Monoblock superheated steam cooling system

Abstract

The invention relates to a superheated steam cooling system (10) used to lower the temperature of steam in power plants, petrochemical facilities, and other industrial processes.

Description

[0001] MONOBLOCK SUPERHEATED STEAM COOLING SYSTEM

[0002] Technical Field

[0003] The invention relates to a superheated steam cooling system used to reduce the temperature of steam in power plants, petrochemical facilities, and other industrial processes.

[0004] State of the Art

[0005] Currently, superheated steam cooling systems are used in industrial processes or power plants. Essentially, they function to cool steam under high-temperature conditions. The superheated steam referred to is typically high-temperature and high- pressure steam, commonly encountered in power plants, chemical industries, or other industrial processes. Superheated steam cooling units are designed to effectively cool this steam.

[0006] Existing superheated steam cooling systems operate by spraying water into the steam to lower its temperature. However, these systems often face challenges in evenly distributing water droplets and achieving effective mixing with the steam, resulting in efficiency losses and uneven temperature profiles. This situation can lead to significant issues, particularly in high-pressure and high-temperature systems, causing excessive condensate accumulation and leading to water hammer. Additionally, the materials and design used in current systems result in long-term durability issues such as wear and corrosion.

[0007] One issue with current technology is the ineffective cooling due to the uneven distribution of water droplets in the steam flow, which leads to imbalances in the steam temperature profile and adversely affects energy efficiency. Additionally, existing systems operating under high pressure and temperature lack sufficient resistance to wear and corrosion, resulting in increased maintenance costs and reduced system lifespan over time.

[0008] These problems necessitate an innovative superheated steam cooling system that utilizes fluid dynamics principles and advanced material technologies. Upon research, document TR 2019 / 06405 was found, which involves a humidification system with superheated steam cooling that mixes steam at saturation point with pure water to lower the dryness level of the steam below 1 , thus improving humidification quality and reducing raw material processing time. This existing technology does not feature integration with a globe-type control valve or optimization via computational fluid dynamics (CFD) simulation.

[0009] Consequently, a development in this technical field is needed due to the inadequacies of existing solutions regarding these challenges.

[0010] Objective of the Invention

[0011] The invention, inspired by current conditions, aims to resolve the aforementioned issues.

[0012] The main objective of the invention is to introduce a superheated steam cooling system that employs fluid dynamics principles and advanced material technologies to lower the temperature of steam in power plants, petrochemical facilities, and other industrial processes.

[0013] Another objective of the invention is to balance the steam’s temperature profile and minimize energy losses by achieving a more homogeneous distribution of cooling water in the steam flow.

[0014] Another objective is to present a system that maintains the desired steam temperature level through integration with a globe-type control valve.

[0015] Additionally, the invention aims to offer a system that optimizes energy consumption, increases efficiency, and reduces fossil fuel use and, consequently, the carbon footprint.

[0016] Another objective is to present a superheated steam cooling system with specialized cooling plates optimized through advanced CFD simulations.

[0017] The invention also aims to provide a system optimized not only for water-steam mixtures but also for other fluids such as oil cooling or gas cooling systems.

[0018] To achieve the objectives outlined above, the invention is a superheated steam cooling system that reduces the steam temperature in power plants, petrochemical facilities, and other industrial processes, containing at least one globe valve, at least one pressure gauge, and at least one thermometer, characterized by:

[0019] A globe control valve that maintains the desired steam temperature level, and

[0020] A superheated steam cooling unit with cooling plates that prevent mixing of steam and water, balance the steam’s temperature profile, and improve energy efficiency through CFD simulations to enhance fluid performance.

[0021] The structural and characteristic features of the invention, along with all its advantages, will be more clearly understood through the figures provided below and the detailed description written with references to these figures. Therefore, the assessment should also consider these figures and detailed explanations.

[0022] Figures to Help Understanding the Invention

[0023] Figure 1 is a general view of the system related to the invention.

[0024] Figure 2 is a general view of the system related to the invention.

[0025] Description of Part References

[0026] 10. Superheated steam cooling system

[0027] 11 . Globe valve

[0028] 12. Globe control valve

[0029] 13. Pressure gauge

[0030] 14. Thermometer

[0031] 15. Superheated steam cooling unit

[0032] 16. Control and monitoring unit

[0033] 17. Pump system Detailed Description of the Invention

[0034] This detailed description clarifies the preferred configurations of the superheated steam cooling system (10) subject to the invention, solely to aid in understanding the concept.

