Waste heat recovery and drying integrated system of air compressor

Abstract

The utility model discloses an air compressor waste heat recovery and drying integrated system which is characterized in that a high-temperature oil way of an air compressor is communicated with an inlet of a multi-stage heat exchanger, and an outlet of the multi-stage heat exchanger is respectively communicated with a regeneration tower inlet of a double-tower adsorption dryer and a workshop heating inlet; a first valve and a second valve are installed on a regeneration tower inlet pipeline and a workshop heating inlet pipeline of the double-tower adsorption type drying machine respectively, a temperature and humidity sensor is installed in the double-tower adsorption type drying machine, and the PLC control system is electrically connected with the first valve, the second valve, the temperature and humidity sensor and the control end of the double-tower adsorption type drying machine. The waste heat of the high-temperature oil way of the air compressor is deeply coupled with the regeneration process of the drying machine, and a multi-stage heat exchanger and an intelligent regulation and control mode are adopted, so that the waste heat can be fully utilized, and the electric heating energy consumption is obviously reduced. The system is more innovative and practical in the aspects of multi-stage heat exchange, structure integration, intelligent valve dispatching, waste heat secondary utilization and the like.

Description

Technical Field

[0001] This utility model relates to the field of air compressor energy-saving technology, and in particular to an integrated system for air compressor waste heat recovery and drying. This utility model can improve energy utilization and reduce the additional energy consumption of the dryer. Background Technology

[0002] An air compressor is a device that converts mechanical energy into gas pressure energy. It is widely used in various fields such as industry, construction, medical, and food processing. The performance and efficiency of an air compressor directly affect production efficiency and costs. Choosing a suitable air compressor and performing proper maintenance can effectively improve the equipment's lifespan and operating efficiency.

[0003] Traditional air compressors generate a significant amount of heat during operation, which is typically released into the environment via oil coolers or air-cooled radiators, resulting in energy waste. Meanwhile, industrial sites commonly require dryers (such as adsorption dryers) to reduce the humidity of compressed air to meet the cleanliness requirements of production air. However, the regeneration process of dryers often requires electric heating or steam heating, consuming additional energy.

[0004] With the increasing demand for energy conservation and emission reduction in industry, the industry has begun to focus on how to utilize the waste heat from air compressors for dryer regeneration, thereby reducing the consumption of electricity or steam and improving overall thermal efficiency. Existing solutions are mostly simple waste heat exchange systems, but they cannot fully utilize the heat from the high-temperature oil circuits of the air compressor, or lack multi-stage heat exchange designs, resulting in low waste heat utilization. At the same time, traditional waste heat systems have limited adjustment methods, easily leading to unstable drying effects or waste heat when the operating temperature deviates from the specified range. Utility Model Content

[0005] The purpose of this invention is to overcome the shortcomings of existing technologies, such as low waste heat recovery efficiency, high energy consumption for drying and regeneration, and limited adjustment methods. This invention provides an integrated waste heat recovery and drying system for air compressors. This invention combines the waste heat from the high-temperature oil circuit of the air compressor with a multi-stage heat exchanger to achieve efficient heat recovery and dryer regeneration, reducing equipment footprint and additional energy consumption.

[0006] This utility model is achieved through the following technical solution:

[0007] An integrated system for waste heat recovery and drying of an air compressor includes an air compressor, a multi-stage heat exchanger, and a dual-tower adsorption dryer. The high-temperature oil circuit of the air compressor is connected to the inlet of the multi-stage heat exchanger, and the outlet of the multi-stage heat exchanger is connected to the regeneration tower inlet and the workshop heating inlet of the dual-tower adsorption dryer, respectively. Valves one and two are installed on the regeneration tower inlet pipe and the workshop heating inlet pipe of the dual-tower adsorption dryer, respectively. A temperature and humidity sensor is installed inside the dual-tower adsorption dryer. The system also includes a PLC control system, which is electrically connected to valve one, valve two, the temperature and humidity sensor, and the control terminal of the dual-tower adsorption dryer.

[0008] The air compressor is a 37KW air compressor with an exhaust temperature of 90°C-100°C. The air compressor may be a single air compressor or multiple air compressors connected in parallel.

[0009] The multi-stage heat exchanger is a three-stage heat exchanger, which sequentially reduces the temperature to 70°C, 50°C, and 40°C.

[0010] The three heat exchangers are connected by heat-conducting oil pipes or high-efficiency heat-conducting pipes.

[0011] The PLC control system is also connected to a remote monitoring platform.

[0012] The air compressor, multi-stage heat exchanger, and dual-tower adsorption dryer are configured as an integrated frame.

[0013] In this utility model, the air compressor is equipped with a high-temperature oil circuit and a conventional cooling and heat dissipation device.

[0014] The multi-stage heat exchange section consists of multi-stage heat exchangers and is connected to the high-temperature oil circuit of the air compressor.

