, the water in the makeup water tank 600 can also be heated to a certain extent, which can improve energy utilization efficiency and optimize the performance of the entire circulation system.

[0026] In summary, this application divides the waste heat recovery process of the flue gas emitted by the steam boiler 100 into two steps to achieve deep extraction of heat from the flue gas. Specifically, the first step uses a condenser economizer 200 to initially recover the sensible heat of the high-temperature flue gas, and the second step utilizes spray condensation technology to further recover the latent heat of the flue gas, thereby forming a temperature gradient recovery and utilization. This design can significantly improve the overall energy utilization efficiency; at the same time, the temperature of the emitted flue gas is reduced, pollutants are reduced, and the heat load and emission burden on the environment are effectively reduced. After two heat exchange cooling processes, the flue gas temperature is reduced to 15±3℃ (below room temperature), and the flue gas emission volume can be reduced by about 16% due to water vapor condensation. With a sufficiently low flue gas temperature, a PVC chimney can be used instead of a metal chimney, improving corrosion resistance and reducing equipment costs.

[0027] In one possible implementation, such as Figure 3As shown, a first water inlet is provided on the side wall of the water supply tank 600. The first water inlet is connected to a water inlet pipe 650. The first water inlet of the water supply tank 600 is suitable for introducing external water supply (such as tap water) through the water inlet pipe 650 to supplement the basic water volume in the water supply tank 600, ensuring that the subsequent related equipment can continuously obtain a stable water supply, meeting the water supply needs of the steam boiler 100 during operation, and also providing a reliable water source guarantee for the stable operation of the system.

[0028] Furthermore, multiple different types of valves, a first filter 652, and a first pressure gauge 654 are arranged on the inlet pipe 650, and as follows: Figure 3 As shown, the first valve 651, the first filter 652, the second valve 653, the first pressure gauge 654, the third valve 655, the fourth valve 656, the fifth valve 657, and the sixth valve 658 are arranged sequentially along the flow direction of the liquid in the inlet pipe 650.

[0029] Preferably, the first valve 651, the third valve 655, the fourth valve 656, and the sixth valve 658 are all shut-off valves; the fifth valve 657 is an electric valve controlled by the controller; and the second valve 653 is a bypass valve on the bypass pipeline. It should be noted that the multiple valves are provided for ease of maintenance and replacement in case of failure. For example, when replacing or repairing the fifth valve 657, the fourth valve 656 and the sixth valve 658 can be closed, while the shut-off valve 659 on the return water pipeline 810 can be opened simultaneously, without affecting the entry of purified RO water.

[0030] In one possible implementation, a water softening device 700 is also included. The water softening device 700 is installed on the inlet pipe 650 connected to the first inlet of the water supply tank 600, and is specifically used to soften the water flowing into the water supply tank 600. This device can effectively remove calcium and magnesium ions from the water, significantly reducing water hardness, thereby preventing scale buildup in the pipes. This helps protect the water supply tank 600 and system pipes from corrosion and blockage, improves the reliability of the entire water supply system, and ensures the long-term stable operation of the subsequent steam boiler 100.

[0031] Furthermore, such as Figure 3 As shown, a seventh valve 710 is installed on the pipeline connecting the inlet of the water softening equipment 700 to the inlet pipe 650; an eighth valve 720 is installed on the pipeline connecting the outlet of the water softening equipment 700 to the inlet pipe 650. Preferably, both the seventh valve 710 and the eighth valve 720 are shut-off valves. The third valve 655 is located between the pipeline containing the seventh valve 710 and the pipeline containing the eighth valve 720. Under normal operating conditions, the third valve 655 is closed, and the seventh valve 710 and the eighth valve 720 are open, allowing external water to flow through the water softening equipment 700 and then into the water replenishment tank 600.

[0032] In one possible implementation, the water softening equipment 700 adopts industrial water softening equipment, which has a larger water treatment capacity and a higher degree of automation.

