Energy-saving vacuum station for continuous vacuum crystallization system

Abstract

An energy-saving vacuum station for a continuous vacuum crystallization system belongs to the technical field of vacuum formation of flash evaporation systems. The energy-saving vacuum station comprises: a vacuum pump group comprising a plurality of vacuum pumps for sucking steam from the vacuum flash evaporation system; a vacuum pump group comprising a main vacuum pump part and an auxiliary vacuum pump part; an air inlet pipeline connected to the vacuum pump group and the main vacuum pump part, and provided with an air inlet valve group; and a bypass pipeline connected to the vacuum pump group and the auxiliary vacuum pump part, and provided with a bypass valve group. Compared with the prior art, the vacuum station significantly reduces the power consumption of the long-term simultaneous operation of multiple vacuum pumps, and avoids the high energy consumption problem of independent pump allocation for each crystallizer in the prior art.

Description

Technical Field

[0001] This utility model belongs to the field of vacuum forming technology of flash evaporation systems, and specifically relates to a vacuum station for a continuous vacuum crystallization system that saves energy. Background Technology

[0002] In continuous crystallization processes in chemical and pharmaceutical industries, vacuum flash evaporation systems are key equipment for achieving efficient material concentration or crystallization. This system utilizes vacuum conditions to lower the boiling point of materials, causing them to boil and evaporate violently in a vacuum crystallizer. The resulting vapor is discharged through a vacuum pump and condensed under subsequent refrigeration conditions, thus achieving continuous concentration or crystallization separation of the materials.

[0003] Existing technologies typically employ a decentralized vacuum configuration, requiring each vacuum flash crystallizer to be equipped with its own independent vacuum pumping unit. This unit usually includes a pump (such as a Roots pump) directly connected to the flash tank and a vacuum pump (such as a screw pump) for compressed exhaust. A gas purification system is also required to protect the vacuum pump from corrosion or wear. While this "one tank, one pump" approach achieves basic functionality, it reveals the following drawbacks in large-scale continuous production systems with multiple crystallizers operating in parallel:

[0004] Firstly, energy consumption remains high. Each flash tank's corresponding vacuum pump needs to operate independently for extended periods, especially as the vacuum pump continuously consumes high power when compressing gases. When the system includes multiple flash tanks, a corresponding number of vacuum pump sets need to operate synchronously, increasing the total energy consumption proportionally.

[0005] Secondly, there is equipment redundancy and cost waste. The redundant configuration of vacuum pumps and their supporting purification systems not only increases equipment procurement costs but also occupies a large amount of factory space.

[0006] Then there is the low operating efficiency. In the initial stage of vacuum flash evaporation system startup, a vacuum level needs to be established quickly, but the pumping capacity of a single vacuum pump is limited, which prolongs the system stabilization time. In the stable operation stage (vacuum maintenance stage), the vacuum pump still needs to process the significantly reduced gas volume at high power, resulting in energy waste.

[0007] Therefore, there is an urgent need for a centralized vacuum system solution that can significantly reduce the energy consumption of multiple vacuum flash evaporation devices operating in parallel, while ensuring pumping efficiency and reducing long-term operating costs by optimizing the equipment collaboration mode. Utility Model Content

[0008] This application further improves the vacuum station for continuous vacuum crystallization systems, providing an energy-saving vacuum station for continuous vacuum crystallization systems, in order to solve the above-mentioned technical problems.

[0009] The specific technical solution is explained below:

[0010] An energy-saving vacuum station for a continuous vacuum crystallization system includes:

[0011] The vacuum pump set includes several vacuum pumps used to extract steam from the vacuum flash evaporation system.

[0012] The vacuum pump unit includes a main vacuum pump section and an auxiliary vacuum pump section;

[0013] An air inlet pipe connects the air pump unit and the main vacuum pump unit, and an air inlet valve group is provided on the air inlet pipe;

[0014] A bypass pipeline connects the air pump unit and the auxiliary vacuum pump unit, and a bypass valve group is provided on the bypass pipeline.

[0015] In a further embodiment, a gas purification device is also included; the gas purification device is disposed on the flow path of the air inlet pipe.

[0016] In a preferred embodiment, the gas purification device is located after the inlet valve assembly in the direction of gas flow.

[0017] In some embodiments, the gas purification equipment includes a spray tower, a cooling water station, and a spray pump; the spray pump outputs liquid from the cooling water station to the spray tower for spraying, and at least a portion of the sprayed liquid is returned to the cooling water station.

