Heat pump steam generation system and operation method thereof

Abstract

The invention is a recycling mechanism that is put forward to convert excess water, which is considered waste especially in institutions / organizations that carry out industrial activities, into steam with a heat pump and to provide energy production / saving with the said water.

Description

[0001] HEAT PUMP STEAM GENERATION SYSTEM AND OPERATION METHOD THEREOF

[0002] FIELD OF THE INVENTION

[0003] The present invention relates to the system and method that enables the recovery of surplus energy and the production of steam for business needs with this energy.

[0004] STATE OF THE ART

[0005] While known energy resources in the world are rapidly decreasing, society's need for energy is increasing. At the same time, energy costs are constantly changing due to various crises in the world and there are problems in energy supply. One of the areas of activity where energy is used most intensively in our country and in the world is the industrial sector. In line with the increasing energy needs in industrial activities, energy outages often occur. At this point, the importance of energy efficiency, energy recovery and alternative heat recovery systems is increasing, especially in the industrial sector. Difficulties in accessing energy have led businesses to find alternative solutions. With the researches and developing technology, even though many settlement owners try to meet the electricity demand problem with various methods (using solar panels, etc.), electricity production with the mentioned methods is not sufficient. Even if the use of solar panels becomes widespread, especially in organizations engaged in industrial activities, it is understood that it is impossible to meet the entire need of industrial activities, considering that this production is limited. Although alternative solutions are applied to meet electricity needs, there are no such applications for natural gas needs.

[0006] In organizations engaged in industrial activity, natural gas and electricity consumption of machines that produce and / or use steam is high. The cost of using electrical energy will gradually increase over the years and the load impact on the national grid will be greater. Especially in these plants, which are known to have high natural gas consumption, energy recovery to reduce natural gas consumption plays a critical role. In the industrial sector, especially in the textile industry, there are plants with high-temperature flue gas emissions. These plants have a high potential for heat recovery. Disposal of low-temperature and filtered flue gas at a low temperature is a necessity in terms of energy and environment. The aforementioned actions aim to reduce the damage to the atmosphere by filtering the flue gas and (also) to protect the health of the people staying in the settlements close to the organizations engaged in industrial activities. The implementation and enforcement of these actions are required by law. However, when heat recovery systems are added to all chimneys of enterprises with high-temperature flue gas emissions, the recovered energy will be excessive and this will create an out-of-use energy problem. Efficient flue gas filtration and heat recovery systems have been used to eliminate the energy deficit, and efforts are being made to reduce electricity and natural gas consumption, but they have not sufficient. Many textile plants have a serious need for steam. Plants can produce steam with high energy consumption in steam boilers or buy it ready-made from outside. Thanks to the heat recovery system that is the subject of this project, the energy used as waste in the plant will be recovered.

[0007] Many problems arise due to the generation of excess waste energy in industrial organizations. One of the biggest negativities experienced is that the temperature control of hot water tanks is not realized to the desired extent and the water tanks overflow uncontrollably. The mentioned situation causes extra energy consumption and harms both the environment and the operating personnel. It transfers excess hot water to the sewer system against tank overflows in plants. As a result, the thermal balance in nature is disrupted. Another application for the purpose of reusing excess hot water is pouring the excess hot water into the cold water tank. This water added to the cold water tank increases the temperature of the tank. In processes where this water is used, problems occur in product quality depending on the temperature of the water. In addition to additional energy consumption to reduce the temperature of the cold water tank, additional water is also used. Due to the inability to maintain the water temperature or coldness at the desired settings during these processes, there is a delay in production or a decline in the quality of the products produced.

[0008] One of the most commonly used methods to balance and reuse excess hot water is to use a cooling tower. However, it has been realized that the desired recovery and recycling cannot be achieved if the amount of energy consumed by cooling towers and production costs are taken into consideration. The Chinese document with the application number CN112879995B and publication date 01.04.2015, which was put forward in order to overcome the aforementioned negativities and disadvantages, mentions a water-powered heat pump system to recover waste heat, supported by solar energy in cases where there is no waste heat, providing high-temperature heat. However, when the relevant application is examined in detail, there is no information about the operating temperatures of the system. In the relevant study content, it is mentioned that a steam above 100°C will be obtained at the exit of the heat pump regarding the operating temperature. Assuming that one of the main factors in energy recovery is the recovery of surplus hot water obtained from previous heat recovery systems, there is no clear information on the conditions under which the water is recovered and at what temperatures, and subsequently on the extent to which energy recovery is achieved depending on the recovery of water, and the relevant application does not provide a complete solution to the issues mentioned. At the same time, there are technical differences in supporting the project with solar energy. While solar energy is used for heating purposes in the project with application number CN112879995B, in this project it will be used to meet the electricity needs of the heat pump.

