A low-temperature condensation device for VOCs waste gas treatment
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-08-19
- Publication Date
- 2026-08-11
AI Technical Summary
[0003]传统设计采用储液罐集中收集冷凝液，待液位达到阈值后通过泵送系统经排放管道输出；该技术路径在常温工况下可维持基本运行，但在低温环境（如-10℃以下）中，冷凝液中残留的微量挥发性有机物与水分的混合体系会因相变点降低而加剧结晶倾向，导致排放管路内壁逐渐形成冰晶附着层；随着运行周期延长，冰层厚度呈指数增长，造成管道有效流通截面积缩减70%以上，最终引发两种典型失效模式——其一是冷凝液排放流量衰减导致储液罐液位失控，迫使设备频繁启停；其二为冰堵造成的系统背压升高，可能引发冷凝器换热管束破裂等次生事故；另一方面，泵送系统本身存在机械密封泄漏风险，当处理含卤代烃等腐蚀性VOCs时，泵体故障率显著提升，导致设备平均无故障运行时间（MTBF）不足200小时，需人工巡检频次高达每日2-3次，严重制约了低温冷凝工艺在化工园区连续生产场景中的适用性
1.本实用新型通过旁通阀与加热管构成的余热利用实现零能耗动态防冻，利用高温废气余热在锥斗外壁构建均匀热补偿层，有效抑制冰晶附着并维持管道流通截面积95%以上，彻底解决低温工况下冷凝液结晶堵塞难题；通过调节机构建立双闭环控制系统，实时匹配热补偿需求与废气流量，既避免冷凝液二次汽化又确保-20℃极端工况稳定运行，使设备MTBF突破1200小时且人工干预频次降低85%；
Smart Images
Figure CN224613488U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of waste gas treatment technology, and in particular to a low-temperature condensation device for VOCs waste gas treatment. Background Technology
[0002] Condensation is a relatively frequently used VOCs waste gas treatment technology at present. It can be used as a pretreatment measure or a recovery and purification measure, and it is one of the most important technical means. In the existing low-temperature condensation equipment for VOCs waste gas treatment, the condensate discharge system generally has certain technical defects.
[0003] Traditional designs use storage tanks to collect condensate, which is then pumped out through discharge pipes once the level reaches a threshold. While this approach can maintain basic operation at normal temperatures, in low-temperature environments (such as below -10°C), the mixture of trace amounts of volatile organic compounds and moisture in the condensate exhibits increased crystallization tendency due to the lower phase transition point, leading to the gradual formation of an ice crystal layer on the inner wall of the discharge pipe. As the operating cycle extends, the ice layer thickness increases exponentially, reducing the effective flow cross-sectional area of the pipe by more than 70%, ultimately triggering two typical failure modes—the… First, the decrease in condensate discharge flow rate leads to uncontrolled liquid level in the storage tank, forcing frequent equipment start-ups and shutdowns. Second, the increased system back pressure caused by ice blockage may trigger secondary accidents such as condenser heat exchange tube bundle rupture. On the other hand, the pumping system itself has the risk of mechanical seal leakage. When handling corrosive VOCs such as halogenated hydrocarbons, the pump failure rate increases significantly, resulting in a mean time between failures (MTBF) of less than 200 hours. Manual inspections are required as frequently as 2-3 times per day, which seriously restricts the applicability of low-temperature condensation technology in continuous production scenarios in chemical industrial parks.
[0004] Therefore, there is an urgent need to provide a low-temperature condensation device for VOCs waste gas treatment to solve the above problems. Utility Model Content
[0005] The technical problem to be solved by this utility model is to overcome the shortcomings of the prior art and provide a low-temperature condensation device for VOCs waste gas treatment.
[0006] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: a low-temperature condensation device for VOCs waste gas treatment is provided, including a main body of the device, a condenser pipe installed inside the main body of the device, an air inlet pipe connected to one end of the condenser pipe, a water outlet pipe connected to the bottom of the condenser pipe, and a drain connected to the bottom of the main body of the device. The drainer has a cone-shaped hopper fixedly connected inside, located below the water outlet pipe. The air inlet pipe is equipped with a bypass valve, and the bottom of the bypass valve is connected to a heating mechanism. The heating mechanism is used to heat the cone, and an adjustment mechanism is connected inside the cone to sense the temperature inside the cone.
[0007] The present invention is further configured such that: three support legs are installed at the bottom of the main body of the device, a condenser is installed inside the main body of the device, the condenser tube is located inside the condenser, and a heat exchange tube in contact with the condenser tube is installed inside the condenser.
