TWI841185B - Intelligent control system for heat exchanger to remove condensate - Google Patents

Abstract

An intelligent control system for removing condensed water from a heat exchanger is characterized in that: a first power control valve and a second power control valve are respectively installed on the original discharge pipeline; an intelligent monitoring system is set in a computer device, which presets a temperature rise curve. When the temperature starts to rise, the first power control valve opens, and when the set temperature of the temperature rise curve is reached, the first power control valve closes; when the equipment temperature cannot keep up with the preset temperature rise curve, the second power control valve is opened at the same time; further, when the steam pressure of the equipment is sufficient, the two power control valves are all closed to avoid wasting steam, effectively solving the problem of unnecessary consumption of steam energy in traditional mechanical steam drainers.

Description

Intelligent control system for heat exchanger to remove condensate

The present invention relates to an intelligent control system for removing condensed water from a heat exchanger, and more particularly to a device for removing condensed water by intelligently controlling two power control valves in coordination with the temperature rise curve and steam pressure of the equipment.

Heat exchangers are needed in some equipment. For example, in the dyeing process of high-temperature and high-pressure dyeing machines, a large amount of steam is needed to heat the dyeing water through a shell-and-tube gas-water heat exchanger. During the heat exchange process, the steam is cooled to produce a large amount of high-temperature condensate water. This part of the condensate water needs to be discharged from the steam pipeline in time, otherwise a lot of heat will be absorbed by the condensate water on the air side, and the air temperature will drop to the water-gas two-phase point (boiling point), which will affect the heat exchange effect.

Since such equipment needs to control the heating rate, the steam valve is opened and closed under control, causing the pressure in the pipe to change continuously. If there is condensed water, a water hammer effect (water hammer, or water hammer) will occur at the water accumulation point, which not only causes noise pollution, but also causes damage to the dyeing and finishing equipment in serious cases. Therefore, each dyeing machine must be equipped with a steam trap (steam trap, or drain valve) to discharge the condensed water in time.

As shown in FIG. 1 , the structure of a common dyeing machine generally includes: a body 110 having a machine head 111 and a cloth storage tank 112, and a cloth wheel 113 and a nozzle 114 are arranged in the machine head 111; a dye supply unit 120, in which the dye sucked from the dosing tank 122 by the dosing pump 123 is sent to the heat exchanger 130 through the conveying pipeline 124 and then to the nozzle 114; a cloth guide pipe 140 is connected from the nozzle 114 to the tail of the body 110, and forms a loop with the body 110 for the cloth 141 to be circulated and dyed.

Furthermore, the heat exchanger 130 of a general dyeing machine is connected to a steam inlet 131 and a cooling water inlet 132, and a boiler (not shown) provides steam and dye liquid for heat exchange, and the heat exchanger 130 is connected to a condensate recovery pipeline 150, which includes a cooling water outlet 151, a condensate outlet 152 and a manual drain outlet 153.

As shown in FIG. 2 , it is an enlarged schematic diagram of the structure of the condensate recovery pipeline 150 in FIG. 1 , wherein the condensate outlet 152 is equipped with a mechanical steam dehumidifier 154. However, it is found that the mechanical steam dehumidifier 154 will only discharge when there is condensate, so it is more suitable for equipment with a fixed steam usage, and cannot be used for equipment with a large change in steam usage. For example, a dyeing machine needs to rely on steam heating to perform heat exchange dyeing, but the source of steam sometimes fluctuates, causing the mechanical steam dehumidifier 154 to operate abnormally. In addition, the heating part of the equipment sometimes needs to be directly heated, sometimes needs to be heated in stages, and sometimes needs to be kept warm. Because of such changes in the heating curve, the traditional mechanical steam dehumidifier 136 is less applicable and wastes energy. In other words, the biggest problem with the mechanical steam degassing device 154 is that a large amount of steam will leak when draining water. If the amount of steam leakage is calculated by time, the steam leakage of a 5mm diameter drain hole under a steam pressure of 6 bar g is about 50 kg/hour. Taking half of the steam leakage, 25 kg/hour, as an example, if the equipment operates 50 weeks a year, 5 days a week, and 24 hours a day, the steam leakage of this degassing device is about 150 tons/year. At present, the cost of steam in Taiwan is about 1,500 yuan/ton. After one year of use of a mechanical steam degassing device, the leakage amount of each degassing device is about NT$225,000/year. Therefore, mechanical steam dehumidifiers cannot avoid the defect of steam leakage, it’s just a matter of how much leakage there is. Moreover, the longer the use time, the more leakage there will be, resulting in direct energy waste.