[0009] In the Chinese document with application number CN113932208A and publication number 11.01.2022, a multi-heat source heat pump and a high temperature steam supply system are mentioned. However, when the relevant application is examined in detail, clear information about the operating parameters of the system is not provided. Many heat sources mentioned in the project have been disclosed. Steam at high temperature and pressure is mentioned as the system output, but no technical details can be found. Based on this review, it is concluded that the application in question will not be a solution to the relevant problems.

[0010] Even when the CN112879995B and CN113932208A numbered Chinese documents and all other documents are examined in detail, no definitive solution has been found to the mentioned negativities. Waste heat is mentioned in the systems, but the composition of this waste heat and system operating parameters are not specified.

[0011] The invention has been put forward to eliminate the above-mentioned disadvantages and bring new advantages to the relevant technical field. OBJECT OF THE INVENTION

[0012] The main object of the present invention is to produce steam by using the heat (energy) of the source at high temperature and to save energy by using the resulting steam as energy in another process.

[0013] The object of the present invention is to produce steam by reusing excess hot water in industrial institutions / organizations and thus to reduce the consumption of natural gas used in steam production.

[0014] Another object of the present invention is to reduce the amount of water to be used for steam production in steam boilers by recycling excess hot water.

[0015] Another object of the present invention is to save energy and prevent financial losses by eliminating options such as pouring surplus hot water that needs to be removed from the plant into the sewer, transferring it to a cold water tank and using a cooling tower.

[0016] Another object of the present invention is to provide high-temperature steam production; to prevent losses of energy, power and time spent on steam production.

[0017] Another object of the present invention is to ensure the balance of natural life by reducing energy costs and energy consumption.

[0018] Another object of the present invention is to reduce the carbon footprint of industrial institutions / organizations.

[0019] As a result, it is understood that it is appropriate to innovate in the relevant technical field with alternative solutions to all the problems mentioned above and high-tech products.

[0020] BRIEF DESCRIPTION OF THE INVENTION

[0021] In order to achieve all the purposes mentioned above and that will emerge from the detailed explanation below, the present invention is a recovery mechanism for converting surplus water, which is characterized as waste especially in institutions / organizations operating in industry, into steam with a heat pump and to ensure energy production / saving with the said water. Accordingly, a heat pump aims to produce steam by increasing the temperature of excess water, which is considered waste;

[0022] The stenter machine works with natural gas energy and provides the temperature required for the operation of the stenter heat recovery system;

[0023] The ram heat recovery machine obtains hot water by taking the flue gas heat that occurs after the operation of said stenter machine and is considered as waste;

[0024] If the steam produced by the heat pump in the facility is not at the desired pressure and temperature, the fluid will be directed to the flash tank and steam will be produced. It comprises; steam boiler for generating steam, in cases where the amount of steam produced by the heat pump in the plant is insufficient;

[0025] Jet machine that uses steam as an energy source and generates waste hot water containing dye as a by product of its processes;

[0026] Waste water recovery machine to heat the water by recovering the heat of the waste hot water generated in said jet machines;

[0027] Water tank 1 ; water tank 2 and water tank 3 to provide water supply to the system at different temperatures; water pumps to ensure continuous transfer of the recovered heated water to the area where it will be used.

[0028] A preferred embodiment of the invention comprises a PV panel that supplies the electricity needed to operate the heat pump.

[0029] Another preferred embodiment of the invention is to heat the waste water containing dye at 50-70 °C and the water at an average of 20 °C to an average of 45-60 °C in the waste water recovery machine (6);

[0030] Transferring the mains water, whose temperature is increased to an average of 45- 60°C in the waste water recovery machine, to the jet machine as feed water;

[0031] Transferring the water obtained from the waste water recovery machine to water tank 2;

[0032] Sending the water, which is kept at an average of 40-60°C in water tank 2, to the ram heat recovery mechanism and heating the same to 60-70°C;

[0033] Transferring the water with increased temperature to water tank 3 (9); Obtaining steam from water at 45-70°C through a heat pump;

[0034] Transferring the water with a temperature of 45-60°C coming out of the heat pump back to water tank 2, and the mentioned process steps are repeated in a cycle.