[0015] The twin-blade adsorption dryer includes structures such as an adsorption tower and a regeneration tower, with its regeneration section connected to a multi-stage heat exchanger.

[0016] Intelligent control section: The PLC control system automatically adjusts the waste heat distribution ratio based on temperature and humidity sensor data to achieve "prioritizing drying and regeneration, and using the remaining heat for other purposes (such as workshop heating)".

[0017] Temperature and humidity sensors monitor the temperature and humidity inside the dual-tower adsorption dryer in real time and dynamically adjust the waste heat supply.

[0018] The advantages of this utility model are: 1. Direct regeneration of waste heat: The waste heat of the high-temperature oil circuit of the air compressor is directly introduced into the regeneration section of the double-tower adsorption dryer after passing through a multi-stage heat exchanger, replacing the traditional electric heating or steam heating, and reducing heat loss.

[0019] 2. Multi-stage heat exchange: This utility model adopts a multi-stage heat exchanger structure, with the temperature decreasing sequentially between different stages, so that the heat of the high-temperature oil circuit can be fully utilized, and the waste heat utilization rate can reach more than 80%.

[0020] 3. Intelligent control: This utility model uses temperature and humidity sensors and intelligent valves to monitor the temperature and humidity inside the dryer in real time, and automatically adjusts the destination of residual heat (such as providing winter workshop heating) to achieve high efficiency and energy saving.

[0021] 4. Integrated system design: This utility model is structurally integrated into a compact integrated device, which occupies less space and is convenient for installation in small industrial sites.

[0022] This invention deeply couples the waste heat from the high-temperature oil circuit of the air compressor with the regeneration process of the dryer, employing a multi-stage heat exchanger and intelligent control methods to fully utilize waste heat and significantly reduce electric heating energy consumption. Compared with commonly available compression heat desiccant dryers or waste heat recovery dryers, this system is more innovative and practical in terms of multi-stage heat exchange, integrated structure, intelligent valve scheduling, and secondary utilization of waste heat. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the overall system structure of this utility model;

[0024] Figure 2 This is a schematic diagram of a multi-stage heat exchange and drying / regeneration process.

[0025] Figure 3 This is a schematic diagram of valve distribution and temperature and humidity monitoring. Detailed Implementation

[0026] like Figure 1 , 2 As shown in Figure 3, an integrated system for waste heat recovery and drying of an air compressor includes an air compressor 1, a multi-stage heat exchanger 2, and a dual-tower adsorption dryer 3. The high-temperature oil circuit of the air compressor 1 is connected to the inlet of the multi-stage heat exchanger 2, and the outlet of the multi-stage heat exchanger 2 is connected to the regeneration tower inlet and the workshop heating inlet of the dual-tower adsorption dryer 3, respectively. Valves 5 and 6 are installed on the regeneration tower inlet pipe and the workshop heating inlet pipe of the dual-tower adsorption dryer 3, respectively. A temperature and humidity sensor is installed inside the dual-tower adsorption dryer 3. The system also includes a PLC control system 4, which is electrically connected to valves 5, 6, the temperature and humidity sensor, and the control terminal of the dual-tower adsorption dryer 3. The PLC control system 4 controls the operation of valves 5 and 6 based on the temperature and humidity data monitored by the temperature and humidity sensor.

[0027] The air compressor 1 is a 37KW air compressor with an exhaust temperature of 90°C-100°C. The air compressor 1 includes one air compressor or multiple air compressors connected in parallel.

[0028] The multi-stage heat exchanger 2 is a three-stage heat exchanger, which sequentially reduces the temperature to 70°C, 50°C, and 40°C.

[0029] The three heat exchangers are connected by heat-conducting oil pipes or high-efficiency heat-conducting pipes.

[0030] The PLC control system 4 is also connected to a remote monitoring platform 7.

[0031] The air compressor 1, multi-stage heat exchanger 2, and double-tower adsorption dryer 3 are configured as an integrated frame.

[0032] Features of this utility model:

[0033] 1. Multi-stage heat exchange and waste heat utilization rate

[0034] Existing conventional waste heat dryers only use single-stage or double-stage heat exchangers, resulting in relatively limited waste heat utilization. This invention focuses on utilizing the high-temperature oil circuit of the air compressor 1, and in conjunction with the multi-stage heat exchanger 2 to reduce the temperature, so that the waste heat utilization rate can be stabilized at over 80%.

[0035] 2. System integration and secondary waste heat utilization

[0036] Existing waste heat dryers are often independent units or simply interconnected, using heat only for drying; this utility model has a high degree of integration, significantly reducing energy consumption.

[0037] 3. Intelligent control strategy

[0038] Most existing waste heat recovery systems use fixed logic or simple start-stop control, which makes it difficult to precisely match on-site requirements;

[0039] This invention uses PLC / edge computing combined with temperature and humidity sensors to dynamically distribute waste heat in real time, enabling the dryer and other heat-demanding points to achieve better energy efficiency.

