Integrated Boiler Condensate Siphon With Single-Float Pump Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current condensate removal units for boilers are bulky due to the need for multiple components, including a siphon device and an auxiliary tank, which increases production costs and requires two floaters for operation.
Innovation Solution
A compact condensate removal unit integrating a siphon device with a single floater that serves both as a safety element against fume passage and a device for operating the discharge pump, eliminating the need for an auxiliary tank and reducing the number of floaters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a siphon device and an auxiliary tank are used together, then condensate removal reliability is improved, but device complexity and volume increase
Solution Approach 1:
The patent merges the siphon device and auxiliary tank into a single integrated unit. The siphon's hollow body serves as both the siphon chamber and the auxiliary tank, eliminating the need for separate components. The pump is directly integrated into the siphon structure, creating a compact unified system that maintains reliability while reducing complexity.
Solution Approach 2:
The hollow body of the siphon device performs multiple functions: it serves as the siphon chamber for preventing fume escape, as the auxiliary tank for condensate storage, and as the housing for the discharge pump. This multi-functionality eliminates the need for separate dedicated components, reducing overall device complexity.
2Reliability
If two floaters are used (one for siphon, one for pump), then operational reliability is improved, but manufacturing cost increases
Solution Approach 1:
A single floater is designed to perform multiple functions: it acts as the safety element for the siphon device and simultaneously controls the discharge pump operation. The floater's position changes trigger both the siphon activation and pump control, eliminating the need for a second separate floater and reducing manufacturing costs.
Solution Approach 2:
The control functions for both the siphon device and discharge pump are merged into a single floater mechanism. The floater's movement simultaneously controls both systems, consolidating what would traditionally require two separate floaters into one component, thereby reducing production costs.
3Quantity of substance
If an auxiliary tank is added, then condensate collection capacity is improved, but device volume increases
Solution Approach 1:
The auxiliary tank function is merged with the siphon device's hollow body. The same chamber that contains the siphon mechanism also serves as the condensate collection tank, eliminating the need for an additional separate tank and thereby reducing the overall device volume while maintaining collection capacity.
Solution Approach 2:
The pump is nested within the hollow body of the siphon device, and the condensate collection space is integrated within the same structure. This nesting arrangement allows multiple functions to coexist in a compact configuration, maximizing space utilization and minimizing overall device volume.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The integrated design results in a more compact and cost-effective solution that ensures efficient condensate removal while preventing fume escape and ensuring the pump operates only when necessary, avoiding dry running.
Implementation Method 1
a siphon to prevent the release of fumes from the condensate outlet
Implementation Method 2
The hollow body comprises a first branch, to which a condensate inlet pipe is linked, and a second branch, hydraulically linked to a condensate outlet pipe
Implementation Method 3
the inlet branch of the siphon device is provided with a floater which is intended to prevent the passage of fumes to the environment
Implementation Method 4
pumping means for discharging the condensate
Implementation Method 5
the water discharge line can be found on the surface above the one on which the boiler is installed. A pump must therefore be installed in order to pump the condensate to a height of 3÷5 m
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A condensate removal unit (10) in a boiler (100). The removal unit (10) comprises: (f1) a siphon (13) adapted to prevent the release of fumes from the condensate outlet; (f2) a condensate collecting device (13); (f3) a pump (41) for discharging the condensate itself; and (f4) a control device (30) of the pump (41) according to the condensate level in the collecting device (13). The removal unit is characterized in that the siphon (13), the condensate collecting device (13) and the pump (41) are integrated in a single compact apparatus.