Heat Pump Starch Processing Using Paper Machine Waste Heat
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Solution Overview
Problem
Conventional methods for making paper hydrophobic require significant energy consumption due to the use of live steam for heating starch, leading to high production costs and environmental impact.
Innovation Solution
A paper machine equipped with a heat pump that utilizes waste heat from the papermaking process to heat the starch to a process temperature, reducing energy consumption and enabling the use of alternative, eco-friendly refrigerants like R-1233zd and R-1336mzz, which increases the coefficient of performance and allows for fossil fuel-independent starch processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If live steam from a steam generator is used to heat starch, then the starch reaches the required process temperature for hydrophobization, but energy consumption increases significantly
Solution Approach 1:
The invention captures waste heat from the paper machine drying section (a harmful energy loss) and converts it into useful thermal energy for heating starch through a heat pump system, thereby reducing the need for additional live steam generation and lowering overall energy consumption
Solution Approach 2:
A heat transfer medium circulates through a closed circuit between the waste heat source (drying section) and the starch heating system, acting as an intermediary to transfer thermal energy efficiently without direct contact between the two systems
2Use of energy by moving object
If a heat pump system is implemented to utilize waste heat, then energy consumption is reduced, but device complexity increases
Solution Approach 1:
The heat pump system serves multiple functions: it captures waste heat from the drying section, heats the heat transfer medium, and delivers thermal energy to the starch heating system, thereby reducing overall energy consumption while integrating into the existing paper machine infrastructure
Solution Approach 2:
The heat transfer medium circulates continuously in a closed loop, constantly absorbing waste heat from the drying section and delivering it to the starch, ensuring uninterrupted thermal energy transfer and maintaining process efficiency
3Reliability
If conventional steam generation is used, then starch heating is reliable, but environmental impact increases due to fossil fuel dependence
Solution Approach 1:
The invention converts waste heat (an otherwise useless byproduct) into valuable thermal energy for starch heating, eliminating the need for additional fossil fuel combustion and reducing carbon emissions while maintaining heating reliability
Solution Approach 2:
The paper machine's own waste heat serves the dual purpose of maintaining drying section temperature and heating the starch, making the system self-sufficient and independent of external fossil fuel sources
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 solution significantly reduces energy consumption and production costs by efficiently utilizing waste heat, making the papermaking process more environmentally friendly and independent of fossil fuels, while maintaining the hydrophobic properties of the paper.
Implementation Method 1
an evaporator for absorbing thermal energy from the waste heat flow by evaporating the heat transfer fluid
Implementation Method 2
a condenser for releasing thermal energy by condensing the evaporated heat transfer fluid
Implementation Method 3
a heat pump that absorbs thermal energy from a waste heat stream of the papermaking process and releases it to heat the starch to a process temperature
Data Source
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AI summary
The invention relates to a device (1) and a method for processing starch (3) for the water repellent treatment of paper. The device (1) comprises a heat pump (5) which absorbs thermal energy from an exhaust heat flow (9) from the production of paper, and releases it in order to heat the starch (3) up to a processing temperature.