Steam Condenser for Tire Vulcanization Heat Recovery
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Solution Overview
Problem
Existing methods for tire vulcanization do not effectively recover the thermal energy contained in hot steam, leading to inefficiencies and environmental impacts in tire manufacturing processes.
Innovation Solution
A method involving a multi-stage steam condenser with countercurrent water sprinkling, where hot water vapor is cooled and condensed, with the heated water collected and reused in a heat exchanger to supply thermal energy to a consumer, while being circulated back to the condenser, operated at ambient pressure without affecting the vulcanization process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If hot water vapor is discharged outside via an exhaust pipe after tire vulcanization, then the vulcanization process is simple and quick, but thermal energy is lost without recovery
Solution Approach 1:
A steam condenser is introduced as an intermediary device between the vulcanization press and the environment. The condenser receives hot water vapor from the press, condenses it to recover thermal energy, and dissipates only condensed water vapor to the environment. This intermediary system enables energy recovery without complicating the core vulcanization process.
Solution Approach 2:
The harmful factor (excess thermal energy) is extracted from the discharge stream by separating the condensation process from the exhaust process. The steam condenser extracts thermal energy from the hot water vapor before discharge, allowing energy recovery while maintaining simple vulcanization operation.
2Loss of energy
If a steam condenser is introduced to recover thermal energy, then energy recovery efficiency increases, but the vulcanization cycle time may be affected
Solution Approach 1:
The system is segmented into independent functional units: the vulcanization press operates independently for tire curing, while the steam condenser operates independently for energy recovery. The condenser receives vapor from the press without interfering with the press's vulcanization cycle, allowing parallel operation that prevents time loss.
Solution Approach 2:
The steam condenser operates continuously to condense and recover thermal energy from vapor discharged during vulcanization. This continuous energy recovery process occurs in parallel with the vulcanization cycle, ensuring that energy recovery does not interrupt or prolong the tire curing process.
3Loss of energy
If multiple spray levels are used in the steam condenser for efficient condensation, then energy recovery effectiveness increases, but device complexity increases
Solution Approach 1:
The condenser uses multiple spray levels arranged vertically in the vertical dimension. This multi-level configuration increases condensation efficiency by providing multiple contact points for vapor condensation without significantly increasing horizontal space requirements or overall system complexity.
Solution Approach 2:
The condenser utilizes phase transition (condensation) of water vapor at multiple levels. By spraying cooling water at different heights, the system creates multiple zones where vapor condenses, efficiently recovering thermal energy through repeated phase change processes in a compact vertical arrangement.
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 method allows for simple and effective recovery of thermal energy, improving the eco-balance of tire factories by efficiently recovering a large part of the heat input without prolonging the vulcanization cycle and reducing fixed costs.
Implementation Method 1
the hot water vapor being fed and cooled in countercurrent to a cooling medium in the form of water, the water being heated and collected in a collection container
Implementation Method 2
Feeding the hot water vapor into a steam condenser, which is designed in multiple stages with superimposed water sprinkling devices, the hot water vapor being fed and cooled in countercurrent to a cooling medium in the form of water
Implementation Method 3
removing the heated water from the collecting tank and supplying the heated water to a heat exchanger, with thermal energy being removed from the heat exchanger and supplied to a consumer
Data Source
Figure 1
AI summary
To create a process in which the thermal energy contained in the hot water steam can be recovered with high efficiency, a process with the following steps is proposed: a) Performing tire vulcanization with a vulcanizing press (1) and in conjunction with hot water steam (16), b) Discharging the hot water steam (16) from the vulcanizing press (1) via a hot water steam collector (2), c) Feeding the hot water steam (16) into a steam condenser (3), whereby the hot water steam (16) is passed countercurrently to a cooling medium in the form of water and cooled, whereby the water is heated and collected in a collection tank (9), d) Discharging the heated water from the collection tank (9) with a pump (10) and feeding the heated water into a heat exchanger (11), e) Discharging the cooled water from the heat exchanger (11), f) Returning the cooled water to the steam condenser (13)wherein the water is essentially circulated and the waste heat energy is extracted at the heat exchanger (11) and supplied to a consumer.