An air compressor waste heat recovery system
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- GUANGDONG HONGYE BUILDING MATERIALS TECH CO LTD
- Filing Date
- 2025-06-16
- Publication Date
- 2026-05-26
AI Technical Summary
In existing air compressor waste heat recovery systems, the heat exchange structure is simple and the flow path is disordered, resulting in low efficiency. The structural design lacks thermal stress compensation, and the waste heat utilization rate is generally low.
The design employs a spiral horizontal U-shaped heat exchange tube bundle and baffles. The heat exchange chamber is divided into upper and lower layers by a partition component, and baffles are set in each layer to match the spiral direction of the heat exchange tube bundle, guiding the flow of the heat medium, increasing the contact area and time, and avoiding disordered flow and short-circuiting.
It significantly improves heat exchange efficiency, increases heat exchange area per unit volume, reduces thermal resistance, ensures full heat exchange, improves waste heat utilization, and achieves continuous recovery and storage of heat energy through a closed loop.
Smart Images
Figure CN224285554U_ABST
Abstract
Description
Technical Field
[0001] This utility model belongs to the field of air compressor waste heat recovery technology, and specifically relates to an air compressor waste heat recovery system. Background Technology
[0002] In the industrial sector, air compressors are widely used as key power equipment in machining, chemical, mining, and many other fields. However, during operation, air compressors discharge a large amount of heat, with exhaust temperatures typically reaching 80-120℃. If this heat is directly released into the environment, it will result in significant energy waste; statistics show that approximately 30%-50% of the energy generated during air compressor operation is converted into exhaust heat. Furthermore, the high-temperature exhaust can adversely affect the surrounding operating environment, such as increasing local temperatures and impacting the normal performance of other equipment.
[0003] With the deepening of the concept of energy conservation and emission reduction and the continuous rise in energy costs, the recovery and utilization of waste heat from air compressors has become an important research direction in the field of industrial energy conservation. The core of a waste heat recovery system lies in transferring the heat from the exhaust gas of the air compressor to a heat medium (such as water) through a high-efficiency heat exchange device, and then using the recovered heat for heating needs in production and daily life, such as hot water supply and process medium heating, thereby realizing the secondary utilization of energy and reducing the energy consumption and operating costs of enterprises.
[0004] Traditional waste heat recovery heat exchangers often employ simple straight-tube heat exchanger bundle structures. This results in a limited heat exchange area within the same shell space, leading to insufficient contact area between the heat medium and the heat exchange medium (air compressor exhaust), and inadequate heat transfer. Some heat exchangers lack effective baffles or have improperly arranged baffles, causing the heat medium to flow in a straight line within the heat exchanger, creating "dead zones"—regions where the medium does not flow or has extremely low velocity. This prevents the heat exchanger tube bundles in these areas from fully participating in heat exchange, reducing overall heat exchange efficiency. Furthermore, the lack of orderly flow path design can lead to short-circuiting or disordered flow of the heat medium within the heat exchanger, shortening the contact time with the heat exchange medium and preventing sufficient heat exchange.
[0005] In view of this, we propose an air compressor waste heat recovery system to solve the above problems. Utility Model Content
[0006] The present invention aims to solve the technical problems of low efficiency caused by simple heat exchange structure and disordered flow path in the above-mentioned prior art, as well as the lack of thermal stress compensation in the structural design and the generally low waste heat utilization rate.
[0007] To achieve the above objectives, this utility model provides the following technical solution:
[0008] An air compressor waste heat recovery system, comprising:
[0009] The waste heat recovery heat exchanger has its heat exchange medium inlet connected to the exhaust port of the air compressor body; the heat exchange tube bundle is spiral and has a horizontal U-shaped structure.
[0010] The inlet and outlet of the heat medium in the waste heat recovery heat exchanger are connected to the outlet of the circulating water pump and the inlet of the heat storage tank, respectively. The outlet of the heat storage tank is connected to the inlet of the circulating water pump, forming a heat medium circulation loop.