[0008] Through the above technical solution, the main body of the equipment is stably installed with a three-point support structure. The internal condenser adopts a compact layout, and its heat exchange tubes and condenser tubes are in direct contact to form a high-efficiency heat exchange interface. When VOCs-containing waste gas enters the condenser tubes, the heat exchange tubes rapidly reduce the temperature of the waste gas and condense the target components through heat exchange with the external refrigeration system of the main body of the equipment. While ensuring condensation efficiency, this structure optimizes the space utilization of the condenser, reducing the volume of the equipment by 30% under the same processing capacity. It is particularly suitable for space-constrained chemical production scenarios. Moreover, the direct contact design between the heat exchange tubes and condenser tubes can reduce thermal resistance and improve the overall heat transfer coefficient by more than 15%.
[0009] The present invention is further configured such that: the heating mechanism includes a heating tube wound around the outside of the cone, one end of the heating tube is connected to a bypass valve, the other end is connected to a condenser tube, and multiple support frames are fixedly connected to the outside of the cone, and the heating tube is in contact with the multiple support frames.
[0010] Through the above technical solution, the heating mechanism heats the cone when the temperature inside is too low and ice may form. When the controller opens the bypass valve, some of the high-temperature exhaust gas forms a heat flow channel through the heating pipe. The positioning effect of the support frame ensures that the heating pipe and the outer wall of the cone maintain a constant gap, forming a uniform heat radiation field. This design avoids local overheating that could lead to secondary vaporization of the condensate, and achieves zero-energy antifreeze by utilizing the waste heat of the exhaust gas. When the temperature sensor detects that the cone temperature is lower than the set threshold, the bypass valve automatically opens, automatically adjusting the flow rate of the high-temperature exhaust gas in the heating pipe, forming a dynamic heat compensation layer on the cone, effectively suppressing ice crystal adhesion, and keeping the pipeline flow cross-sectional area maintenance rate above 95%.
[0011] The present invention is further configured such that: the regulating mechanism includes a controller installed on one side of the condenser, a temperature sensor is installed inside the cone, the temperature sensor is electrically connected to the controller, and the controller is electrically connected to the bypass valve.
[0012] Through the above technical solution, the function of the regulating mechanism is to control the opening of the bypass valve. When the temperature sensor value is close to the ice crystal formation temperature, the controller immediately sends an opening command to the bypass valve to introduce a quantitative amount of high-temperature waste gas for precise temperature regulation. At the same time, a dual closed-loop control system of temperature and flow is established to dynamically adjust the opening of the bypass valve according to real-time temperature changes. This avoids energy waste and prevents temperature fluctuations from affecting the condensation effect. This control logic enables the equipment to operate stably under extreme conditions of -20℃, increasing the MTBF to more than 1200 hours and reducing the frequency of manual inspection to once a week.
[0013] The present invention is further configured such that: an inclined guide plate is fixedly connected inside the condenser pipe, and the guide plate is located above the water outlet pipe.
[0014] Through the above technical solution, an inclined guide plate is installed inside the condenser tube. When the exhaust gas enters the condenser tube, the guide plate changes the airflow direction, reducing the possibility of the exhaust gas being discharged from the water outlet pipe. The liquid after the exhaust gas is cooled will be discharged through the water outlet pipe. This structure improves the gas-liquid separation efficiency by 40%, while preventing the condensate from forming a liquid film on the inner wall of the tube, reducing flow resistance. Combined with the position design of the water outlet pipe, it ensures a stable discharge flow of condensate and effectively prevents the liquid level in the storage tank from getting out of control.
[0015] The present invention is further configured such that: the top of the condenser tube is fixedly connected to an exhaust pipe that communicates with the main body of the equipment, and an exhaust pipe is installed on one side of the main body of the equipment.
[0016] Through the above technical solution, the condensed waste gas enters the main body of the equipment through the top outlet pipe, where it undergoes secondary heat exchange with the low-temperature environment to achieve deep purification. Finally, the clean gas is discharged through the exhaust pipe in compliance with standards. This dual-channel design enables the waste gas to form a condensation, separation and re-condensation cycle within the equipment, which not only ensures VOCs removal efficiency but also improves heat recovery rate by extending the gas path. At the same time, the back pressure monitoring device installed on the exhaust pipe forms a linkage protection with the bypass valve. When the system experiences abnormal back pressure, the emergency discharge channel is automatically opened to prevent physical damage to the condenser due to a sudden increase in pressure.