[0035] Obtaining steam from the heat pump at a pressure of 3 bar and a temperature of 120-130°C;

[0036] It is characterized by the method steps that include directing the fluid to the flash tank and obtaining steam there if the steam coming out of the heat pump is not at the desired pressure and temperature.

[0037] BRIEF DESCRIPTION OF DRAWINGS

[0038] Figure 1 gives a representative view of said system, and the schematic operation of said system is shown.

[0039] Figure 2 gives A detailed view to enable the invention to be understood and the method steps to be examined

[0040] Figure 3 gives B detailed view to enable the invention to be understood and the method steps to be examined.

[0041] Figure 4 gives C detailed view to enable the invention to be understood and the method steps to be examined.

[0042] DESCRIPTION OF THE REFERENCES IN THE FIGURES

[0043] 1. Heat pump

[0044] 2. Stenter machine

[0045] 3. Heat recovery machine from stenter machine

[0046] 4. Steam boiler

[0047] 5. Jet machine

[0048] 6. Waste water heat recovery machine

[0049] 7. Water tank 1- cold 8. Water tank 2- warm

[0050] 9. Water tank 3- hot

[0051] 10. Water pump

[0052] 11. PV Panel

[0053] 12. Alternative Flash Tank

[0054] 13. Automated Diversion Valves

[0055] DETAILED DESCRIPTION OF THE INVENTION

[0056] In this detailed description, the subject of the invention is described by means of examples only for clarifying the subject matter such that no limiting effect is created

[0057] The invention, which is described in detail below, has been put forward to ensure the recovery of surplus hot water, which is characterized as waste, especially in institutions I organizations operating in industry, and to save energy by producing steam with the said hot water.

[0058] The invention is set forth by comprising the following elements:

[0059] • There is a heat pump (1 ) to ensure that excess hot water, which is considered waste, is converted into steam at higher temperatures and used in this way.

[0060] • There is a stenter machine (2) that works with natural gas energy and provides one of the heat required for the operation of the system.

[0061] • There is a heat recovery machine (3) from the stenter to heat the water by taking the heat that is generated after the operation of the mentioned stenter (2) and characterized as waste and to provide hot water production.

[0062] • There is a steam boiler (4) that meets the steam requirements of the jet machines.

[0063] • There is a jet machine (5) that uses steam as the energy source and produces waste hot water as a result of its processes.

[0064] • There is a waste water heat recovery machine (6) to produce clean hot water by recovering the heat of the waste hot water generated in said jet machines (5). • There is water tank 1 (7) where cold water is stored, water tank 2 (8) where warm water obtained from the waste water heat recovery machine is stored and water tank 3 (9) where hot water is stored.

[0065] • There are water pumps (10) to ensure the transfer of water to the area where it will be used.

[0066] • There is a PV panel (11) generate the electrical energy required for the operation of said heat pump (1 ).

[0067] • The hot water, which is considered as waste in the business, will be used in the heat recovery systems (3), (6) and the hot water obtained as process output will be used in the heat pump (1 ) to produce steam.

[0068] • If the steam produced in the heat pump is not at the desired pressure and temperature value, the hot water obtained goes to the flash tank (12) via automated diversion valves (13). Steam at the desired pressure and temperature is obtained in the flash tank (12) and transmitted to the jet machine.

[0069] • In cases where the stenter heat recovery machine (3) does not operate, the automated diversion valves located at the outlet of the water tank 2 - warm (8) will be notified and the hot water required by the heat pump will be supplied from the water tank 2 - warm.

[0070] Above, the elements that make up the invention / system and the functions of said elements within the invention are given. The interconnection of said elements and the working stages of said system are explained in detail below.

[0071] The invention will be used mainly in textile dyehouses. Textile dyehouses are institutions / organizations suitable for heat recovery due to their intense steam consumption, waste hot water and high temperature flue gas emissions.