[0033] In one possible implementation, the water supply tank 600 is equipped with a drain pipe 670 and an overflow pipe 660. The drain pipe 670 is located at the bottom of the water supply tank 600 and communicates with the cavity of the water supply tank 600. A ninth valve 671 is provided on the drain pipe 670 for controlling drainage. The overflow pipe 660 is located on the side wall of the water supply tank 600 and communicates with the cavity of the water supply tank 600. It automatically drains water when the water level exceeds the safety line. The drain pipe 670 and the overflow pipe 660 work together to promptly drain water when the water level in the water supply tank 600 is too high, effectively preventing water overflow or damage to the equipment, thereby ensuring the stable operation and long-term safety of the equipment.

[0034] In one possible implementation, the water supply tank 600 is provided with a first outlet and a second outlet. The first outlet is connected to the inlet of the condenser 200 via a first water supply pipe 610, thereby supplying water to the steam boiler 100 through the condenser 200. The second outlet is connected to the coil inlet of the heat exchange tank 500 via a second water supply pipe 620, thereby cooling the condensate in the heat exchange tank 500. The water in the water supply tank 600 is divided into two streams, flowing to the condenser 200 and the heat exchange tank 500 respectively. It should be noted that the first outlet and the second outlet can be set separately, or they can be set as a single outlet connected to both the first water supply pipe 610 and the second water supply pipe 620.

[0035] In one possible implementation, a first liquid level sensor 640 is installed inside the water replenishment tank 600 to monitor and provide feedback on the water level changes in the water replenishment tank 600 in real time. By accurately detecting the water level, the water storage status of the water replenishment tank 600 can be grasped in a timely manner, and key data support can be provided for automatic water replenishment control. This ensures that the water replenishment tank 600 maintains a suitable water level range during operation, thereby improving the stability and reliability of the entire water supply system.

[0036] Preferably, the high trigger liquid level height of the first liquid level sensor 640 inside the water replenishment tank 600 accounts for 80% of the overall height of the water replenishment tank 600; the low trigger liquid level height of the first liquid level sensor 640 inside the water replenishment tank 600 accounts for 60% of the overall height of the water replenishment tank 600, that is, to ensure that the water level in the water replenishment tank 600 is between 60% and 80% of the height of the water replenishment tank 600.

[0037] In one possible implementation, it also includes: a boiler feed water pump 631; the boiler feed water pump 631 is installed on the first water supply pipeline 610 between the inlet of the condenser economizer 200 and the first outlet of the makeup water tank 600; used to pressurize and transport the water in the makeup water tank 600 to the condenser economizer 200, thereby ensuring the continuity and stability of the boiler water supply system.

[0038] Furthermore, a first valve group is provided on the first water supply pipeline 610 between the inlet of the condenser energy saver 200 and the first outlet of the water supply tank 600; and a tenth valve 611 is provided at the outlet of the first water supply pipeline 610 to control the opening and closing of the first water supply pipeline 610.

[0039] In one possible implementation, such as Figure 3 As shown, it also includes a bypass pipe; both ends of the bypass pipe are connected to the first water supply line 610 between the inlet of the condensing energy-saving unit 200 and the first outlet of the makeup water tank 600. This bypass pipe serves as a backup flow path for the first water supply line 610 and is designed for emergency activation in case of blockage or other malfunctions in the main first water supply line 610, ensuring the continuous and stable operation of the entire system. The bypass pipe is also equipped with a boiler feedwater pump 631 and a second valve group to ensure that necessary feedwater pressure and flow are maintained during switching; simultaneously, the second valve group is used to precisely regulate water flow interruption, thereby improving the operational flexibility and safety of the system.

[0040] In one possible implementation, a water tank circulation pump 621 is also included. The water tank circulation pump 621 is installed on the second water supply pipeline 620 between the coil inlet in the hot water exchange tank 500 and the second outlet of the makeup water tank 600. The water tank circulation pump 621 promotes the directional flow of cold water within the coil 510 of the hot water exchange tank 500, ensuring that temperature can be efficiently and stably transferred from the coil 510 to the condensate in the hot water exchange tank 500, maintaining reliable circulation during long-term operation.

[0041] Furthermore, it also includes: a third valve assembly; the third valve assembly is installed on the second water supply pipeline 620 between the coil inlet of the hot water exchange tank 500 and the second outlet of the water supply tank 600; used to control the flow of water in the second water supply pipeline 620.

