An energy-saving heat pump energy station system

Abstract

An energy-saving heat pump power station system includes a hot water circulation system, a cold water circulation system, and a heat energy application terminal connected to both systems. The hot water circulation system includes a heat pump assembly and a hot water circulation tank connected to the heat pump assembly. The cold water circulation system includes a condenser assembly and a heat exchanger connected to the condenser assembly. The heat pump assembly includes a heat pump unit, and the heat exchanger is connected to the heat pump unit. By coordinating the heat pump unit with the hot water and cold water circulation systems, efficient heat recovery and reuse are achieved, avoiding energy waste caused by direct emissions of steam or electric heating in traditional systems, thus achieving high energy efficiency.

Description

Technical Field

[0001] This utility model relates to an energy-saving heat pump energy station system. Background Technology

[0002] In industrial production, evaporation and condensation systems are widely used. They utilize electric heating and steam to heat materials. The steam generated by the evaporation of materials is cooled by circulating cooling water and becomes condensate. Through this process, the materials are concentrated, dried, or purified.

[0003] There are two common and typical evaporation-condensation systems:

[0004] Dryer: It uses electric heating or steam to heat the material to be dried, causing the moisture in it to evaporate. The evaporated water vapor is either directly discharged into the atmosphere or cooled by circulating cooling water and becomes condensate, thereby achieving the drying of the material.

[0005] Evaporator: It uses electric heating and steam to heat the material to be evaporated to boiling, and then the generated steam is cooled by circulating cooling water to become condensate, thereby achieving material concentration; there are single-effect evaporators and multi-effect evaporators.

[0006] Both systems share the characteristic of producing steam through evaporation, which is then condensed using cooling water. However, both systems result in a significant waste of energy.

[0007] For a system using steam, approximately 1.1 tons of steam are required to produce 1 ton of condensate. In some areas, the price of steam can reach as high as 350 yuan / ton or more, resulting in a cost of up to 385-400 yuan per ton of condensate produced.

[0008] For a system that uses electricity without steam, it requires a minimum of 825 kWh of electricity to produce 1 ton of condensate. Based on an average industrial electricity cost of 0.8 yuan / kWh, this means that it costs an average of 660 yuan to produce 1 ton of condensate.

[0009] In summary, the use of evaporation and condensation systems, such as evaporators and dryers, all face the problem of high energy consumption caused by energy waste. Utility Model Content

[0010] The technical problem to be solved by this utility model is to provide an energy-saving heat pump energy station system.

[0011] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is: an energy-saving heat pump energy station system, including a hot water circulation system, a cold water circulation system, and a heat energy application end connected to the hot water circulation system and the cold water circulation system. The hot water circulation system includes a heat pump component and a hot water circulation tank connected to the heat pump component. The cold water circulation system includes a condensing component and a heat exchanger connected to the condensing component. The heat pump component includes a heat pump main unit, and the heat exchanger is connected to the heat pump main unit.

[0012] Preferably, in the hot water circulation system, the heat pump assembly includes the hot water circulation pump, which can transport clean water in the hot water circulation tank to the heater of the heat pump host, heat it to 120°C and then supply it to the heat energy user end. After use, the hot water is cooled to 115°C and returned to the hot water circulation tank.

[0013] Preferably, in the cold water circulation system, the condensation component includes a condensation tower and a cold water circulation pump. The condensation tower receives the steam generated at the heat energy application end and exchanges heat with 80°C cold water. After the cold water is heated to 85°C, it enters the refrigeration unit of the heat pump host through the heat exchanger and is cooled to 80°C before being sprayed back onto the condensation tower.

[0014] Preferably, it also includes a heat balance system, which includes a heat balance valve and a cooling fan connected to the condenser assembly. The heat balance valve opens when the cold water temperature exceeds 85°C to introduce air into the condenser assembly to dissipate excess heat. The cooling fan is used to assist in cooling when the cold water temperature exceeds 85°C.

[0015] Preferably, the heat exchanger uses a three-way valve to exchange heat between hot and cold water when heat exchange is insufficient.

[0016] Preferably, the heat energy application end is a dryer and / or an evaporator.