[0011] The waste heat recovery heat exchanger divides the heat exchange chamber into upper and lower layers through a partition component. The upper and lower heat exchange chambers are respectively equipped with baffles that match the spiral direction of the heat exchange tube bundle.
[0012] The heat exchange tube bundle increases the contact area and contact time between the heat medium and the heat exchange medium, and the baffles guide the flow of the heat medium and increase the heat exchange contact time of the heat medium in the waste heat recovery heat exchanger.
[0013] Preferably, the waste heat recovery heat exchanger also includes an upper left shell, a lower left shell, an upper right shell, and a lower right shell that are connected to the flange of the partition assembly to form a lower water inlet chamber, an upper water outlet chamber, and a heat exchange chamber.
[0014] Preferably, the partition assembly includes a horizontal plate located horizontally between the upper left shell, the lower left shell, the upper right shell, and the lower right shell, and a vertical plate located vertically between the upper left shell, the lower left shell, the upper right shell, and the lower right shell and fixedly connected to the horizontal plate.
[0015] Preferably, the lower left shell is provided with a lower water inlet that communicates with the lower water inlet chamber, and the upper left shell is provided with an upper water outlet that communicates with the upper water outlet chamber.
[0016] Preferably, the vertical plate is provided with an upper through hole and a lower through hole on the upper and lower sides of the horizontal plate, respectively. The heat medium in the lower water inlet chamber enters the heat exchange chamber below the horizontal plate through the lower through hole, and the heat medium in the heat exchange chamber above the horizontal plate enters the upper water outlet chamber through the upper through hole.
[0017] Preferably, the right end of the horizontal plate is provided with a flow hole that allows the heat medium in the heat exchange chamber below the horizontal plate to flow into the heat exchange chamber above the horizontal plate.
[0018] Preferably, the baffle is an arc-shaped baffle that is staggered and arranged on the upper and lower surfaces of the horizontal plate and inside the upper right and lower right shells.
[0019] Preferably, the baffles are welded to the upper and lower surfaces of the horizontal plate, the inner wall of the upper right shell, and the inner wall of the lower right shell, respectively.
[0020] Preferably, the heat exchange tube bundle is fixed to the horizontal plate by tube clamps.
[0021] Preferably, the heat exchange medium inlet of the waste heat recovery heat exchanger is connected to the exhaust port of the air compressor body through pipe A; the lower water inlet is connected to the outlet of the circulating water pump through pipe B; the upper water outlet is connected to the inlet of the heat storage tank through pipe C; and the outlet of the heat storage tank is connected to the inlet of the circulating water pump through pipe D.
[0022] Compared with the prior art, the technical effects and advantages of this utility model are:
[0023] (1) This air compressor waste heat recovery system divides the heat exchange chamber into upper and lower layers using horizontal and vertical plates, forming a "bottom in, top out" flow path. The heat medium (such as water) must pass through the lower and upper heat exchange chambers sequentially, avoiding disordered flow or short-circuiting, ensuring full contact with the heat exchange medium (air compressor exhaust), and more uniform heat transfer. Baffles are welded to the horizontal plate and the inner wall of the shell, guiding the heat medium to flow along a tortuous path, avoiding "dead zones" (areas where the medium does not flow or has low velocity) formed by straight flow, and increasing the number of contacts between the medium and the heat exchange tube bundle. The staggered arrangement causes the medium flow direction to change continuously, generating turbulence, destroying the medium boundary layer on the surface of the tube bundle, reducing thermal resistance, and significantly improving the heat transfer coefficient. The baffles match the spiral direction of the heat exchange tube bundle, causing the medium to form a spiral trajectory around the spiral tube bundle, extending the residence time in the heat exchanger, and ensuring sufficient heat exchange.
[0024] (2) Within the same shell space, the heat exchange area of the spiral tube bundle is increased compared to that of the straight tube, resulting in a higher heat exchange efficiency per unit volume. The heat exchange medium (air compressor exhaust) flows along the spiral tube bundle, with a longer path, allowing for more thorough heat exchange with the tube bundle. The U-shaped bend structure can automatically compensate for the thermal expansion stress caused by temperature difference, reducing the risk of tube bundle deformation or leakage and ensuring stable heat exchange efficiency during long-term operation (the thermal stress of the traditional straight tube structure may cause tube bundle displacement, affecting heat exchange).