[0042] In one possible implementation, such as Figure 3 As shown, the first valve group, the second valve group, and the third valve group each include three valves arranged sequentially along the direction of water flow in the pipe, specifically the eleventh valve 626, the twelfth valve 623, and the thirteenth valve 622 arranged sequentially along the direction of water flow in the pipe; wherein the eleventh valve 626 is a butterfly valve, the twelfth valve 623 is a check valve, and the thirteenth valve 622 is a butterfly valve.

[0043] In one possible implementation, a second filter 625 is provided on both the first water supply pipeline 610 and the second water supply pipeline 620; and the second filter 625 is located between the eleventh valve 626 and the water tank circulation pump 621 / boiler feed pump 631.

[0044] In one possible implementation, both the first water supply pipeline 610 and the second water supply pipeline 620 are provided with flexible connection shock absorbers 624, and the flexible connection shock absorbers 624 are located between the second filter 625 and the water tank circulation pump 621 / boiler feed pump 631.

[0045] In one possible implementation, a second liquid level sensor 310 is provided inside the spray recovery unit 300, and the second liquid level sensor 310 is located in the water collection tank 360 of the spray recovery unit 300; it is used to monitor and provide feedback on the changes in the condensate water level in the spray recovery unit 300 in real time. By accurately detecting the water level height, the water storage status of the spray recovery unit 300 can be grasped in a timely manner, and data support can be provided for automatic drainage control, ensuring that the spray recovery unit 300 maintains a suitable water level range during operation, thereby improving the stability and reliability of the entire water supply system.

[0046] Preferably, the height of the high trigger level of the second liquid level sensor 310 inside the spray recovery unit 300 from the bottom surface of the spray recovery unit 300 accounts for 80% of the overall height of the water collection tank 360 of the spray recovery unit 300; the height of the low trigger level of the second liquid level sensor 310 from the bottom surface of the spray recovery unit 300 accounts for 60% of the height of the water collection tank 360 of the spray recovery unit 300, that is, ensuring that the water level in the water collection tank 360 of the spray recovery unit 300 is between 60% and 80% of the height of the water collection tank 360 of the spray recovery unit 300.

[0047] In one possible implementation, it also includes: a spray recovery pump 321; the spray recovery pump 321 is installed on the pipeline 320 between the first outlet of the spray recovery unit 300 and the inlet of the hot water exchange tank 500, and is suitable for sending condensate into the hot water exchange tank 500 for cooling to form spray ice water.

[0048] In one possible implementation, such as Figure 2 As shown, a valve 322 is provided on the pipeline 320 between the first outlet of the spray recovery unit 300 and the inlet of the hot water exchange tank 500.

[0049] In one possible implementation, each spray pipe 400 is connected to the outlet of the hot water tank 500 via a spray manifold 530; a spray water pump 531 is installed on the spray manifold 530 and is suitable for sending the cooled spray ice water into the interior of the spray recovery unit 300 for spraying.

[0050] In one possible implementation, it also includes: a water purification device 800 (biofilm recovery device); the second outlet of the spray recovery device 300 is connected to the inlet of the water purification device 800 via a pipe 330; the outlet of the water purification device 800 is connected to the third inlet of the makeup water tank 600 via a return water pipe 810 to purify the condensate generated by the high-temperature flue gas condensation recovery and prepare it into RO water, which is then stored in the makeup water tank 600.

[0051] In one possible implementation, the outlet of the water purification device 800 is connected to the third inlet of the water supply tank 600 via a return water pipe 810, and a shut-off valve 811 is provided on the return water pipe 810.

[0052] In one possible implementation, a shut-off valve 332, a booster pump 331, a third pressure gauge 333, and a shut-off valve 334 are installed on the pipeline 330 between the second outlet of the spray recovery unit 300 and the inlet of the water purification equipment 800. The shut-off valve 332, the booster pump 331, the third pressure gauge 333, and the shut-off valve 334 are arranged sequentially along the water flow direction in the pipeline 330 to ensure that the system can effectively regulate the water flow, maintain stable pressure, and display key parameters in real time during operation.