[0018] In a further embodiment, a switching pipeline is also included; the switching pipeline connects the intake pipeline and the bypass pipeline, and a switching valve is provided on the switching pipeline.

[0019] In a preferred embodiment, the switching pipeline is located after the gas purification device in the gas flow direction.

[0020] In a preferred embodiment, the air pump is a Roots pump.

[0021] In a preferred embodiment, the vacuum pumps in the main vacuum pump section and the auxiliary vacuum pump section are selected from high-vacuum pump sets such as screw pumps, water ring pumps, water ring Roots pumps, hydraulic jet pumps, and steam jet pumps.

[0022] In some embodiments, the main vacuum pump section consists of a single vacuum pump, and the auxiliary vacuum pump section consists of a single vacuum pump.

[0023] A continuous vacuum crystallization system using the energy-saving vacuum station described in any of the above technical solutions.

[0024] In summary, the technical solution described in this utility model has the following main beneficial effects:

[0025] Compared with the prior art, the vacuum station described in this utility model significantly reduces the power consumption of multiple vacuum pumps operating simultaneously for a long time, and avoids the high energy consumption problem of each crystallizer having its own pump in the prior art.

[0026] Meanwhile, the vacuum station has the advantages of low equipment failure rate and low downtime maintenance frequency, which can improve the overall reliability of the system.

[0027] Furthermore, this vacuum station can more flexibly switch between the initial and stable operation phases of the vacuum flash evaporation system, allowing the auxiliary vacuum pump to participate more fully in gas extraction, thereby improving the system's response speed and energy efficiency.

[0028] Further or more detailed beneficial effects will be described in conjunction with specific embodiments in the detailed implementation. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the vacuum station structure in a specific implementation.

[0030] Figure label:

[0031] 1: Air pump set, 1.1: Air pump;

[0032] 2: Vacuum pump unit; 2.1: Main vacuum pump section; 2.2: Auxiliary vacuum pump section;

[0033] 3: Intake piping; 3.1: Intake valve assembly;

[0034] 4: Bypass pipeline; 4.1: Bypass valve assembly;

[0035] 5: Gas purification equipment; 5.1: Spray tower; 5.2: Cold water station; 5.3: Spray pump;

[0036] 6: Switching pipelines, 6.1: Switching valves. Detailed Implementation

[0037] The present invention will be further explained in conjunction with the embodiments:

[0038] The core technical problem faced by the technical solution of this application embodiment stems from the inventor's accurate understanding of the prior art. Therefore, how to further save energy consumption of the energy-saving vacuum station used in the continuous vacuum crystallization system is a technical problem that the inventor urgently needs to solve.

[0039] It should be noted that the embodiments do not constitute a limitation on the scope of protection of the claims of this utility model. All technical solutions that can be reasonably expected by those skilled in the art based on the technical concepts provided / proved by the embodiments should be covered within the scope of protection of the claims of this utility model.

[0040] The specific implementation examples are detailed below:

[0041] Please refer to the attached instruction manual. Figure 1 First, provide Implementation of the main body The energy-saving vacuum station for the continuous vacuum crystallization system described in this embodiment includes a pumping unit 1, a vacuum pumping unit 2, an air inlet pipe 3, and a bypass pipe 4.

[0042] Specifically, the vacuum pump group 1 consists of several independent vacuum pumps 1.1, each of which is directly connected to the vacuum flash evaporation system for efficient extraction of steam from the system.

[0043] Vacuum pump unit 2 is divided into main vacuum pump section 2.1 and auxiliary vacuum pump section 2.2. The two are arranged side by side in structure to provide vacuum support in different operating modes.

[0044] The air intake pipe 3 connects the vacuum pump group 1 to the main vacuum pump section 2.1, and an air intake valve group 3.1 is installed on it. The air intake valve group 3.1 consists of multiple air intake valves, each valve corresponding to an air intake branch of the vacuum pump 1.1 to independently control the airflow.

[0045] The bypass line 4 connects the vacuum pump group 1 and the auxiliary vacuum pump section 2.2. It is equipped with a bypass valve group 4.1, which is also composed of multiple bypass valves. Each valve corresponds to a bypass branch of the vacuum pump 1.1 to ensure flexible switching of the airflow path.

[0046] In actual operation, before the vacuum flash evaporation system is initially started and reaches stability, there is a large amount of gas inside the system that needs to be quickly discharged to establish a vacuum. At this time, the pumping pump unit 1 draws gas at a high volume rate, and the auxiliary vacuum pump unit 2.2 maintains its operation. The bypass pipeline 4 helps to quickly draw gas. At the same time, the main vacuum pump unit 2.1 also runs synchronously. The three work together to accelerate the discharge of gas.