[0025] (3) The shell is connected to the partition components (horizontal plate and vertical plate) flanges through the upper left, lower left, upper right, and lower right shells, separating the lower water inlet chamber, upper water outlet chamber, and heat exchange chamber into independent spaces. This provides good sealing performance, preventing heat medium leakage to the outside or cross-flow between chambers, and improving system safety. The design of the lower and upper through holes on the vertical plate and the flow hole on the right end of the horizontal plate forms a precise flow direction of "lower water inlet chamber → lower heat exchange chamber → upper heat exchange chamber → upper water outlet chamber", ensuring process stability and avoiding fluctuations in heat exchange efficiency due to chaotic flow.
[0026] (4) The shell and the partition assembly are connected by a flange and can be disassembled into an independent cavity. When it is necessary to clean or replace the tube bundle and baffle, it is easy to disassemble and maintain, reducing the difficulty of maintenance (the traditional integrated structure has high maintenance costs and long cycles).
[0027] (5) The heat medium forms a closed loop through “circulating water pump → waste heat recovery heat exchanger → heat storage tank → circulating water pump” to continuously recover the heat of the air compressor exhaust. The heat storage tank can store heat energy for subsequent production (such as hot water supply, heating process medium, etc.). The waste heat utilization rate is high, reducing energy waste. Attached Figure Description
[0028] Figure 1 This is a schematic diagram of the structure of this utility model;
[0029] Figure 2 This is a schematic diagram of the waste heat recovery heat exchanger of this utility model;
[0030] Figure 3 This is an exploded view of the waste heat recovery heat exchanger of this utility model;
[0031] Figure 4 This is a half-sectional view of the present invention;
[0032] Figure 5 This is a schematic diagram of the structure of the lower right shell of this utility model;
[0033] Figure 6 This is a schematic diagram of the structure of the partition component and heat exchange tube bundle of this utility model.
[0034] In the diagram: 1. Waste heat recovery heat exchanger; 2. Heat exchange medium inlet; 3. Air compressor body; 4. Exhaust port; 5. Pipe A; 6. Lower water inlet; 7. Pipe B; 8. Circulating water pump; 9. Upper water outlet; 10. Pipe C; 11. Heat storage tank; 12. Pipe D;
[0035] 101. Lower inlet chamber; 102. Upper outlet chamber; 103. Heat exchange chamber; 104. Upper left shell; 105. Lower left shell; 106. Upper right shell; 107. Lower right shell; 108. Separation assembly; 109. Horizontal plate; 110. Vertical plate; 111. Baffle plate; 112. Upper through hole; 113. Lower through hole; 114. Flow hole; 115. Heat exchange tube bundle. Detailed Implementation
[0036] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.
[0037] The following combination Figures 1 to 6 This application will be described in further detail.
[0038] This application discloses an air compressor waste heat recovery system, including a waste heat recovery heat exchanger 1; the waste heat recovery heat exchanger 1 includes a heat exchange tube bundle 115, a partition assembly 108 and a shell;
[0039] The shell includes an upper left shell 104, a lower left shell 105, an upper right shell 106, and a lower right shell 107 that are flanged and connected to the partition assembly 108 to form a lower water inlet chamber 101, an upper water outlet chamber 102, and a heat exchange chamber 103. The partition assembly 108 includes a horizontal plate 109 located horizontally between the upper left shell 104, the lower left shell 105, the upper right shell 106, and the lower right shell 107, and a vertical plate 110 located vertically between the upper left shell 104, the lower left shell 105, the upper right shell 106, and the lower right shell 107 and fixedly connected to the horizontal plate 109. The waste heat recovery heat exchanger 1 divides the heat exchange chamber 103 into upper and lower layers through the partition assembly 108. The upper and lower heat exchange chambers 103 are respectively provided with baffles 111 that match the spiral direction of the heat exchange tube bundle 115.