[0017] The beneficial effects of this utility model are as follows: 1. This utility model achieves zero-energy dynamic antifreeze by utilizing waste heat through a bypass valve and heating pipe. It uses the waste heat from high-temperature exhaust gas to construct a uniform heat compensation layer on the outer wall of the cone, effectively inhibiting ice crystal adhesion and maintaining a pipe flow cross-sectional area of over 95%, completely solving the problem of condensate crystallization and blockage under low-temperature conditions. A dual closed-loop control system is established through an adjustment mechanism to match heat compensation requirements with exhaust gas flow in real time, preventing secondary vaporization of condensate and ensuring stable operation under extreme conditions of -20℃. This allows the equipment's MTBF to exceed 1200 hours and reduces the frequency of manual intervention by 85%. 2. This utility model improves gas-liquid separation efficiency by 40% through the guide plate installed inside the condenser tube, and ensures stable discharge of condensate by optimizing the position of the water outlet pipe, effectively avoiding the risk of uncontrolled liquid level in the storage tank; it extends the waste gas treatment path through dual-channel condensation-re-condensation, and forms a safety linkage with the exhaust pipe back pressure monitoring device, improving the comprehensive VOCs treatment efficiency to over 99% while avoiding physical damage to the condenser due to abnormal back pressure. It is particularly suitable for continuous treatment scenarios of corrosive media such as halogenated hydrocarbons, and achieves a high-efficiency recovery rate of 97% under ultra-low temperature conditions of -75℃. Attached Figure Description
[0018] Figure 1 This is a first-view structural diagram of the present invention; Figure 2 This is a second-view sectional view of the present invention; Figure 3 This is a third-view sectional view of the present invention; Figure 4 This is a fourth-angle sectional view of the present invention; Figure 5 for Figure 4 A magnified view of a section at point A in the middle; Figure 6 This is a fifth-angle sectional view of the present invention; Figure 7 for Figure 6 A magnified view of a section at point B.
[0019] In the diagram: 1. Main body of the equipment; 2. Condenser pipe; 3. Air inlet pipe; 4. Water outlet pipe; 5. Drainage device; 6. Conical hopper; 7. Bypass valve; 8. Heating mechanism; 801. Heating tube; 802. Support frame; 9. Adjustment mechanism; 901. Controller; 902. Temperature sensor; 10. Support leg; 11. Condenser; 12. Heat exchange tube; 13. Guide plate; 14. Air outlet pipe; 15. Exhaust pipe. Detailed Implementation
[0020] The preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings, so that the advantages and features of the present invention can be more easily understood by those skilled in the art, thereby making a clearer and more definite definition of the scope of protection of the present invention.
[0021] Please see Figures 1-7This embodiment of a low-temperature condensation device for VOCs waste gas treatment includes a main body 1. A condenser pipe 2 is installed inside the main body 1. One end of the condenser pipe 2 is connected to an inlet pipe 3, and the bottom of the condenser pipe 2 is connected to a water outlet pipe 4. A drainer 5 is connected to the bottom of the main body 1. A conical hopper 6 located below the water outlet pipe 4 is fixedly connected inside the drainer 5. A bypass valve 7 is installed inside the inlet pipe 3. A heating mechanism 8 is connected to the bottom of the bypass valve 7. The heating mechanism 8 is used to heat the conical hopper 6. The heating mechanism 8 includes a heating pipe 801 wound around the outside of the conical hopper 6. One end of the heating pipe 801 is connected to the bypass valve 7, and the other end is connected to the condenser pipe 2. Multiple support frames 802 are fixedly connected to the outside of the conical hopper 6. The heating pipe 801 and the multiple support frames 802... In contact with the heating mechanism 8, the function of the heating mechanism 8 is to heat the cone 6 when the temperature inside the cone 6 is too low and may freeze. When the controller 901 controls the bypass valve 7 to open, some of the high-temperature exhaust gas forms a heat flow channel through the heating pipe 801. The positioning function of the support frame 802 ensures that the heating pipe 801 and the outer wall of the cone 6 maintain a constant gap, forming a uniform heat radiation field. This design not only avoids local overheating that leads to secondary vaporization of condensate, but also achieves zero-energy antifreeze by utilizing the waste heat of the exhaust gas. When the temperature sensor 902 detects that the temperature of the cone 6 is lower than the set threshold, the bypass valve 7 automatically opens and automatically adjusts the flow rate of the high-temperature exhaust gas in the heating pipe 801, forming a dynamic heat compensation layer on the cone 6, effectively suppressing ice crystal adhesion and keeping the pipeline flow cross-sectional area maintenance rate above 95%.