[0047] Once the system reaches a stable operating stage and the vacuum level is established, the auxiliary vacuum pump unit 2.2 and the bypass valve group 4.1 are shut off, and the pump group 1 continues to draw in gas. At this point, most of the vapor has been condensed before entering the pump group 1, and only the main vacuum pump unit 2.1 needs to compress the remaining gas through the inlet pipe 3 and discharge it. Through this centralized pumping design, the system does not need to be equipped with an independent vacuum pump group 2 for each vacuum flash evaporation device, but instead shares vacuum resources among multiple devices. This significantly reduces the power consumption of multiple vacuum pumps operating simultaneously for a long time, and avoids the high energy consumption problem of each crystallizer having its own pump in the existing technology. The energy-saving effect is significantly reflected in the savings in electricity costs for equipment operation and the reduction in maintenance costs.

[0048] As a preferred embodiment, the pump 1.1 is specifically a Roots pump. This type of pump features a rotary Roots rotor design, providing high pumping capacity and low-pulsation airflow. During operation, the Roots pump generates a powerful suction force within the vacuum flash evaporation system through the rotation of the rotor, making it suitable for handling large volumes of steam. By selecting a Roots pump as the pump 1.1, the system can efficiently meet the pumping capacity requirements of the vacuum flash evaporation system, such as rapidly extracting a large amount of gas in the initial stage. This is due to the high pumping capacity characteristic of the Roots pump, ensuring rapid vacuum establishment while reducing energy loss and adapting to the operating characteristics of the flash evaporation equipment.

[0049] As a preferred embodiment, the vacuum pumps in the main vacuum pump unit 2.1 and the auxiliary vacuum pump unit 2.2 are selected from types such as screw pumps, water ring pumps, water ring Roots pumps, hydraulic jet pumps, or steam jet pumps. These pump types all have gas compression capabilities; for example, screw pumps compress gas through a screw rotor, and water ring pumps utilize water ring seals for compression. They can maintain a high vacuum at low volumetric rates. Since the gas is compressed and its volume is reduced in the vacuum pump unit 2, the required pump delivery volume is not high, but compression efficiency must be guaranteed. Through this vacuum pump selection, the system can flexibly select the pump type according to specific applications (such as pressure requirements or media characteristics), ensuring vacuum formation while optimizing energy consumption because the compression process reduces the burden of subsequent processing, thus improving overall efficiency.

[0050] As a further preferred embodiment, the main vacuum pump section 2.1 consists of a single vacuum pump, and the auxiliary vacuum pump section 2.2 also consists of a single vacuum pump; that is, both are single-pump structures rather than a multi-pump combination. This configuration simplifies the system; for example, one pump in the main vacuum pump section 2.1 handles the gas during the stable phase, while one pump in the auxiliary vacuum pump section 2.2 handles the high load during the initial phase. Typically, this single-pump design can meet most production requirements—as shown in the appendix. Figure 1 The production requirements of the three vacuum flash crystallizers shown are reduced because it decreases the number and complexity of equipment. By employing a main vacuum pump section 2.1 consisting of a single vacuum pump and an auxiliary vacuum pump section 2.2, the system achieves cost savings and ease of maintenance, while ensuring reliable operation under typical conditions and avoiding redundant equipment.

[0051] Nevertheless, when the number of vacuum flash crystallizers is significantly large (e.g., ≥5 units), the number of vacuum pumps in the main vacuum pump section 2.1 and the auxiliary vacuum pump section 2.2 can be increased according to production needs.

[0052] Please continue to refer to the appendix. Figure 1 , In further embodiments The energy-saving vacuum station also includes a gas purification device 5, which is installed on the gas flow path of the inlet pipe 3, specifically in the pipeline system of the inlet pipe 3, and is used to process the airflow from the pumping pump group 1 to the main vacuum pump section 2.1.

[0053] The gas purification device 5 removes harmful components from the gas through internal structures (such as filters or chemical treatment units), ensuring the cleanliness of the gas entering the vacuum pump unit 2. During operation, the gas flow must pass through the gas purification device 5 before entering the main vacuum pump unit 2.1, thus pre-treating the gas. By integrating the gas purification device 5 into the inlet pipe 3, the system can effectively remove droplets and particulate matter entrained in the exhaust gas before compression, preventing these impurities from causing chemical corrosion or physical wear to the rotor of the vacuum pump unit 2. This directly extends the service life of the vacuum pump, reduces equipment failures and downtime maintenance frequency, and improves the overall reliability of the system.