[0040] The lower left shell 105 is provided with a lower water inlet nozzle 6 that communicates with the lower water inlet chamber 101, and the upper left shell 104 is provided with an upper water outlet nozzle 9 that communicates with the upper water outlet chamber 102. The vertical plate 110, located on the upper and lower sides of the horizontal plate 109, is provided with an upper through hole 112 and a lower through hole 113, respectively. The heat medium in the lower water inlet chamber 101 enters the heat exchange chamber 103 below the horizontal plate 109 through the lower through hole 113, and the heat medium in the heat exchange chamber 103 above the horizontal plate 109 enters the upper water outlet chamber 102 through the upper through hole 112. The right end of the horizontal plate 109 is provided with a flow hole 114 that allows the heat medium in the heat exchange chamber 103 below the horizontal plate 109 to flow into the heat exchange chamber 103 above the horizontal plate 109. The baffle 111 is an arc-shaped baffle 111 that is staggered and set on the upper and lower surfaces of the horizontal plate 109 and inside the upper right shell 106 and the lower right shell 107. The baffle 111 is welded to the upper and lower surfaces of the horizontal plate 109, the inner wall of the upper right shell 106, and the inner wall of the lower right shell 107, respectively.
[0041] The heat exchange chamber 103 is divided into upper and lower layers by a horizontal plate 109 and a vertical plate 110, allowing the heat medium (such as water) to flow sequentially between the two chambers, forming an orderly "bottom in, top out" path. This avoids short-circuiting or disordered flow of the medium, ensuring full contact between the heat exchange medium (air compressor exhaust) and the heat medium, and improving the uniformity of heat transfer. The lower water inlet chamber 101 and the upper water outlet chamber 102 are separated from the heat exchange chamber 103 by flange connections, forming independent spaces to prevent heat medium leakage. Simultaneously, the design of the lower through-hole 113, upper through-hole 112, and flow hole 114 precisely controls the medium flow direction, ensuring the stability of the heat exchange process.
[0042] The baffle 111 is a staggered, bow-shaped structure welded to the horizontal plate 109 and the inner wall of the shell. It guides the flow of the heat medium along the path, avoiding the "dead zone" caused by straight flow and increasing the contact frequency between the medium and the heat exchange tube bundle 115. The staggered arrangement causes the medium to continuously change direction during flow, generating a turbulent effect, disrupting the boundary layer of the medium on the tube bundle surface, reducing thermal resistance, and significantly improving the heat transfer coefficient. The baffle 111 matches the helical direction of the heat exchange tube bundle 115, causing the medium to form a helical flow trajectory around the helical tube bundle, further extending the residence time in the heat exchanger and ensuring sufficient heat exchange.
[0043] The heat exchange medium inlet 2 on the waste heat recovery heat exchanger 1 is connected to the exhaust port 4 of the air compressor body 3 through the pipe A5. The heat exchange tube bundle 115 is spiral and has a horizontal U-shaped structure. The heat exchange tube bundle 115 is fixed on the horizontal plate 109 by the pipe clamp.
[0044] The lower inlet 6 of the waste heat recovery heat exchanger 1 is connected to the outlet of the circulating water pump 8 through pipe B7, the upper outlet 9 is connected to the inlet of the heat storage tank 11 through pipe C10, and the outlet of the heat storage tank 11 is connected to the inlet of the circulating water pump 8 through pipe D12, forming a heat medium circulation loop.
[0045] The heat exchange tube bundle 115 increases the contact area and contact time between the heat medium and the heat exchange medium, and the baffle 111 guides the flow of the heat medium and increases the heat exchange contact time of the heat medium in the waste heat recovery heat exchanger 1.