[0017] Preferably, when the heat energy application end is a dryer, the 90~100℃ steam generated by the dryer is drawn into the condensing component by a fan to exchange heat with cold water and condense; when the heat energy application end is an evaporator, the steam of the evaporator exchanges heat with cold water through the condensing component, and the remaining exhaust gas is cooled by the condensing component before being discharged.

[0018] The scope of this utility model is not limited to technical solutions formed by specific combinations of the above-mentioned technical features, but should also cover other technical solutions formed by arbitrary combinations of the above-mentioned technical features or their equivalent features. For example, technical solutions formed by substituting the above-mentioned features with (but not limited to) technical features with similar functions disclosed in this application.

[0019] Due to the application of the above technical solution, this utility model has the following advantages compared with the prior art:

[0020] 1. This utility model provides an energy-saving heat pump energy station system, which achieves efficient recovery and reuse of heat energy through the heat pump host working in conjunction with the hot water circulation system and the cold water circulation system, avoiding the energy waste caused by the direct discharge of steam or electric heating in traditional systems;

[0021] 2. Using clean water as the circulating medium avoids problems such as scaling and corrosion caused by direct contact between materials and heat pumps or compressors in traditional systems, thus extending the service life of the equipment;

[0022] 3. The system adopts a heat balance system, which can automatically adjust the heating and cooling loads to ensure long-term stable operation of the system and avoid downtime caused by temperature fluctuations or insufficient heat exchange.

[0023] 4. The heat energy application end can be flexibly switched to a dryer or an evaporator to meet different industrial needs;

[0024] 5. By recovering waste heat and reducing dependence on external energy sources, the system significantly reduces carbon emissions, which aligns with the trend of green manufacturing. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the system structure;

[0026] Figure 2 Flowchart for an example of a dryer application;

[0027] Figure 3 This is a flowchart illustrating an example of an evaporator application. Detailed Implementation

[0028] like Figure 1 The energy-saving heat pump power station system shown mainly includes the following parts:

[0029] Hot water circulation system:

[0030] Hot water circulation tank TK-1: Used to store circulating clean water, the capacity can be adjusted according to actual needs.

[0031] Hot water circulation pump P101: It adopts a high-temperature resistant centrifugal pump with adjustable flow rate to deliver clean water to the heat pump host M101.

[0032] Heat pump unit M101: Employs a two-stage compression heat pump, including a first-stage compression unit to improve the cold water circulation system's energy recovery efficiency; a second-stage compression unit to heat the hot water to 120±2℃, operating in series with the first-stage compression unit; and a PID dynamic adjustment module for real-time monitoring of the hot water temperature. and cold water temperature The pressure ratio of the two-stage compression is dynamically adjusted, and the specific formulas are as follows: , ,in, This indicates the pressure ratio adjustment value for hot water. This is the pressure ratio adjustment value for cold water. , , For PID control parameters, To set the temperature, the thermal balance system dynamically adjusts the opening of the thermal balance valve and activates the cooling fan when the cold water temperature exceeds 85°C using a PID algorithm.

[0033] Cold water circulation system:

[0034] Condensing tower TK-2: It has a built-in packing layer and atomizing nozzles. Steam and 80°C cold water exchange heat in contact with each other in the packing layer, and the cold water is heated to 85°C.

[0035] Cold water circulation pump P201: The flow rate is matched with that of hot water circulation pump P101.

[0036] Heat exchanger EX101: Plate heat exchanger, used to regulate the heat exchange between hot and cold water via three-way valve P101-EV04 when heat exchange is insufficient.

[0037] Thermal balance system:

[0038] Thermal balance valve FAN201-PV03: It dynamically adjusts the opening threshold according to the PID algorithm to introduce air and expel excess heat.

[0039] Cooling fan FAN201: Assists in cooling to ensure cold water temperature ≤85℃.

[0040] The heat energy application terminal TK-3 can be either a dryer M301 or an evaporator M302, and the operating mode can be selected through the switching valves P201-V02.

[0041] The process flow of an energy-saving heat pump power station system:

[0042] Hot water circulation:

[0043] Clean water is pumped from the hot water circulation tank TK-1 into the heat pump host M101 via the hot water circulation pump P101 and heated to 120°C. It is then delivered to the heat energy application end TK-3, such as the heating coil of a dryer.

[0044] After use, the hot water cooled to 115°C is returned to the hot water circulation tank TK-1, forming a closed loop.