[0035] The superheated steam cooling system (10), shown in Figure 1 , primarily comprises at least one globe valve (11 ), at least one pressure gauge (13), at least one thermometer (14), a superheated steam cooling unit (15), a control and monitoring unit (16), and a pump system.

[0036] The system, which is the subject of the invention, aims to enhance thermal efficiency and reduce energy consumption by lowering the steam temperature in power plants, petrochemical facilities, and other industrial processes. Utilizing fluid dynamics principles, the invention provides more effective temperature control by working integrated with a control and monitoring (SCADA - Supervisory Control and Data Acquisition) unit, enhancing the overall efficiency of industrial processes. It offers more precise and efficient control through coupling with a globe-type control valve. Additionally, the integrated design significantly reduces maintenance and operating costs. Regulating the steam temperature in industrial facilities is critical for energy efficiency and operational reliability. The invention provides an optimized, innovative solution to meet these requirements.

[0037] The system, to achieve the objectives outlined above and increase efficiency, includes a globe control valve (12) that maintains the steam temperature at the desired level and a superheated steam cooling unit (15) with cooling plates that prevent the mixing of steam and water, balance the steam’s temperature profile, and improve energy efficiency through enhanced fluid performance via CFD simulations. Moreover, it features a control and monitoring unit (16) that increases fluid dynamics and heat transfer efficiency by monitoring flow rate, pressure, and temperature along the pipeline. The system also includes a pump system (17) that continuously pumps cold water from a cold water tank into the steam line.

[0038] The superheated steam cooling system (10) subject to the invention, with the help of the SCADA unit on the pipeline, aims to provide a more effective cooling system by optimizing fluid dynamics and heat transfer principles through the control of flow rate, pressure, and temperature. The system contains a specialized cooling circuit that distributes cooling water more homogeneously to the steam flow. The pump system (17) continuously pumps water from the cold water tank into the steam line; the heated cooling water can be used in the factory line within the scope of energy efficiency by feeding showers or radiator systems, or it can re-enter the heating cycle during preheating regimes. The system ensures cooling according to the flow rate calculated per unit area. Cooling optimization considers the flow rate inversely proportional. Additionally, an advanced cooling plate chamber optimized by CFD simulations is available to prevent steam and water mixing. This feature represents the most distinguishing characteristic of our invention, the superheated steam cooling unit (15) (SSC). The SSC unit balances the steam's temperature profile, enhancing energy efficiency and improving overall system performance. The materials used are selected to withstand high pressure and temperature conditions. Integration with the globe control valve (12) enhances the precision and controllability of the SSC unit system. This integrated structure supports operational efficiency and longevity of the system. Since temperature, pressure, and flow measurements in the system operate integrated with the SCADA unit, energy efficiency and the operational efficiency of the control valve are at maximum levels. Flow adjustment is achieved through the positioner on the globe control valve (12) via the SCADA unit. Water output from the pump is directed to the SSC Unit according to the flow rate, and the stable working position of the system is set via the SCADA unit based on changes in pressure and temperature, ensuring the superheated steam is cooled to the desired pressure and temperature.

[0039] The Superheated Steam Cooling System, with the SSC unit (15), control and monitoring system (16) (SCADA), and globe control valve (12), offers superior performance, durability, and energy efficiency compared to conventional systems. No condensate accumulates in the steam line. The system can be controlled more quickly and efficiently since it does not involve water injection as in traditional systems. Design selection challenges based on line diameter and flow rate are eliminated. This system stands out as a more reliable and efficient solution in industrial applications. While optimizing energy consumption, it reduces operational costs and minimizes environmental impact. With features easily understood and implemented by professionals, it represents a significant advancement in industrial standards.

Claims

CLAIMS1. A superheated steam cooling system (10) that reduces steam temperature in power plants, petrochemical facilities, and other industrial processes, comprising at least one globe valve (11), at least one pressure gauge (13), and at least one thermometer (14), characterized by comprising:• a globe control valve (12) that maintains the steam temperature at the desired level, and• a superheated steam cooling unit (15) with cooling plates that prevent mixing of steam and water, balance the steam's temperature profile, and enhance energy efficiency through computational fluid dynamics simulations to improve fluid performance.

2. The superheated steam cooling system (10) according to claim 1 , characterized by comprising a control and monitoring unit (16) that enhances fluid dynamics and heat transfer efficiency based on flow rate, pressure, and temperature control along the line.

3. The superheated steam cooling system (10) according to claim 1 , characterized by comprising a pump system (17) that continuously pumps cold water from a cold water tank into the steam line.

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