In view of the above problems, the inventor has been adhering to the spirit of continuous improvement and actively researching and improving, in order to effectively solve the shortcomings of conventional mechanical steam dehumidifiers.

Therefore, the main purpose of the present invention is to provide an intelligent control system for removing condensed water from a heat exchanger, which effectively solves the problem of unnecessary consumption of steam energy in traditional mechanical steam drainers and has improved energy-saving effects.

To achieve the above-mentioned purpose, the technical means adopted by the present invention include: an apparatus, including a carcass and a heat exchanger, the heat exchanger is arranged outside the carcass, is provided with an input pipeline and a discharge pipeline, and is connected to the carcass by a liquid input pipe; The characteristics are: a first power control valve and a second power control valve are respectively installed on the exhaust pipeline; a computer device includes a controller, and the controller is electrically connected to the first power control valve and the second power control valve, respectively, for controlling them to open (OPEN) or close (CLOSE); a temperature sensor is arranged on the device and electrically connected to the controller, for reporting the detected temperature to the controller in real time; a pressure sensor is arranged on the device and electrically connected to the controller, for reporting the detected pressure to the controller in real time; and An intelligent monitoring system is installed in the computer device, which presets a temperature rise curve. When the equipment starts to heat up, the controller opens the first power control valve (OPEN). When the set temperature of the temperature rise curve is reached, the first power control valve is closed (CLOSE). When the temperature of the equipment cannot keep up with the temperature rise curve, the controller opens the second power control valve (OPEN) at the same time. Furthermore, when the steam pressure of the equipment is sufficient, the first power control valve and the second power control valve are all closed (CLOSE) to avoid wasting steam.

According to the aforementioned features, the first power control valve and the second power control valve may be composed of either an electric valve or a pneumatic valve.

According to the aforementioned features, the first power control valve and the second power control valve may include two power control valves having the same drainage hole diameter.

According to the aforementioned features, the first power control valve and the second power control valve may include two power control valves with different drainage hole diameters.

With the help of the above-mentioned technical means, the present invention uses two power control valves to cooperate with the temperature rise curve of the equipment and the steam pressure to intelligently control the removal of condensed water to control the steam to increase, decrease or turn off. Therefore, it will not be like the fixed discharge method of the traditional mechanical steam dehumidifier, which cannot control the size and waste steam; thus effectively solving the problem of unnecessary energy consumption of the traditional mechanical steam dehumidifier, and has the effect of saving at least 30% of steam.

The following is a specific embodiment to illustrate the implementation of the invention. People familiar with the art can easily understand other advantages and effects of the invention from the contents disclosed in this manual. The invention can also be implemented or applied through other different specific embodiments, and the details in this manual can also be modified and changed based on different viewpoints and applications without departing from the spirit of the invention.

First, please refer to Figures 3 to 7. A preferred embodiment of the present invention includes: an apparatus 10, including a carcass 20 and a heat exchanger 30. The heat exchanger 30 is arranged outside the carcass 20, and is provided with an input pipeline 31 and a discharge pipeline 40. The input pipeline 31 is provided with a steam inlet 311 and a cooling water inlet 312. In this embodiment, the apparatus 10 is a dyeing machine, but it is not limited to this. Any apparatus having a heat exchanger 30 can be implemented. The following description takes the dyeing machine as an example for easy understanding.

As shown in FIG3 , in this embodiment, the liquid (dye solution in this embodiment) L of the dyeing machine 10 is sent into the heat exchanger 30 through a delivery pipeline 32 for heat exchange, and then connected to the nozzle 24 in the head 21 of the body 20 through a liquid delivery pipe 33; in addition, the dyeing machine 10 basically includes: a cloth storage tank 22 arranged in the body 20, a cloth wheel 23 in the head 21; and a cloth guide pipe 25, which is connected from the nozzle 24 to the tail of the body 20 and forms a loop with the body 20 for the cloth C to be circulated and dyed. However, the above structure belongs to the prior art of the dyeing machine 10, which is not the subject of this patent and will not be described in detail.