[0040] 4. Operational stability and applicable scenarios

[0041] Existing waste heat dryers are susceptible to fluctuations in exhaust temperature or unit load, leading to unstable drying and regeneration.

[0042] This invention allows multiple air compressors to be connected in parallel in the high-temperature oil circuit of air compressor 1. Through multi-stage heat exchange and intelligent valve switching, it can achieve a more balanced and stable drying temperature supply, and is suitable for various industries with high requirements for air quality and energy saving.

[0043] This utility model features an air compressor 1 that outputs high-temperature oil; an intermediate multi-stage heat exchanger 2 that gradually reduces the oil temperature and uses waste heat to heat the regeneration tower of the dryer; and a dual-tower adsorption dryer 3 that dries the air before outputting it to the production air pipeline network.

[0044] The multi-stage heat exchanger 2 sequentially lowers the oil temperature from a high temperature to a level suitable for dryer regeneration; the regeneration section of the dual-tower adsorption dryer 3 desorbs moisture from the desiccant at a higher temperature.

[0045] Valve 5 and valve 6 can be switched according to the temperature and humidity sensor data and the dryer's requirements; when the dual-tower adsorption dryer 3 has completed regeneration or the temperature is sufficient, the waste heat can be guided to the workshop for heating or for discharge.

[0046] The PLC control system 4 collects data in real time and reports it to the remote monitoring platform, realizing visualization and intelligent management.

[0047] Example 1: Waste heat from a single air compressor is used to regenerate the dryer.

[0048] A 37kW air compressor was selected, equipped with a high-temperature oil circuit (exhaust temperature approximately 90°C-100°C).

[0049] The system is equipped with multi-stage heat exchangers (primary, secondary, and tertiary stages) to sequentially reduce the oil temperature to 70°C, 50°C, and 40°C; the oil is then transferred to the dryer regeneration tower; excess heat is discharged to radiators for workshop heating, achieving a heat utilization rate of up to 85%.

[0050] Energy saving effect:

[0051] The electric heating power of the dryer is reduced by more than 70%, and the overall system energy efficiency is significantly improved.

[0052] Example 2: Parallel operation of multiple air compressors for waste heat recovery

[0053] 1. System Composition:

[0054] Multiple air compressors are connected in parallel within the air compressor station, and their high-temperature oil circuits are concentrated in a common multi-stage heat exchanger;

[0055] Large-scale adsorption dryers meet the demand for larger air volumes, and intelligent control modules manage waste heat distribution.

[0056] 2. Intelligent control:

[0057] The system monitors the temperature and humidity requirements of the dryer in real time, and prioritizes importing more waste heat when these requirements are insufficient.

[0058] The system features a compact, integrated rack that includes an air compressor, dryer, and heat exchange module, reducing the floor space by more than 30%.

[0059] This invention deeply couples the waste heat from the high-temperature oil circuit of the air compressor with the regeneration process of the dryer, employing a multi-stage heat exchanger and intelligent control methods to fully utilize waste heat and significantly reduce electric heating energy consumption. Compared with commonly available compression heat desiccant dryers or waste heat recovery dryers, this system is more innovative and practical in terms of multi-stage heat exchange, integrated structure, intelligent valve scheduling, and secondary utilization of waste heat.

Claims

1. An integrated system for waste heat recovery and drying of an air compressor, characterized in that: It comprises an air compressor, a multi-stage heat exchanger and a double-tower adsorption dryer, the high-temperature oil path of the air compressor is communicated with the inlet of the multi-stage heat exchanger, the outlet of the multi-stage heat exchanger is respectively communicated with the regeneration tower inlet and the workshop heating inlet of the double-tower adsorption dryer, valve one and valve two are respectively installed on the regeneration tower inlet pipeline and the workshop heating inlet pipeline of the double-tower adsorption dryer, a temperature and humidity sensor is installed in the double-tower adsorption dryer, and a PLC control system is further included, and the PLC control system is electrically connected with valve one, valve two, the temperature and humidity sensor and the control end of the double-tower adsorption dryer.

2. The air compressor waste heat recovery and drying integrated system according to claim 1, characterized in that: The air compressor is a 37KW air compressor, and the exhaust temperature is 90°C-100°C.

3. The air compressor waste heat recovery and drying integrated system according to claim 1, characterized in that: The multi-stage heat exchanger is a three-stage heat exchanger, and the three-stage heat exchanger sequentially reduces the temperature to 70°C, 50°C and 40°C.

4. The air compressor waste heat recovery and drying integrated system according to claim 3, characterized in that: The three-stage heat exchangers are communicated through heat-conducting oil pipes or high-efficiency heat-conducting pipes.

5. The air compressor waste heat recovery and drying integrated system according to claim 1, characterized in that: The PLC control system is further connected with a remote monitoring platform.

6. The air compressor waste heat recovery and drying integrated system of claim 1, wherein: The air compressor, the multi-stage heat exchanger and the double-tower adsorption dryer are arranged in an integrated rack.

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