[0053] In one possible implementation, the water purification equipment 800 (biofilm recovery device) adopts an industrial-grade RO reverse osmosis pure water system, a modular water treatment system based on reverse osmosis (RO) technology. Through selective recovery via a biofilm, the condensate from the flue gas condensed in the hot water exchange tank 500 is converted into RO water and stored in the makeup water tank 600 via the return water pipe 810, thus realizing the resource utilization of condensate wastewater and reducing the operating water consumption of the steam boiler 100. It should be noted that when there is excess condensate in the spray recovery unit 300, the condensate needs to be discharged to the water purification equipment 800 for purification. Because the water purification equipment 800 has excellent purification capabilities, it can effectively remove heavy metal ions (such as lead and mercury), bacteria, viruses, organic matter, and dissolved solids from the water, transforming it from industrial wastewater discharge into high-purity industrial water produced by reverse osmosis. The RO water produced is pure and odorless and can be directly used as boiler feedwater. Furthermore, RO water has strong stability and is not easily affected by fluctuations in the water quality of the source, making it both environmentally friendly and economical.

[0054] In one possible implementation, the concentrated water outlet of the water purification device 800 is connected to the inlet of the spray recovery unit 300 via a concentrated circulation pipe 820 to return the generated concentrated water to the interior of the spray recovery unit 300 for recycling. A shut-off valve 821 is installed on the concentrated circulation pipe 820. It should be noted that this is done to minimize system wastewater discharge and achieve high-level water resource capture and recycling throughout the system; the concentrated water generated by the water purification device 800 is returned to the spray recovery unit 300 for recycling.

[0055] It should be noted that, in order to prevent scaling and water pollution in the system, the conductivity of the condensate in the spray recovery unit 300 needs to be monitored regularly. When the conductivity of the condensate in the spray recovery unit 300 exceeds 6000 microSiemens, the condensate needs to be drained and the spray recovery unit 300 needs to be cleaned before it can be put back into use.

[0056] In summary, this invention solves the problems of poor energy utilization efficiency, high carbon emissions, and "white smoke" caused by supersaturated water vapor condensation in flue gas during operation of existing steam boilers 100, which leads to public misunderstanding. It is an ultra-efficient gas heat pump heat pipe coupled heat source device that effectively realizes energy utilization and has high economic value.

[0057] Specifically, the condenser energy saver 200 is equipped with a spray recovery unit 300 and achieves first-level energy efficiency operation through a water supply tank 600 and a boiler feed water pump 631. The temperature of the condensate entering the water purification equipment 800 is reduced to below 50℃, achieving first-level chemical energy utilization. High-temperature flue gas enters the spray recovery unit 300, and spray chilled water at about 7℃, pressurized by the spray feed water pump 531, is sprayed out. The spray chilled water directly contacts the incoming flue gas for heat exchange, reducing the flue gas temperature to 15±3℃ (below room temperature). At the same time, the water vapor generated by the combustion of gas is effectively condensed and can enter the water supply tank 600 through the water purification equipment 800 to achieve water resource collection and recovery of sensible and latent heat of flue gas.

[0058] After absorbing the waste heat from the flue gas, the temperature of the spray chilled water increases and, together with the condensate, it accumulates in the lower part of the spray recovery unit 300 under the action of gravity. After being pressurized by the spray recovery pump 321, it enters the hot water tank 500. After being absorbed by the coil 510, the water temperature drops to about 7°C and is sent back to the spray recovery unit 300 by the spray water supply pump 531 for spraying, thus completing the reciprocating cycle to recover heat.

[0059] Water is drawn from the water supply tank 600, pressurized, and sent into the coil 510 to absorb the heat from the water in the heat exchange tank 500. After the water in the water supply tank 600 is heated, it is further heated by the condenser energy-saving device 200 before entering the steam boiler 100 to produce steam. Increasing the feed water temperature can reduce gas consumption.

