Single Heat Exchanger Steam Generation from Low-Grade Waste Heat
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Solution Overview
Problem
Current heat recovery methods are inefficient in generating high-temperature steam from low-grade waste heat sources, often requiring additional energy and equipment, which increases costs and energy consumption.
Innovation Solution
A heat recovery apparatus utilizing a single heat exchanger, compressor, and pressure drop device to circulate refrigerant, allowing for the generation of high-temperature steam (120 °C or more) from low-grade waste heat (70 °C or more) through optimized temperature and pressure ratios, reducing the need for external steam sources and additional heat supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional heat recovery methods are used to generate high-temperature steam from low-grade waste heat, then additional energy and equipment are required, but system complexity and initial costs increase
Solution Approach 1:
The patent combines the heat exchange and steam generation functions into a single integrated heat exchanger system. The waste heat from industrial processes is directly utilized to evaporate water and generate high-temperature steam (120°C or more) in one device, eliminating the need for separate steam generation equipment and reducing system complexity while achieving the desired temperature output
Solution Approach 2:
The patent changes the operational parameters of the heat exchanger, specifically operating it at pressures above atmospheric pressure (e.g., 2-20 bar). This parameter change allows the heat exchanger to generate high-temperature steam directly from low-grade waste heat (70-90°C) without requiring additional heating stages or equipment, thus reducing system complexity while maintaining high steam temperature
2Temperature
If conventional heat recovery methods are used to generate high-temperature steam from low-grade waste heat, then additional equipment is required, but initial system costs increase
Solution Approach 1:
The patent combines the heat exchange and steam generation functions into a single integrated heat exchanger system. The waste heat from industrial processes is directly utilized to evaporate water and generate high-temperature steam (120°C or more) in one device, eliminating the need for separate steam generation equipment and reducing system complexity while achieving the desired temperature output
Solution Approach 2:
The heat exchanger is designed to perform multiple functions: it serves as both the heat exchange device and the steam generation device. By making the heat exchanger universal, the system eliminates the need for dedicated steam boilers or additional heating equipment, thereby reducing initial system costs while still producing high-temperature steam from low-grade waste heat
3Loss of energy
If waste heat of 70-90°C is discarded without recovery, then energy efficiency is reduced, but no additional equipment or cost is incurred
Solution Approach 1:
The heat exchanger system is designed to automatically generate high-temperature steam using the available waste heat (70-90°C) as its sole heat source. The system serves itself by utilizing the waste heat that would otherwise be discarded, converting it directly into useful high-temperature steam without requiring external energy input or complex additional equipment, thus improving energy efficiency while maintaining simple system architecture
Solution Approach 2:
The patent changes the operational parameters of the heat exchanger, specifically operating it at pressures above atmospheric pressure (e.g., 2-20 bar). This parameter change allows the heat exchanger to generate high-temperature steam directly from low-grade waste heat (70-90°C) without requiring additional heating stages or equipment, thus reducing system complexity while maintaining high steam temperature
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
This approach efficiently generates high-temperature steam using only one heat exchanger, maximizing energy savings and reducing initial system costs by leveraging waste heat, thereby enhancing energy efficiency in industrial processes.
Implementation Method 1
the first heat exchanger (101) is included in the heat recovery apparatus 10 in order to heat-exchange the refrigerant flow with the fluid flow flowing from the outside
Implementation Method 2
Through the heat exchange, the refrigerant is evaporated
Implementation Method 3
a compressor 102...the refrigerant with a vapor phase flow having a temperature relatively higher than that of the refrigerant flow flowing into the first heat exchanger may flow out of the first heat exchanger 101
Implementation Method 4
a second heat exchanger 103...exchanges heat with the discharged refrigerant to become superheated steam
Implementation Method 5
The evaporated water enters a second heat exchanger, which serves as a desuperheater in the heat pump circuit, and exchanges heat with the discharged refrigerant
Implementation Method 6
a pressure drop device 104...exchanges heat with the discharged refrigerant to become superheated steam at said pressure
Data Source
Figure 1~4
AI summary
The present application relates to a heat recovery apparatus and a method thereof, according to the heat recovery apparatus and a method thereof according to an embodiment of the present application, steam of 120 °C or more may be generated using only one heat exchanger using waste heat of a low-grade heat source in the state of a sensible heat of 70 °C or more discharged in industrial sites or various chemical processes, for example, such as a manufacturing process of petrochemicals, and the generated steam may also be used in various processes, and thus the use of high temperature steam which is an external heat source to be used in a reactor or a distillation column may be decreased, thereby maximizing energy saving efficiency.