[0045] Cold water circulation: Steam generated at the heat energy application end TK-3, such as 100℃ steam from a dryer, enters the condenser tower TK-2 and exchanges heat with 80℃ cold water for condensation. The 85℃ cold water then enters the heat pump main unit M101 refrigerator via heat exchanger EX101 and is cooled to 80℃ before being sprayed back into the condenser tower TK-2.

[0046] Thermal balance control: When the cold water temperature is >85℃, the thermal balance valve FAN201-PV03 opens to introduce air and expel water vapor; at the same time, the cooling fan FAN201 starts to assist in heat dissipation.

[0047] If the heat exchange at the TK-3 heat energy application end is insufficient, such as due to scaling leading to a decrease in thermal efficiency, the three-way valve P101-EV04 will guide some hot water into the heat exchanger EX101 to exchange heat with cold water, thus preventing the heat pump host M101 from overheating and shutting down.

[0048] The heat pump energy station system of this utility model has a heat efficiency ratio (COP) ≥ 4.0. Taking the heat power required to produce 1 t / h of condensate as 750 kW as an example, and calculating based on an average electricity cost of 0.8 yuan / kWh, the electricity cost required to produce 1 ton of condensate is 750 / 4*0.8 = 150 yuan, which is only 39% of that of using steam and 23% of that of using electric heating. This brings huge economic benefits to the user. The heat pump main unit is designed to have a service life of more than 20 years. The medium is all clean water, and the operating conditions are good, so it can be used stably for a long time. The unique heat balance system allows the heat pump energy station system to run continuously without stopping for a long time.

[0049] Example 1: The heat energy user is a dryer M301:

[0050] like Figure 2 As shown, dryer M301 is an IN-MVR dryer, which is an indirect mechanical vapor compression technology dryer. It utilizes recycled waste steam generated during drying for drying and heating, thus achieving energy saving.

[0051] The 90~100℃ steam generated by the dryer M301 is drawn into the condenser tower TK-2 by the high-temperature fan FAN201, and the condensate is discharged into the water tank. The liquid level control valve P201-PV06 opens and closes automatically.

[0052] Anti-clogging design: The packing layer of the TK-2 condenser tower is made of PP material, and the nozzle orifice diameter is ≥5mm to prevent clogging by fruit residue and other particles.

[0053] The working principle and process are as follows:

[0054] The hot water circulation process is achieved using hot water as a medium. A certain amount of clean water is stored in the hot water circulation tank TK-1 and the pipeline. Under the action of the hot water circulation pump P101, it enters the heater of the heat pump host M101 and is heated to 120°C to form superheated water. Then it is sent to the dryer TK-3 for use. After use, the temperature of the hot water drops to 115°C and returns to the hot water circulation tank TK-1, and enters the heater of the heat pump host M101 again. This cycle continues to achieve hot water circulation.

[0055] During the drying process of dryer TK-3, water vapor with a temperature of approximately 90~100℃ is generated. This steam is drawn into condenser tower TK-2 by fan FAN201. It comes into contact with 80℃ cold water sprayed from atomizing nozzles in the packing layer and cools down to condense into condensate, raising the temperature of the cold water to 85℃. This 85℃ cold water flows through heat exchanger EX101 via cold water circulation pump P201 and then into the cooler of heat pump host M101, where the temperature is lowered back to 80℃. It then enters condenser tower TK-2 and is sprayed down from atomizing nozzles, where it comes into contact with the steam generated by dryer TK-3 again for heat exchange. This cycle continues, achieving cold water circulation.

[0056] As the cycle continues, the moisture in the material in the dryer TK-3 is continuously transferred to the water tank at the bottom of the condenser tower TK-2. After the water level in the tank rises to a certain height, the condensate drain valve P201-PV06 automatically opens and discharges the condensate.

[0057] The heat pump unit M201 can generate both heat and cooling simultaneously, but its heat output is greater than its cooling output. Generally, P_heat - P_cooling = P_input, where P_heat is the heat pump's thermal power, P_cooling is the heat pump's cooling power, and P_input is the heat pump's input power. Therefore, during the operation of the heat pump unit M201, the imbalance between heat and cooling will cause the circulating chilled water temperature to rise above 85°C and continue to rise, eventually causing the heat pump unit M201 to shut down.