[0060] When the water level inside the water supply tank 600 rises to the high level detection point of the first level sensor 640, the first level sensor 640 is triggered and immediately sends a signal to the system controller. Upon receiving this high level signal, the system controller quickly responds and executes control commands, driving the fifth valve 657 to close, thereby cutting off the inflow of external water supply and effectively preventing the water supply tank 600 from overflowing due to overfilling, ensuring the safety and stability of system operation. When the water level inside the water supply tank 600 drops to the low level detection point of the first level sensor 640, the first level sensor 640 is also triggered and sends a low level signal to the system controller. Upon receiving this signal, the system controller will again control the opening of valve 675 to restore the external water supply to the water supply tank 600, ensuring that the water tank always maintains sufficient water volume to meet the continuous water supply needs of subsequent process stages.

[0061] The lower part of the spray recovery unit 300 collects condensate. As the amount of steam condensation gradually increases, the condensate level also rises. When the condensate level in the spray recovery unit 300 reaches the high-level sensor detection point of the second level sensor 310, the system controller receives the signal from the second level sensor 310 and starts the booster pump 331 to pressurize the condensate and pump it into the water purification equipment 800. Through selective recycling by the biofilm, the condensate generated from the flue gas condensation recovery is prepared into RO water and stored in the makeup water tank 600 through the return water pipeline 810, realizing the resource utilization of the condensate wastewater generated by condensation and reducing the working water consumption of the steam boiler 100. The RO water produced by the water purification equipment 800 is supplied to the steam boiler 100 for use, and the concentrated water returns to the spray recovery unit 300 for recycling through the concentrated circulation pipeline 820.

[0062] When the condensate level in the spray recovery unit 300 drops to the low liquid level sensor detection point of the spray medium of the second liquid level sensor 310, the system controller receives the signal from the second liquid level sensor 310 and shuts down the booster pump 331 to continue circulating the water source heat pump spray water, continuing to recover the sensible heat of the flue gas, the latent heat of water vapor, and the condensate. When the condensate volume reaches the high liquid level sensor detection point of the spray medium of the second liquid level sensor 310 again, the system controller restarts the booster pump 331 to produce RO water. This cycle repeats efficiently to recover water resources generated from the gas, and ensures the operational stability of the equipment.

[0063] After passing through the spray recovery unit 300, the flue gas temperature drops to 15±3℃ (below room temperature). The water vapor produced by the combustion of the gas is condensed, and the flue gas emission will not have the problem of temperature drop and water vapor supersaturation condensation, thus eliminating whitening. The flue gas volume is reduced by about 16% due to water vapor condensation. The flue gas temperature is low enough that PVC can be used to replace the metal chimney, improving corrosion resistance and reducing costs.

[0064] This application couples other combustion chemical energy, condenser energy saver 200, spray recovery unit 300 and water purification equipment 800 to achieve full utilization of energy and material recovery, achieve low carbon and low nitrogen emissions, and at the same time recycle and utilize the water resources generated by gas combustion and produce RO water from the condensate that originally needed to be discharged into the system for resource utilization.

[0065] Example: In one possible implementation, such as Figure 4 As shown, the condensing energy-saving device 200 is installed beside the steam boiler 100. The air inlet of the condensing energy-saving device 200 is connected to the flue gas outlet of the steam boiler 100 through a flange, thereby receiving the high-temperature flue gas discharged from the steam boiler 100. The top air outlet of the condensing energy-saving device 200 is connected to one end of the connecting chimney 210, and the other end of the connecting chimney 210 is connected to the spray recovery device 300. The condensing energy-saving device 200 is connected to the air inlet of the spray recovery device 300 through the connecting chimney 210 to send the high-temperature flue gas discharged from the steam boiler 100 into the spray recovery device 300 for secondary cooling.

[0066] In one possible implementation, such as Figure 6 As shown, the main body of the water replenishment tank 600 is a rectangular box structure. The bottom of the water replenishment tank 600 is equipped with a support frame 691 composed of multiple vertical plates arranged in parallel, suitable for supporting the water replenishment tank 600 off the ground, thereby reducing the interference of the installation ground on the water temperature inside the water replenishment tank 600. The top of the water replenishment tank 600 is equipped with a protective railing 690, which is a quadrilateral fence structure continuously surrounding the edge area of ​​the top of the water replenishment tank 600 on all four sides. This effectively prevents workers from accidentally falling while working on top, thereby improving the safety of maintenance personnel during inspection and repair operations. In addition, a vertical ladder 692 is fixedly installed on the side wall of the water replenishment tank 600, facilitating safe and convenient access for workers to the top platform of the water replenishment tank 600, ensuring unimpeded access for daily maintenance and emergency repairs.