[0072] As a result of the use of the steam produced in the steam boilers (4) in the jet machines (5), dye-containing hot water at an average temperature of 50°C - 70°C is produced as waste. The cold water (7), which is at an average temperature of 20°C, is heated to an average of 45°C - 60°C in the waste water heat recovery machine (6), together with said waste hot water. In the wastewater heat recovery system, after the relevant process, water at an average temperature of 30°C and unsuitable for use is drained (removed) from the facility. Water whose temperature is increased to an average of 50-60°C in the waste water heat recovery machine (6); is also used as feed hot water in jet machines (5). Thus, the energy cycle is achieved.

[0073] The stenter machines (2) contained in the process provide the heat need with natural gas. These machines emit flue gas whose temperature varies between 120-180°C. By adding a stenter heat recovery machine (3) to the chimney of the stenter machine

[0074] (2), hot water between 40-50°C is obtained. With the filter systems installed on the stenter machines (2) in accordance with legal obligations and the heat recovery machine (3), excess hot water is obtained in institutions / organizations.

[0075] The main object of the present invention is to ensure the recycling and use of excess hot water in organizations, as in the example mentioned above.

[0076] First of all, the water obtained in the waste water recovery machine (6) will be transferred to water tank 2 (warm water tank) (8). The water stored at 40-50°C in water tank 2 (8) will be sent from the stenter machine to the heat recovery machine

[0077] (3) and its temperature will be increased to 60-70°C. The water with increased temperature will be transferred to water tank 3 (9).

[0078] Steam will be obtained from the energy of hot water (water in water tank 3 at 60- 70°C) through the heat pump (1 ). After obtaining steam from the heat pump (1 ), the water in the range of 50-60°C will be transferred back to water tank 2 (8). However, if the steam obtained from the heat pump does not meet the process needs, the fluid will be directed to the flash tank (12) via automated diversion valves (13). Steam will be obtained in the flash tank (12) and transferred to the jet machine. In this way, the system will create a loop within itself. It will use high temperature water by preventing it from being discharged from the system, thus saving energy.

[0079] In cases where the heat recovery machine (3) from the Stenter machine, which is a part of the energy cycle mentioned above, does not work, the water tank 2 (8) will be notified by the automation system and the automation controlled valves (13) will be activated and the hot water that the heat pump (1 ) will use in steam production will be taken from the water tank 2 (8). The operation of the system / method is explained in the operating principle mentioned above. The explanation below explains how the task elements in the system operate the system as a whole.

[0080] As can be seen from Figure 1 , the stenter machine (2) works in connection with the stenter heat recovery machine (3). Stenter machines (2) obtain the energy required for their operation with natural gas. In alternative applications of the invention, the energy required for the operation of the stenter machines (2) is provided by electricity, coal, or other fuels. The energy required for the operation of the stenter machine (2) and the steam boiler (4) is provided by natural gas. In alternative embodiments of the invention, the energy required for the operation of the steam boiler (4) is provided by electricity, coal, etc.

[0081] The water converted into steam via the steam boiler (4) is transferred to the jet machine (5). Waste dyed hot water (at 50-70°C) is continuously supplied to the system through the jet machine (5). The jet machine (5) continuously draws water from water tank 2 (8) to complete its processes. The jet machine (5) also works in conjunction with the heat pump (1) to heat the water it contains and turn it into steam. It will work together with the heat pump (1 ), flash tank (12) and steam boiler (4) to provide the steam needed by the jet machine (5). When the steam obtained from the heat pump (1) is not at the desired pressure value, the automated diversion valves (13) will be activated and the fluid will be directed to the flash tank and steam will be obtained there. When the amount of steam produced in this entire system is insufficient, information will be transferred to the steam boiler (4) and the steam boost of the steam boiler (4) will increase. The heat pump (1 ) is activated to support steam generation.

[0082] Water is continuously supplied from water tank 1 (7) to the waste water recovery machine (6) and from the waste water recovery machine (6) to water tank 2 (8).

[0083] Whenever the water value in water tank 1 (7) approaches the critical value, water is automatically fed into the tank. The unusable dyed water at approximately 30°C, which is output in the waste water heat recovery machine (6), is drained.

[0084] Water is continuously transferred from the heat pump (1 ) to the water tank 2 (8) and from the water tank 2 (8) to the heat recovery machine (3). Water is continuously transferred from water tank 3 (9) to the heat pump (1 ) from 2 different directions via water pumps (10). The electrical energy required for the operation of said heat pump (1 ) is provided through the PV panel (11 ) connected to the heat pump (1).