[0022] like Figures 1-5 As shown, an adjustment mechanism 9 is connected inside the cone hopper 6. The adjustment mechanism 9 is used to sense the temperature inside the cone hopper 6. The adjustment mechanism 9 includes a controller 901 installed on one side of the condenser 11. A temperature sensor 902 is installed inside the cone hopper 6. The temperature sensor 902 is electrically connected to the controller 901. The controller 901 is electrically connected to the bypass valve 7. The function of the adjustment mechanism 9 is to control the opening of the bypass valve 7. When the value monitored by the temperature sensor 902 is close to the ice crystal formation temperature, the controller 901 immediately sends an opening command to the bypass valve 7 to introduce a quantitative amount of high-temperature waste gas for precise temperature adjustment. At the same time, a dual closed-loop control system of temperature and flow is established. The opening degree of the bypass valve 7 is dynamically adjusted according to the real-time temperature change, which avoids energy waste and prevents temperature fluctuations from affecting the condensation effect. This control logic enables the equipment to operate stably under extreme conditions of -20℃, increasing the MTBF to more than 1200 hours and reducing the frequency of manual inspection to once a week.
[0023] like Figures 1-4As shown, the bottom of the main body 1 of the equipment is equipped with three support legs 10. A condenser 11 is installed inside the main body 1, and a condenser tube 2 is located inside the condenser 11. A heat exchange tube 12 that contacts the condenser tube 2 is installed inside the condenser 11. The main body 1 is stably installed by a three-point support structure. The internal condenser 11 adopts a compact layout, and its heat exchange tube 12 directly contacts the condenser tube 2 to form a high-efficiency heat exchange interface. When VOCs-containing waste gas enters the condenser tube 2, the heat exchange tube 12 rapidly reduces the temperature of the waste gas and causes the target components to condense through heat exchange with the external refrigeration system of the main body 1. This structure ensures condensation efficiency while optimizing the space utilization of the condenser 11, reducing the volume of the equipment by 30% under the same processing capacity. It is particularly suitable for space-constrained chemical production scenarios. Moreover, the direct contact design between the heat exchange tube 12 and the condenser tube 2 can reduce thermal resistance and improve the overall heat transfer coefficient by more than 15%.
[0024] like Figures 6-7 As shown, an inclined guide plate 13 is fixedly connected inside the condenser pipe 2. The guide plate 13 is located above the water outlet pipe 4. When the waste gas enters the condenser pipe 2, the guide plate 13 changes the airflow direction, reducing the possibility of the waste gas being discharged from the water outlet pipe 4. The liquid after the waste gas is cooled will be discharged through the water outlet pipe 4. This structure improves the gas-liquid separation efficiency by 40%, while avoiding the formation of a liquid film on the inner wall of the pipe, reducing flow resistance. Combined with the position design of the water outlet pipe 4, it ensures a stable discharge flow of condensate and effectively prevents the liquid level in the storage tank from getting out of control.
[0025] like Figures 4-7 As shown, the top of the condenser pipe 2 is fixedly connected to the exhaust pipe 14, which is connected to the main body of the equipment 1. An exhaust pipe 15 is installed on one side of the main body of the equipment 1. The condensed waste gas enters the main body of the equipment 1 through the top exhaust pipe 14 and undergoes secondary heat exchange with the low temperature environment to achieve deep purification. Finally, the clean gas is discharged through the exhaust pipe 15 in compliance with standards. This dual-channel design enables the waste gas to form a condensation, separation and re-condensation cycle within the equipment, which not only ensures the VOCs removal efficiency, but also improves the heat recovery rate by extending the gas path. At the same time, the back pressure monitoring device installed on the exhaust pipe 15 forms a linkage protection with the bypass valve 7. When the system has abnormal back pressure, the emergency discharge channel is automatically opened to prevent the condenser 11 from being physically damaged due to a sudden increase in pressure.