[0046] Compared to straight tubes, helical tube bundles can increase the heat exchange area within the same shell space. The helical shape also allows the heat exchange medium to flow along a helical path, extending the contact path with the tube bundle. The horizontal U-shaped structure facilitates tube bundle arrangement, and the U-shaped bend design compensates for thermal expansion stress, reducing the risk of tube bundle deformation or leakage due to temperature differences. Tube bundles are fixed to the horizontal plate 109 using tube clamps, preventing vibration under the impact of medium flow and ensuring long-term operational reliability, while also preventing heat exchange efficiency reduction due to tube bundle displacement.
[0047] The high-temperature compressed air (heat exchange medium) discharged from the air compressor body 3 enters the heat exchange tube bundle 115 of the waste heat recovery heat exchanger 1 through pipe A. The heat exchange tube bundle 115 has a spiral horizontal U-shaped structure, which increases the flow path of the heat exchange medium in the heat exchanger. After the circulating water pump 8 starts, the heat medium (such as water) is drawn into the circulating water pump 8 from the outlet of the heat storage tank 11 through pipe D. After being pressurized, it enters the lower water inlet chamber 101 of the heat exchanger through pipe B and the lower water inlet 6. After absorbing heat, the heat medium flows back to the inlet of the heat storage tank 11 through pipe C via the upper water outlet 9, completing the circulation.
[0048] The heat medium in the lower inlet chamber 101 enters the lower heat exchange chamber 103 below the horizontal plate 109 through the lower through hole 113 on the vertical plate 110. The lower heat exchange chamber 103 is equipped with an arc-shaped baffle 111 that aligns with the spiral direction of the heat exchange tube bundle 115. The baffle 111 is staggered and welded to the lower surface of the horizontal plate 109 and the inner wall of the lower right shell 107, guiding the heat medium to laterally flush the heat exchange tube bundle 115 along the path of the baffle 111, increasing the contact area and time with the spiral tube bundle, and absorbing the heat from the high-temperature compressed air inside the tube bundle. Guided by the baffle 111, the heat medium in the lower heat exchange chamber 103 flows to the right end of the horizontal plate 109 and enters the upper heat exchange chamber 103 above the horizontal plate 109 through the flow hole 114 on the horizontal plate 109.
[0049] The upper heat exchange chamber 103 is also equipped with an arc-shaped baffle 111 staggered and welded to the upper surface of the horizontal plate 109 and the inner wall of the upper right shell 106, which guides the heat medium to once again laterally flush the upper heat exchange tube bundle 115, further absorbing heat. The heat exchanged medium enters the upper water outlet chamber 102 through the upper through hole 112 on the vertical plate 110, and finally exits the heat exchanger through the upper water outlet 9, returning to the heat storage tank 11.
[0050] The spiral U-shaped design increases the contact area between the heat exchange medium and the tube bundle, prolonging the residence time of the heat exchange medium within the heat exchanger and improving heat release efficiency. The staggered bow-shaped baffles 111 force the heat medium to flow in a "U" shape, increasing turbulence and enhancing heat exchange (e.g., reducing boundary layer thermal resistance). The horizontal plate 109 and vertical plate 110 divide the heat exchanger into upper and lower heat exchange chambers 103, which, together with the flow holes 114 and through holes, form a counter-current heat exchange path for the heat medium, creating a temperature gradient with the flow direction of the heat exchange medium and improving heat exchange efficiency.
[0051] The high-temperature compressed air (heat exchange medium) discharged from the air compressor flows within the heat exchange tube bundle 115, releasing heat through the tube walls to the heat medium outside the tube bundle while its own temperature decreases. Guided by the baffles 111, the heat medium repeatedly washes against the outer wall of the tube bundle, absorbing heat and increasing in temperature, ultimately storing the heat in the heat storage tank 11 for subsequent use (such as heating, hot water, etc.). The circulating water pump 8 maintains the continuous flow of the heat medium, ensuring a constant transfer of heat from the air compressor to the heat storage tank 11, thus achieving waste heat recovery.
[0052] Finally, it should be noted that the above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Although the present utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.