[0058] To achieve thermal balance, a thermal balance valve FAN201-PV03 is installed. When the circulating chilled water temperature exceeds 85℃, the thermal balance valve FAN201-PV03 automatically opens, allowing outdoor air to enter and flow through the packing layer to contact the chilled water sprayed from the atomizing nozzles. This transfers humidity, transferring some water vapor into the incoming air and discharging it from the top of the condenser tower TK-2. This maintains the chilled water in the bottom tank of the condenser tower TK-2 at a temperature of approximately 85℃. By discharging water vapor, excess heat is removed, ultimately achieving system thermal balance.

[0059] In actual operation, insufficient heat exchange due to factors such as insufficient heat exchange area of ​​the TK-3 dryer or scaling during use can lead to inadequate heat exchange. This results in the heat generated by the heat pump unit M201 not being fully utilized, causing the heat pump unit M101 to shut down due to excessively high hot water circulation system temperature. Therefore, the heat exchanger EX101 is designed to directly supply the heat generated by the heat pump unit M201 to the heat exchanger EX101 via a three-way valve during such situations, allowing for heat exchange with the cold water circulation process and achieving energy circulation. This ensures the normal operation of the heat pump unit M201.

[0060] Example 2: The heat energy application end is the evaporator M302:

[0061] like Figure 3 As shown, evaporator M302 is an IN-MVR evaporator, which is an indirect mechanical vapor compression evaporator. It adopts a multi-stage condensate tank, including a first-stage condenser EX302: titanium alloy tube side, 85℃ cold water condenses steam to 85~90℃; and a second-stage condenser EX303: the remaining exhaust gas is cooled to 40~45℃ before being discharged.

[0062] The working principle is as follows: A certain amount of clean water is stored in the hot water circulation tank TK-1 and the pipeline. Under the action of the hot water circulation pump P101, it enters the heater of the heat pump host M101 and is heated to 120°C to form superheated water. Then it is sent to the shell side of the heater EX301 in the evaporator TK-3. After heat exchange with the material in the tube side of the heater EX301, the material is heated to the boiling point of 100°C to form steam, while the temperature of the circulating hot water drops to 115°C and returns to the hot water circulation tank TK-1, and re-enters the heater of the pump host M101. This cycle continues to achieve the hot water circulation process.

[0063] Circulating chilled water enters the shell side of the first-stage condenser EX302 in evaporator TK-3, where it exchanges heat with the steam in the tube side, raising the chilled water temperature from 80℃ to 85℃. Simultaneously, the steam in the tube side is condensed into liquid condensate. The 85℃ circulating chilled water flows through heat exchanger EX101 via chilled water circulation pump P201 and then into the refrigerator of heat pump unit M101, where its temperature is lowered back to 80℃ before re-entering the shell side of the first-stage condenser EX302, thus continuously circulating. A cooling fan FAN201 is installed on the chilled water circulation pipeline between the first-stage condenser EX302 and the heat pump unit to cool the circulating chilled water when its temperature rises above 85℃, thus achieving the chilled water circulation process.

[0064] The material is pumped into the separator SP301 in the evaporator TK-3, and the liquid level is automatically maintained according to the liquid level of the separator SP301. After evaporation and concentration, the concentrated mother liquor is discharged from the evaporator for subsequent crystal separation / drying treatment. The generated condensate enters the condensate tank TK2 for temporary storage and is then discharged out of the system.

[0065] Steam is generated in separator SP301 in evaporator TK-3, and then first passes through the tube side of primary condenser EX302, where it is condensed to 85~90℃ using circulating chilled water at 80℃. Then it passes through the tube side of secondary condenser EX303, where it is cooled to 40~45℃ using circulating water at 80℃. Finally, a small amount of tail gas remains, which is either directly discharged or enters the subsequent waste gas treatment system for harmless treatment.

[0066] The heat pump unit M201 can generate both heat and cooling simultaneously, but its heat output is greater than its cooling output. Generally, P_heat - P_cooling = P_input, where P_heat is the heat pump's thermal power, P_cooling is the heat pump's cooling power, and P_input is the heat pump's input power. Therefore, during the operation of the heat pump unit M201, the imbalance between heat and cooling will cause the circulating chilled water temperature to rise above 85°C and continue to rise, eventually causing the heat pump unit M201 to shut down.