[0067] In one possible implementation, such as Figure 8 As shown, the spray recovery unit 300 includes: a spray box 350 and a water collection tank 360 connected to each other; the spray box 350 is located above the water collection tank 360 and the two are interconnected; both sides of the spray box 350 have openings, one end of which is suitable for connection to the connecting chimney 210 via a flange to receive high-temperature flue gas, and the other end of which is connected to the exhaust chimney 340 to discharge low-temperature flue gas to the outside; multiple through holes are arranged on the side wall of the spray box 350, which are adapted to the spray pipes 400, and the spray pipes 400 can be inserted into the interior of the spray box 350 through the through holes; all the spray pipes 400 are inserted into the cavity of the spray box 350 so that the spraying operation is carried out inside the spray box 350; the main body of the water collection tank 360 has a cuboid structure and is used to collect spray water and condensate.

[0068] In one possible implementation, the spray recovery unit 300 has a guide plate 380 inside, and the guide plate 380 is located between the spray box 350 and the water collection tank 360 of the spray recovery unit 300. The plane of the guide plate 380 is at a preset angle to the horizontal plane so that the guide plate 380 is tilted. The opposite sides of the guide plate 380 are at a preset distance from the inner wall of the spray recovery unit 300, so that the water flows into the water collection tank 360 after passing through the guide plate 380, thereby avoiding splashing.

[0069] Furthermore, the main body of the guide plate 380 is a rectangular plate structure, in which the opposite sides are fixed to the inner wall of the spray recovery unit 300 by welding. In addition, a preset distance is provided between the opposite sides and the inner wall of the spray recovery unit 300 so as not to obstruct the smooth flow of water.

[0070] Preferably, the preset angle between the guide plate 380 and the horizontal plane is in the range of 5°-10°.

[0071] In one possible implementation, a horizontal first plate 370 and a second plate 390 are fixedly provided inside the spray recovery unit 300; the first plate 370 and the second plate 390 are respectively located at both ends of the guide plate 380 and are provided with a vertical distance between them, and the first plate 370 is located above the bottom side of the guide plate 380, and the second plate 390 is located below the high side of the guide plate 380.

[0072] In one possible implementation, all spray pipes 400 are arranged parallel to each other inside the spray recovery unit 300; and the length direction of the spray pipes 400 is perpendicular to the flow direction of the flue gas. The parallel arrangement ensures that the sprayed chilled water can be sprayed comprehensively and evenly, thereby achieving comprehensive and thorough spraying treatment of high-temperature flue gas. Each spray pipe 400 has multiple spray holes regularly opened on its pipe wall. These spray holes are arranged in multiple rows, and the multiple rows of spray holes are arranged evenly around the circumference of the spray pipe. The spacing between two adjacent spray holes in each row is the same. When the high-temperature flue gas flows through the spray recovery unit 300, it will come into full and direct contact with the chilled water sprayed from these spray holes, thereby completing an efficient heat exchange and material recovery process.

[0073] In one possible implementation, there are 48 spray pipes 400 arranged in 8 rows and 6 columns, running parallel into the interior of the spray recovery unit 300. Each spray pipe 400 has three rows of spray holes, with 16 spray holes in each row. Preferably, the spacing between two adjacent spray pipes 400 in each column is the same, and any two adjacent columns of spray pipes 400 are staggered to further improve spraying efficiency.

[0074] In one possible implementation, such as Figure 6 As shown, the main spray pipe 530 is connected to all 48 spray pipes 400, which efficiently and evenly distributes the spray ice water from the hot water tank 500 to each spray pipe 400.