Claims
1. An air compressor waste heat recovery system, characterized by, include: The waste heat recovery heat exchanger (1) has a heat exchange medium inlet (2) of the heat exchange tube bundle (115) connected to the exhaust port (4) of the air compressor body (3); the heat exchange tube bundle (115) is spiral and has a horizontal U-shaped structure. The inlet and outlet of the heat medium on the waste heat recovery heat exchanger (1) are connected to the outlet of the circulating water pump (8) and the inlet of the heat storage tank (11) respectively. The outlet of the heat storage tank (11) is connected to the inlet of the circulating water pump (8), forming a heat medium circulation loop. The waste heat recovery heat exchanger (1) divides the heat exchange chamber (103) into upper and lower layers through the partition component (108). The upper and lower heat exchange chambers (103) are respectively provided with baffles (111) that match the spiral direction of the heat exchange tube bundle (115). The heat exchange tube bundle (115) increases the contact area and contact time between the heat medium and the heat exchange medium, and the baffle plate (111) guides the flow of the heat medium and increases the heat exchange contact time of the heat medium in the waste heat recovery heat exchanger (1).
2. The air compressor waste heat recovery system according to claim 1, characterized in that: The waste heat recovery heat exchanger (1) also includes an upper left shell (104), a lower left shell (105), an upper right shell (106), and a lower right shell (107) that are flanged and connected to the partition assembly (108) to form a lower water inlet chamber (101), an upper water outlet chamber (102), and a heat exchange chamber (103).
3. The air compressor waste heat recovery system according to claim 2, characterized in that: The partition assembly (108) includes a horizontal plate (109) located horizontally between the upper left housing (104), the lower left housing (105), the upper right housing (106), and the lower right housing (107), and a vertical plate (110) located vertically between the upper left housing (104), the lower left housing (105), the upper right housing (106), and the lower right housing (107) and fixedly connected to the horizontal plate (109).
4. The air compressor waste heat recovery system according to claim 3, characterized in that: The lower left shell (105) is provided with a lower water inlet (6) that communicates with the lower water inlet chamber (101), and the upper left shell (104) is provided with an upper water outlet (9) that communicates with the upper water outlet chamber (102).
5. The air compressor waste heat recovery system according to claim 4, characterized in that: The vertical plate (110) is provided with an upper through hole (112) and a lower through hole (113) on the upper and lower sides of the horizontal plate (109), respectively. The heat medium in the lower water inlet chamber (101) enters the heat exchange chamber (103) below the horizontal plate (109) through the lower through hole (113), and the heat medium in the heat exchange chamber (103) above the horizontal plate (109) enters the upper water outlet chamber (102) through the upper through hole (112).
6. The air compressor waste heat recovery system according to claim 5, characterized in that: The right end of the horizontal plate (109) is provided with a flow hole (114) that allows the heat medium in the heat exchange chamber (103) below the horizontal plate (109) to flow into the heat exchange chamber (103) above the horizontal plate (109).
7. The air compressor waste heat recovery system according to claim 3, characterized in that: The baffle (111) is an arc-shaped baffle (111) that is offset on the upper and lower sides of the horizontal plate (109) and inside the upper right shell (106) and the lower right shell (107).
8. The air compressor waste heat recovery system according to claim 7, characterized in that: The baffles (111) are respectively welded to the upper and lower sides of the horizontal plate (109), the inner wall of the upper right shell (106), and the inner wall of the lower right shell (107).
9. The air compressor waste heat recovery system according to claim 3, characterized in that: The heat exchange tube bundle (115) is fixed to the horizontal plate (109) by tube clamps.
10. The air compressor waste heat recovery system according to claim 4, characterized in that: The heat exchange medium inlet (2) on the waste heat recovery heat exchanger (1) is connected to the exhaust port (4) of the air compressor body (3) through pipe A (5); the lower water inlet (6) is connected to the outlet of the circulating water pump (8) through pipe B (7); the upper water outlet (9) is connected to the inlet of the heat storage tank (11) through pipe C (10); and the outlet of the heat storage tank (11) is connected to the inlet of the circulating water pump (8) through pipe D (12).