[0026] In use, when VOCs-containing waste gas enters the condenser pipe 2 through the inlet pipe 3, the heat exchange pipe 12 rapidly reduces the waste gas temperature through the external refrigeration system, causing the target components to condense. The condensate enters the cone 6 through the outlet pipe 4 and is then discharged through the cone 6. At this time, the temperature sensor 902 monitors the wall temperature of the cone 6 in real time. When the detected value approaches the ice crystal formation temperature, the controller 901 immediately activates the bypass valve 7, allowing some of the high-temperature waste gas to form a heat flow channel through the heating pipe 801 wrapped around the outside of the cone 6. The support frame 802 maintains a constant gap between the heating pipe 801 and the outer wall of the cone 6, constructing a uniform thermal radiation field to precisely regulate the temperature of the cone 6. At the same time, a dual closed-loop control system for temperature and waste gas flow is established, dynamically adjusting the opening of the bypass valve 7 according to real-time temperature changes. This avoids local overheating that could lead to secondary vaporization of the condensate, and achieves zero-energy antifreeze by utilizing the waste heat of the waste gas. This maintains a dynamic heat compensation layer on the inner wall of the cone 6, effectively inhibiting ice crystal adhesion and ensuring that the cross-sectional area of the pipeline remains at over 95%. After condensation, the gas enters the main body 1 of the equipment through the top outlet pipe 14, where it undergoes secondary heat exchange with the low-temperature environment for deep purification. Finally, the clean gas is discharged through the exhaust pipe 15, meeting emission standards. This dual-channel design forms a cyclical treatment path of condensation separation and re-condensation, extending the gas flow path to improve heat recovery rate. Simultaneously, the back pressure monitoring device installed on the exhaust pipe 15 forms a linkage protection system with the bypass valve 7. When abnormal back pressure occurs in the system, the emergency discharge channel is automatically opened to prevent physical damage to the condenser 11 due to a sudden increase in pressure. The entire system utilizes waste heat utilization, intelligent temperature control, and flow field optimization technology, enabling stable operation even under extreme conditions of -20℃. The problem of condensate discharge flow rate attenuation is fundamentally solved, and the risks of uncontrolled liquid level in the storage tank and the potential for increased system back pressure are effectively eliminated. The average mean time between failures (MTBF) of the equipment is increased to over 1200 hours, and the frequency of manual inspections is reduced to once a week. This system is particularly suitable for continuous treatment of corrosive VOCs such as halogenated hydrocarbons; automated and efficient VOCs treatment. The recycling and treatment equipment has a typical component treatment efficiency of ≥90% for high-concentration VOCs and an overall treatment efficiency of ≥99%; the low-temperature condensation temperature can reach -75℃, and the condensation recovery efficiency is ≥97%.
[0027] The above description is merely an embodiment of this utility model and does not limit the patent scope of this utility model. Any equivalent structural or procedural transformations made based on the description and drawings of this utility model, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of this utility model.
Claims
1. A low-temperature condensation device for VOCs waste gas treatment, comprising a main body (1), wherein a condenser pipe (2) is installed inside the main body (1), one end of the condenser pipe (2) is connected to an air inlet pipe (3), and the bottom of the condenser pipe (2) is connected to a water outlet pipe (4), characterized in that: A drainer (5) is connected to the bottom of the main body (1) of the equipment. The drainer (5) is fixedly connected to a cone (6) located below the water outlet pipe (4), and the air inlet pipe (3) is equipped with a bypass valve (7), and the bottom of the bypass valve (7) is connected to a heating mechanism (8). An adjustment mechanism (9) is connected inside the cone (6). The adjustment mechanism (9) is used to sense the temperature inside the cone (6) and to heat the cone (6) through the heating mechanism (8).
2. The low-temperature condensation device for VOCs waste gas treatment according to claim 1, characterized in that: The bottom of the main body (1) of the equipment is equipped with three support legs (10), a condenser (11) is installed inside the main body (1), the condenser tube (2) is located inside the condenser (11), and a heat exchange tube (12) in contact with the condenser tube (2) is installed inside the condenser (11).
3. A low-temperature condensation device for VOCs waste gas treatment according to claim 1, characterized in that: The heating mechanism (8) includes a heating tube (801) wound around the outside of the cone (6) in multiple turns. The multiple turns of the heating tube (801) are interconnected. One end of the heating tube (801) is connected to the bypass valve (7), and the other end is connected to the condenser tube (2). Multiple support frames (802) are fixedly connected to the outside of the cone (6), and the heating tube (801) is in contact with the multiple support frames (802).
4. A low-temperature condensation device for VOCs waste gas treatment according to claim 2, characterized in that: The regulating mechanism (9) includes a controller (901) installed on one side of the condenser (11), a temperature sensor (902) installed in the cone (6), the temperature sensor (902) and the controller (901) being electrically connected, and the controller (901) being electrically connected to the bypass valve (7).
5. A low-temperature condensation device for VOCs waste gas treatment according to claim 1, characterized in that: An inclined guide plate (13) is fixedly connected inside the condenser pipe (2), and the guide plate (13) is located above the water outlet pipe (4).
6. A low-temperature condensation device for VOCs waste gas treatment according to claim 1, characterized in that: The top of the condenser tube (2) is fixedly connected to the exhaust pipe (14) which is connected to the main body of the equipment (1), and an exhaust pipe (15) is installed on one side of the main body of the equipment (1).