[0075] In one possible implementation, such as Figure 7 As shown, it also includes: a second water softening device 830; the second water softening device 830 is installed on the pipeline 330 between the second outlet of the spray recovery unit 300 and the inlet of the water purification device 800. The inlet of the second water softening device 830 is connected to the second outlet of the spray recovery unit 300, and the outlet of the second water softening device 830 is connected to the inlet of the water purification device 800; that is, another set of second water softening devices 830 is installed in front of the inlet of the water purification device 800. The system makeup water flows through the second water softening device 830 before flowing into the water purification device 800, thereby removing calcium and magnesium ions in the system makeup water, reducing the burden on the water purification device 800, and avoiding excessive calcium and magnesium ions in the water used by the steam boiler 100, which could lead to boiler scaling and explosion.

[0076] like Figure 4 , Figure 5 and Figure 6 As shown, the inlet of the condenser 200 is connected to the first outlet of the water supply tank 600 through the first water supply pipe 610, and the outlet of the condenser 200 is connected to the inlet of the steam boiler 100 so that the water in the water supply tank 600 enters the steam boiler 100 after heat exchange; the first inlet of the water supply tank 600 introduces external water supply through the inlet pipe 650; the first outlet of the spray recovery unit 300 is connected to the inlet of the hot water exchange tank 500 through the pipe 320; the second outlet of the spray recovery unit 300 is connected to the water purification equipment 800 through the pipe 330; and the outlet of the water purification equipment 800 is connected to the third inlet of the water supply tank 600 through the return water pipe 810. The coil inlet in the hot water exchange tank 500 is connected to the second outlet of the water supply tank 600 through the second water supply pipe 620 to receive water from the water supply tank 600 and exchange heat with the water in the hot water exchange tank 500. The coil outlet in the hot water exchange tank 500 is connected to the second inlet of the water supply tank 600 through the pipe 540.

[0077] Preferably, all pipelines, spray recovery unit 300, and water replenishment tank 600 of the equipment are made of stainless steel 022Cr17Ni12Mo2; the exhaust chimney 340 can be made of PVC or the same material as the spray recovery unit 300.

[0078] Both the first liquid level sensor 640 and the second liquid level sensor 310 employ magnetically coupled liquid level gauges to convert liquid level signals into 4-20mA analog signals. The system controller receives and analyzes the 4-20mA measurement signals from the first liquid level sensor 640 and the second liquid level sensor 310 in real time, thereby accurately determining the real-time liquid level status in the water supply tank 600 and the spray recovery unit 300. Based on the signal from the first liquid level sensor 640, the controller dynamically adjusts the opening of the fifth valve 657 to control the flow rate of water into the water supply tank 600; simultaneously, based on the signal from the second liquid level sensor 310, it automatically controls the start and stop of the booster pump 331 to ensure that the spray recovery unit 300 operates stably and efficiently within a suitable liquid level range.

[0079] In this embodiment, the temperature of the high-temperature flue gas coming out of the steam boiler 100 is about 240°C; the condenser 200 first cools the flue gas to about 50°C before sending it into the spray recovery unit 300, and the final discharged flue gas temperature is about 15°C; the condenser 200 can heat the water from the water supply tank 600 to about 120°C before sending it into the steam boiler 100.

[0080] The beneficial effects of this application are as follows: (1) The present invention reduces the temperature of flue gas emitted by gas-fired steam boiler 100 to 15±3℃ in two stages by setting up condenser energy saver 200 and spray recovery device 300, thereby efficiently recovering the chemical energy of gas fuel combustion, reducing energy consumption and carbon emissions.

[0081] (2) The present invention uses a spray recovery device 300 to condense and recover the latent heat of water vapor in flue gas, and at the same time condenses the water vapor in flue gas into condensate, thus avoiding the appearance of "white smoke" in the exhaust, which has great environmental protection value.

[0082] (3) The present invention uses water purification equipment 800 to prepare RO water from the collected condensate and continue to use it for industrial steam production. It turns the original sewage condensate into industrial RO water, turning waste into treasure, and has great environmental and economic value.