[0054] As a preferred embodiment, the gas purification device 5 is specifically positioned after the inlet valve group 3.1 in the gas flow direction, that is, the airflow first passes through the inlet valve group 3.1 and then enters the gas purification device 5;

[0055] This arrangement means that the intake valve assembly 3.1 not only controls whether airflow enters the intake pipe 3, but also directly determines whether gas flows through the gas purification device 5 through the opening and closing of the valve. For example, when the intake valve is closed, the airflow is blocked, and the purification process is paused; conversely, when the valve is open, the gas automatically enters the purification stage. Through this sequential design, the intake valve assembly 3.1 achieves dual-function control, both regulating the intake flow and managing the purification intervention. This simplifies system operation, avoids additional control valves, ensures that the purification process is activated only when needed, improves energy utilization efficiency, and maintains the purification effect.

[0056] As a further preferred embodiment, the gas purification device 5 includes a spray tower 5.1, a cold water station 5.2, and a spray pump 5.3;

[0057] Specifically, spray tower 5.1 is a tower-shaped container equipped with spray nozzles; chilled water station 5.2 is a storage tank for cooling liquid; and spray pump 5.3 is a pump body used to draw and pressurize the cooling liquid from chilled water station 5.2 and deliver it to spray tower 5.1, where it is atomized and sprayed through the nozzles. During operation, the sprayed liquid comes into contact with the airflow in spray tower 5.1, and some of the liquid captures condensable vapors from the gas, forming droplets that are then returned to chilled water station 5.2 for recycling. This spray-type purification not only efficiently removes impurities from the gas (such as acidic droplets or dust) but also converts vapors into liquids through condensation, reducing the volume of gas entering vacuum pump unit 2. By adopting this preferred gas purification method, the system can both purify the gas to protect the equipment and reduce the workload of vacuum pump unit 2 by capturing condensable vapors, such as reducing the amount of gas in the compression process, thereby directly reducing energy consumption and operating pressure and improving system efficiency.

[0058] Please continue to refer to the appendix. Figure 1 , In further embodiments The energy-saving vacuum station also includes a switching pipeline 6, which connects the inlet pipeline 3 and the bypass pipeline 4, and is equipped with a switching valve 6.1.

[0059] The switching line 6, structurally a bypass channel, allows airflow to switch between the inlet line 3 and the bypass line 4. It can initially evacuate a specific flash unit via the auxiliary vacuum pump 2.2, reaching the operating vacuum range before switching to the main vacuum pump 2.1 to maintain vacuum. The switching valve 6.1 is a control valve used to open and close this channel. During operation, when the vacuum flash system is in its initial high-volume evacuation state, the switching valve 6.1 closes, and a bypass valve 4.1 opens, allowing airflow to switch from the inlet line 3 to the bypass line 4. This guides a large volume of air into the auxiliary vacuum pump 2.2, evacuating until the set vacuum condition is reached and the system reaches a stable operating state. At this point, the bypass valve 4.1 closes, and the corresponding inlet valve 3.1 opens. The airflow is then concentrated and drawn by the main vacuum pump 2.1 to maintain vacuum. The auxiliary vacuum pump 2.2 can then stop operating and become a standby pump, awaiting the initial startup of the next flash unit. This method effectively avoids the situation where a large amount of air discharged by a certain unit during the initial restart of production disrupts the vacuum level of other flash units that are operating stably, forcing other units to suspend operation and wait for the unit to evacuate the vacuum. Once the vacuum conditions are met, they can resume evacuation simultaneously, thus avoiding delays in effective production time.

[0060] When starting up for the first time, or when all crystallization units start up at the same time (the whole system restarts production), in the initial stage, the auxiliary vacuum pump unit 2.2 can work simultaneously with the main vacuum pump unit 2.1 to accelerate the establishment of vacuum in the whole system. After the operating vacuum conditions are reached, the auxiliary vacuum pump unit 2.2 stops working, and only the main vacuum pump unit 2.1 is kept to maintain the system vacuum. In this way, the time for the whole system to establish vacuum can be shortened.

[0061] As a preferred embodiment, the switching pipeline 6 is positioned after the gas purification device 5 in the gas flow direction, that is, the gas flow first passes through the gas purification device 5 to complete the purification, and then reaches the connection point of the switching pipeline 6.