[0085] With the automation system within the system, control valves direct the fluids. In this way, the system will be designed for multiple different situations.

[0086] In summary, the invention is demonstrated by the cooperation of sections A shown in figure 2, B shown in figure 3 and C shown in figure 4.

[0087] As can be seen from the cross-sectional view A shown in Figure 2, there is a water flow between the heat pump (1 ) and the water tank 3 (9). Water transfers between each other (from water tank 3 (9) to heat pump (1)) are carried out by water pumps (10). The energy required for the operation of the heat pump is provided by the PV panel (11). The water required for water tank 3 (9) is supplied by the ram heat recovery machine (3).

[0088] As can be seen from the cross-sectional view B in Figure 3, the stenter (2) is connected to the stenter heat recovery machine (3) and provides the hot flue gas transfer that the heat recovery machine (3) needs to operate. Simultaneously with the mentioned situation, the steam boiler (4) operates in connection with the jet machine (5).

[0089] As can be seen from the C section view shown in Figure 4, water tank 1 (7) is connected to the waste water recovery machine (6); the waste water recovery machine (6) is also connected to water tank 2 (8). Water is transferred from water tank 1 (7) to waste water recovery machine (6) and from waste water recovery machine (6) to water tank 2.

[0090] The protection scope of the invention is specified in the appended claims and cannot be limited to the description made for illustrative purposes in this detailed description. Likewise, it is clear that a person skilled in the art can present similar embodiments in the light of the above descriptions without departing from the main theme of the invention.

Claims

CLAIMS1. Recovery mechanism for converting surplus water, which is characterized as waste especially in institutions / organizations operating in industry, into steam with a heat pump and to ensure energy production / saving with the said water, characterized by comprising of;• Heat pump (1 ), which aims to produce steam by increasing the temperature of excess water, which is considered waste;• Stenter machine (2) which works with natural gas energy and provides the temperature required for the operation of the stenter heat recovery system (3);• Ram heat recovery machine (3) which obtains hot water by taking the flue gas heat that occurs after the operation of said stenter machine (2) and is considered as waste;• Wherein, if the steam produced by the heat pump (1 ) in the facility is not at the desired pressure and temperature, the fluid will be directed to the flash tank (12) and steam will be produced,• Steam boiler (4) used for generating steam in cases where the amount of steam produced by the heat pump (1 ) in the plant is insufficient;• Jet machine (5) that uses steam as an energy source and produces hot water with waste dye as a result of its processes;• Waste water recovery machine (6) to heat the water by recovering the heat of the waste hot water generated in said jet machines (5);• Water tank 1 (7); water tank 2 (8) and water tank 3 (9), to provide water supply to the system at different temperatures;• Water pump (10) to ensure continuous transfer of the recovered heated water to the area where it will be used.

2. Recovery mechanism according to claim 1 , characterized by comprising PV panel that meets the electricity needs required to operate the heat pump (1 ).

3. Recovery method for recovering excess hot water, which is considered waste, obtaining steam with a heat pump and producing / saving energy with said water characterized in that; it repeats the following process steps in the form of a loop;i. heating the dye-containing wastewater at 50-70°C and the water at an average of 20°C to an average of 45-60°C in the waste water recovery machine (6); ii. Transferring the mains water, whose temperature is increased to an average of 45-60°C in the waste water recovery machine (6), to the jet machine as feed water; iii. Transferring the water obtained from the waste water recovery machine (6) to water tank 2 (8); iv. Sending the water, which is kept at an average of 40-60°C in water tank 2 (8), to the ram heat recovery mechanism and heating the same to 60-70°C; v. Transferring the water with increased temperature to water tank 3 (9); vi. Obtaining steam from water at 45-70°C through a heat pump (1 ); vii. The water with a temperature of 45-60 oC coming out of the heat pump (1) is transferred back to the water tank 2 (8) and the mentioned process steps are repeated in a cycle; viii. it comprises the following method steps; Obtaining steam from the heat pump (1 ) at 3 bar 120-130°C; ix. Directing the fluid to the flash tank (12) and obtaining steam here if the steam produced by the heat pump (1 ) in the plant is not at the desired pressure and temperature.

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