[0083] (4) The RO water produced by the 800 water purification equipment can also be directly used for domestic water use, realizing energy conservation and reducing carbon emissions while realizing water resource preparation and reducing groundwater extraction. This has both economic value and great environmental and social value. Northern regions are short of water. The combustion of one molecule of natural gas produces two molecules of water. This application utilizes the chemical energy generated by the combustion of natural gas efficiently and recovers the water vapor generated by the combustion into water resources, which can reduce groundwater extraction in northern regions and is of great significance for promoting "carbon peaking and carbon neutrality".

[0084] The various embodiments of this application have been described above. These descriptions are exemplary and not exhaustive, nor are they limited to the disclosed embodiments. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments. The terminology used herein is chosen to best explain the principles, practical application, or improvement of the technology in the market, or to enable others skilled in the art to understand the embodiments disclosed herein.

Claims

1. A gas-fired steam boiler energy utilization and material recovery device, characterized in that, include: Condensing energy saver, spray recovery unit, hot water exchange tank and water supply tank; The air inlet of the condenser is suitable for connection with the flue gas outlet of the steam boiler, and the air outlet of the condenser is suitable for connection with the air inlet of the spray recovery unit to send the high-temperature flue gas discharged from the steam boiler into the spray recovery unit for cooling; the water inlet of the condenser is connected to the first water outlet of the water supply tank, and the water outlet of the condenser is suitable for connection with the water inlet of the steam boiler so that the water in the water supply tank exchanges heat with the high-temperature flue gas before entering the steam boiler; The first inlet of the water supply tank is suitable for introducing external water supply; The spray recovery unit is equipped with multiple spray pipes, the inlet of which is connected to the outlet of the hot water exchange tank to receive low-temperature water and spray it out into the high-temperature flue gas inside the spray recovery unit; the first outlet of the spray recovery unit is connected to the inlet of the hot water exchange tank; the flue gas outlet of the spray recovery unit is suitable for discharging low-temperature flue gas. The coil inlet of the hot water exchange tank is connected to the second outlet of the water supply tank to receive water from the water supply tank and exchange heat with the water in the hot water exchange tank. The coil outlet of the hot water exchange tank is connected to the second inlet of the water supply tank.

2. The gas-fired steam boiler energy utilization and material recovery device according to claim 1, characterized in that, Also includes: Water softening equipment; The water softening device is installed on the pipeline connected to the first inlet of the water supply tank and is suitable for softening the external water supplied into the water supply tank.

3. The energy utilization and material recovery device for a gas-fired steam boiler according to claim 1, characterized in that, Also includes: Boiler feed water pump; The boiler feedwater pump is installed on the pipeline between the inlet of the condenser and the first outlet of the makeup water tank.

4. The energy utilization and material recovery device for a gas-fired steam boiler according to claim 1, characterized in that, Also includes: Water tank circulation pump; the water tank circulation pump is installed on the pipeline between the coil inlet of the hot water exchange tank and the second outlet of the water supply tank.

5. The gas-fired steam boiler energy utilization and material recovery device according to claim 1, characterized in that, Also includes: Sprinkler water pump; The spray water pump is installed on the pipeline between the inlet end of the multiple spray pipes and the outlet of the hot water exchange tank.

6. The energy utilization and material recovery device for a gas-fired steam boiler according to claim 1, characterized in that, Also includes: Water purification equipment; The second outlet of the spray recovery unit is connected to the inlet of the water purification equipment; the outlet of the water purification equipment is connected to the third inlet of the water replenishment tank so that the condensate generated by the high-temperature flue gas condensation recovery is purified and stored in the water replenishment tank.

7. The energy utilization and material recovery device for a gas-fired steam boiler according to claim 6, characterized in that, It also includes: booster pumps; The booster pump is installed on the pipeline between the second outlet of the spray recovery unit and the inlet of the water purification equipment.

8. The energy utilization and material recovery device for a gas-fired steam boiler according to claim 1, characterized in that, All the spray pipes are arranged in parallel to each other in the spray recovery unit, and each spray pipe has multiple rows of spray holes.

9. The energy utilization and material recovery device for a gas-fired steam boiler according to claim 8, characterized in that, There are a total of 48 spray pipes, which are arranged in 8 rows and 6 columns.

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