[0062] Specifically, one end of the switching line 6 is connected to the downstream position of the gas purification device 5 on the inlet line 3, and the other end is connected to the bypass line 4. When the switching valve 6.1 is open, the bypass valve 4.1 must be closed. At this time, the purified gas can be directly drawn by the operating auxiliary vacuum pump section 2.2, preventing unpurified gas from entering the bypass path. With this arrangement, when the switching valve 6.1 is opened, the auxiliary vacuum pump section 2.2 can draw clean gas processed by the gas purification device 5. This ensures that the auxiliary pump is not exposed to corrosive or abrasive impurities when participating in the pumping process, protecting the integrity of the pump body, maintaining the consistency of the purification effect, and extending the service life of the auxiliary vacuum pump section 2.2.

[0063] As the continuous vacuum crystallization system corresponding to the above embodiments An energy-saving vacuum station is integrated into the crystallization system. Vacuum flash evaporation equipment (such as flash tanks) is connected to pump group 1, and the vacuum process is managed through the operating modes of the energy-saving vacuum station (such as switching between initial and stable phases). By using this energy-saving vacuum station, the continuous vacuum crystallization system inherits all its energy-saving and optimization characteristics. For example, the centralized pumping design reduces the parallel energy consumption of multiple vacuum pumps, which directly solves the high energy consumption problem of independent pumps for each crystallizer in the prior art, achieving system-level energy-saving effects, reflected in the reduction of overall power consumption and operating costs. Moreover, the more subsystems corresponding to the crystallizer, the more obvious the energy-saving effect.

[0064] In the description of this specification, the references to terms such as "embodiment," "basic embodiment," "preferred embodiment," "other embodiment," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0065] Although preferred embodiments of the present invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of the present invention.

[0066] Obviously, those skilled in the art can make various modifications and variations to this utility model without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this utility model and their equivalents, this utility model also intends to include these modifications and variations.

Claims

1. An energy-saving vacuum station for a continuous vacuum crystallization system, characterized in that, Including: The vacuum pump assembly (1) includes several vacuum pumps (1.1) for drawing steam from the vacuum flash evaporation system; The vacuum pump unit (2) includes a main vacuum pump unit (2.1) and an auxiliary vacuum pump unit (2.2). An air inlet pipe (3) is connected to the air pump group (1) and the main vacuum pump unit (2.1), and an air inlet valve group (3.1) is provided on the air inlet pipe (3). A bypass pipeline (4) is connected to the vacuum pump unit (1) and the auxiliary vacuum pump unit (2.2). A bypass valve group (4.1) is provided on the bypass pipeline (4).

2. The energy-saving vacuum station according to claim 1, characterized in that: It also includes gas purification equipment (5); The gas purification device (5) is installed on the flow path of the air inlet pipe (3).

3. The energy-saving vacuum station according to claim 2, characterized in that: The gas purification device (5) is located after the inlet valve group (3.1) in the direction of gas flow.

4. The energy-saving vacuum station according to claim 2 or 3, characterized in that: The gas purification equipment (5) includes a spray tower (5.1), a cold water station (5.2), and a spray pump (5.3). The spray pump (5.3) outputs the liquid in the cold water station (5.2) to the spray tower (5.1) for spraying, and at least part of the sprayed liquid flows back to the cold water station (5.2).

5. The energy-saving vacuum station according to claim 2, characterized in that: It also includes a switching pipeline (6); The switching pipeline (6) connects the intake pipeline (3) and the bypass pipeline (4), and a switching valve (6.1) is provided on the switching pipeline (6).

6. The energy-saving vacuum station according to claim 5, characterized in that: In the direction of gas flow, the switching pipeline (6) is located after the gas purification device (5).

7. The energy-saving vacuum station according to claim 1, characterized in that: The air pump (1.1) is a Roots pump.

8. The energy-saving vacuum station according to claim 7, characterized in that: The vacuum pumps in the main vacuum pump section (2.1) and the auxiliary vacuum pump section (2.2) are selected from high-vacuum units such as screw pumps, water ring pumps, water ring Roots pumps, hydraulic jet pumps, and steam jet pumps.

9. The energy-saving vacuum station according to claim 7 or 8, characterized in that: The main vacuum pump unit (2.1) consists of a vacuum pump, and the auxiliary vacuum pump unit (2.2) consists of a vacuum pump.

10. A continuous vacuum crystallization system, characterized in that: Use the energy-saving vacuum station as described in any one of claims 1 to 9.

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