[0067] To achieve thermal balance, a heat balancing fan coil unit FAN201 is installed. When the circulating chilled water temperature is higher than 85℃, the heat balancing fan coil unit FAN201 is automatically turned on, allowing heat exchange between the circulating chilled water and the air, thus controlling the circulating chilled water temperature below 85℃ and ultimately achieving system thermal balance.

[0068] In actual operation, insufficient heat exchange due to factors such as insufficient heat exchange area of ​​heater EX301 or scaling during use can lead to inadequate heat exchange, resulting in the heat generated by heat pump unit M101 not being fully utilized. Consequently, heat pump unit M101 may shut down due to excessively high hot water circulation system temperature. Therefore, heat exchanger EX101 is installed. In the event of the above situation, the heat generated by heat pump unit M201 is controlled by three-way valve P101-EV04 to directly supply the hot water circulation process to heat exchanger EX101 and exchange heat with the cold water circulation process, achieving energy circulation and ensuring the normal operation of heat pump unit M201.

[0069] The above embodiments are only for illustrating the technical concept and features of this utility model, and are intended to enable those skilled in the art to understand the content of this utility model and implement it accordingly. They should not be construed as limiting the scope of protection of this utility model. All equivalent changes or modifications made in accordance with the spirit and essence of this utility model should be included within the scope of protection of this utility model.

Claims

1. An energy-saving heat pump energy station system, characterized in that: The system includes a hot water circulation system, a cold water circulation system, and a heat energy application terminal connected to the hot water circulation system and the cold water circulation system. The hot water circulation system includes a heat pump assembly and a hot water circulation tank connected to the heat pump assembly. The cold water circulation system includes a condensing assembly and a heat exchanger connected to the condensing assembly. The heat pump assembly includes a heat pump unit, and the heat exchanger is connected to the heat pump unit.

2. The energy-saving heat pump energy station system according to claim 1, characterized in that: In the hot water circulation system, the heat pump assembly includes a hot water circulation pump, which can transport clean water from the hot water circulation tank to the heater of the heat pump host, heat it to 120°C and then supply it to the heat energy user end. After use, the hot water is cooled to 115°C and returned to the hot water circulation tank.

3. The energy-saving heat pump energy station system according to claim 1, characterized in that: In the cold water circulation system, the condensation component includes a condensation tower and a cold water circulation pump. The condensation tower receives the steam generated at the heat energy application end and exchanges heat with 80°C cold water. After the cold water is heated to 85°C, it enters the refrigeration unit of the heat pump host through the heat exchanger and is cooled to 80°C before being sprayed back onto the condensation tower.

4. The energy-saving heat pump energy station system according to claim 1, characterized in that: It also includes a heat balance system, which includes a heat balance valve and a cooling fan connected to the condenser assembly. The heat balance valve opens when the cold water temperature exceeds 85°C to introduce air into the condenser assembly to dissipate excess heat. The cooling fan is used to assist in cooling when the cold water temperature exceeds 85°C.

5. The energy-saving heat pump energy station system according to claim 4, characterized in that: The heat pump unit is a two-stage compression heat pump unit, including a first-stage compression unit for improving the cold water circulation system's cold energy recovery efficiency; a second-stage compression unit for heating the hot water to 120±2℃, and operating in series with the first-stage compression unit; and a PID dynamic adjustment module for real-time monitoring of the hot water temperature. and cold water temperature The pressure ratio of the two-stage compression is dynamically adjusted, and the specific formulas are as follows: , ,in, This indicates the pressure ratio adjustment value for hot water. This is the pressure ratio adjustment value for cold water. , , For PID control parameters, To set the temperature, the thermal balance system dynamically adjusts the opening of the thermal balance valve and activates the cooling fan when the cold water temperature exceeds 85°C using a PID algorithm.

6. The energy-saving heat pump energy station system according to claim 1, characterized in that: The heat energy is used by a dryer and / or an evaporator.

7. The energy-saving heat pump energy station system according to claim 6, characterized in that: When the heat energy application end is a dryer, the 90~100℃ steam generated by the dryer is drawn into the condensing component by a fan to exchange heat with cold water and condense; when the heat energy application end is an evaporator, the steam of the evaporator exchanges heat with cold water through the condensing component, and the remaining exhaust gas is cooled by the condensing component before being discharged.

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