The main feature of the present invention is that a first power control valve 41 and a second power control valve 42 are respectively installed on the original discharge pipeline 40 of the heat exchanger 30 of the equipment 10; in this embodiment, the first power control valve 41 and the second power control valve 42 can be composed of either an electric valve or a pneumatic valve. FIG5 shows a three-dimensional external view of a feasible embodiment of the power control valve of the present invention, which includes a valve body 411 and a power control member 412 arranged above the valve body 411. The power control member 412 shown in FIG5 is a pneumatic control member, which belongs to a pneumatic valve type. Similarly, if the internal part of the power control member 412 is composed of a motor, it belongs to an electric valve type (not shown). However, it is found that both electric valves and pneumatic valves are mature products on the market, and their detailed structures and control circuits are not the subject of this patent and need not be described in detail. The present invention mainly uses a first power control valve 41 and a second power control valve 42 to replace the conventional mechanical drain 154 and manual drain 153 in FIG. 2 to control the discharge time and discharge speed of condensed water (W) to optimize. In this embodiment, the discharge pipeline 40 further includes a manual drain valve 43 with a cooling water outlet, but the manual drain valve 43 belongs to the prior art and need not be described in detail.

In this embodiment, the first power control valve 41 and the second power control valve 42 may include two valves with the same drainage hole diameter (D). However, this is not limited to this. The actual drainage hole diameter needs to be set according to the model and capacity of the device 10. It may include two valves with different drainage hole diameters (D), which can also be implemented to control the optimization of the discharge flow rate and speed of the condensed water (W).

Please refer to FIG. 3 and FIG. 4 . The present invention needs to include a computer device 50, which includes a host (such as a server) and a display unit. A controller 51 can be set in the computer device 50, and the controller 51 is electrically connected to the first power control valve 41 and the second power control valve 42 to control them to open (OPEN) or close (CLOSE). In this embodiment, the "electrical connection" includes wired transmission or wireless transmission to control the first and second power control valves 41, 42 to open or close, which can be implemented.

As mentioned above, a temperature sensor 60 is provided on the device 10 and is electrically connected to the controller 51, so as to report the detected temperature to the controller 51 in real time; a pressure sensor 70 is provided on the device 10 and is electrically connected to the controller 51, so as to report the detected pressure to the controller 51 in real time.

An intelligent monitoring system 52 is installed in the computer device 50, and a temperature rise curve 53 is preset, as shown in FIG6 . The “solid line” in the figure is the temperature rise curve 53 set according to the requirements of the dyed fabric. When the device 10 starts to heat up (e.g., 20-80 degrees C stage), the controller 51 opens the first power control valve 41. When the temperature reaches the set temperature of the temperature rise curve 53, the first power control valve 41 closes. When the temperature of the device 10 cannot keep up with the temperature rise curve 53 (e.g., the position indicated by A in the dotted line), the controller 51 opens the second power control valve 42 at the same time. Furthermore, when the steam pressure of the device 10 is sufficient, the controller 51 closes both the first power control valve 41 and the second power control valve 42 to avoid wasting steam.

FIG. 7 shows a flow chart of a preferred implementation of the present invention. The intelligent monitoring system 52 of the computer device 50 is controlled according to this implementation flow chart. The process includes S1 to S6, wherein: S1 : A first power control valve 41 and a second power control valve 42 are respectively installed on the exhaust pipe 40 of the device 10; →S2 : When the device 10 starts to heat up, the first power control valve 41 is opened first; →S3 : Determine whether the device 10 reaches a preset temperature rise curve 53, if "yes", return to →S2, if "no", go to the next process; →S4 : Open the second power control valve 42; →S5 : Detect whether the steam pressure of the device 10 is sufficient. If "no", return to →S4 and the second power control valve 42 continues to be opened. If "yes", go to the next process; →S6 : Close the first and second power control valves 41 and 42 to avoid wasting steam.

With the help of the above-mentioned technical means, the present invention has the following effects that need to be further explained: 1. The present invention uses the first and second power control valves 41 and 42, in conjunction with the temperature rise curve 53 of the equipment 10 and the steam pressure, to remove condensed water with the intelligent monitoring system 52 to control the steam to be turned on, turned off or turned off. Therefore, it will not be like the fixed discharge method of the traditional mechanical steam water heater, which cannot control the size and waste steam; thus effectively solving the problem of energy consumption of the traditional mechanical steam water heater, and having the effect of saving at least 30% of steam. 2. The present invention uses the intelligent monitoring system 52 to remove condensed water (C), so that the body 20 of the equipment 10 is close to the preset temperature rise curve 53, which can achieve the effect of making the dye liquid have a uniform temperature and improving the dyeing quality of the dyed object. 3. The intelligent monitoring system 52 of the present invention can discharge condensed water in time, reduce the water hammer effect, avoid damage to the equipment and water hammer noise, and has the effect of increasing the service life.

In summary, the technical means disclosed in this invention do meet the patent requirements of invention such as "novelty", "progressiveness" and "availability for industrial application". We pray that the Bureau of Justice will grant us a patent to encourage inventions, without any sense of gratitude.

However, the above disclosed drawings and descriptions are only preferred embodiments of the present invention. Any modifications or equivalent changes made by persons skilled in the art according to the spirit and scope of the present invention should still be included in the scope of the patent application of the present invention.

10: Equipment 20: Carcass 21: Machine head 22: Cloth storage tank 23: Cloth wheel 24: Nozzle 25: Cloth guide pipe 30: Heat exchanger 31: Input pipeline 311: Steam inlet 312: Cooling water inlet 32: Transport pipeline 33: Dye liquid input pipe 40: Discharge pipeline 41: First power control valve 42: Second power control valve 411: Valve body 412: Power control element 43: Manual drain valve 50: Computer device 51: Controller 52: Intelligent monitoring system 53: Temperature rise curve 60: Temperature sensor 70: Pressure sensor L: Liquid C: Cloth W: Condensate

Figure 1 is a schematic diagram of the structure of a conventional dyeing machine. Figure 2 is an enlarged schematic diagram of the structure of the condensate recovery pipeline of a conventional dyeing machine. Figure 3 is a schematic diagram of the structure of a preferred feasible embodiment of the present invention. Figure 4 is a schematic diagram of the structure and control of a condensate recovery pipeline of the present invention. Figure 5 is a three-dimensional diagram of the appearance of the power control valve of the present invention. Figure 6 is a temperature rise curve diagram of a feasible embodiment of the present invention. Figure 7 is a flowchart of a preferred feasible implementation of the present invention.

10: Equipment

20: Body

30: Heat exchanger

40: Discharge pipeline

41: First power control valve

42: Second power control valve

43: Manual drain valve

50:Computer equipment

51: Controller

52: Intelligent monitoring system

53: Heating curve

60: Temperature sensor

70: Pressure sensor

Claims (4)

An intelligent control system for removing condensed water from a heat exchanger comprises: An equipment including a carcass and a heat exchanger, the heat exchanger being arranged outside the carcass, and having an input pipeline and a discharge pipeline, and being connected to the carcass by a liquid input pipe; Its characteristics are: A first power control valve and a second power control valve are respectively installed on the discharge pipeline; A computer device including a controller, and the controller is respectively electrically connected to the first power control valve and the second power control valve to control them to open (OPEN) or close (CLOSE); A temperature sensor is arranged on the equipment and electrically connected to the controller to report the detected temperature to the controller in real time; A pressure sensor is provided on the device and electrically connected to the controller to report the detected pressure to the controller in real time; and An intelligent monitoring system is provided in the computer device, which pre-sets a heating curve. When the device starts to heat up, the controller opens the first power control valve (OPEN). When the set temperature of the heating curve is reached, the first power control valve is closed (CLOSE); when the temperature of the device cannot keep up with the heating curve, the controller opens the second power control valve (OPEN) at the same time. Furthermore, when the steam pressure of the device is sufficient, the controller closes the first power control valve and the second power control valve (CLOSE) to avoid wasting steam. An intelligent control system for removing condensate from a heat exchanger as described in claim 1, wherein the first power control valve and the second power control valve are composed of either an electric valve or a pneumatic valve. An intelligent control system for removing condensate from a heat exchanger as described in claim 2, wherein the first power control valve and the second power control valve comprise two power control valves having the same drainage hole diameter. An intelligent control system for removing condensate from a heat exchanger as described in claim 2, wherein the first power control valve and the second power control valve include two power control valves with different drainage hole diameters.

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