US20110220326A1 - Energy recovery unit - Google Patents

Energy recovery unit Download PDF

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Publication number
US20110220326A1
US20110220326A1 US13/045,204 US201113045204A US2011220326A1 US 20110220326 A1 US20110220326 A1 US 20110220326A1 US 201113045204 A US201113045204 A US 201113045204A US 2011220326 A1 US2011220326 A1 US 2011220326A1
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US
United States
Prior art keywords
condensate
recovery unit
energy recovery
unit according
vessel
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US13/045,204
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English (en)
Inventor
Amir AMINI
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Spirax Sarco Ltd
Original Assignee
Spirax Sarco Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Spirax Sarco Ltd filed Critical Spirax Sarco Ltd
Assigned to SPIRAX-SARCO LIMITED reassignment SPIRAX-SARCO LIMITED ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: AMINI, AMIR
Publication of US20110220326A1 publication Critical patent/US20110220326A1/en
Abandoned legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F22—STEAM GENERATION
    • F22D—PREHEATING, OR ACCUMULATING PREHEATED, FEED-WATER FOR STEAM GENERATION; FEED-WATER SUPPLY FOR STEAM GENERATION; CONTROLLING WATER LEVEL FOR STEAM GENERATION; AUXILIARY DEVICES FOR PROMOTING WATER CIRCULATION WITHIN STEAM BOILERS
    • F22D1/00—Feed-water heaters, i.e. economisers or like preheaters
    • F22D1/32—Feed-water heaters, i.e. economisers or like preheaters arranged to be heated by steam, e.g. bled from turbines
    • F22D1/325—Schematic arrangements or control devices therefor
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F22—STEAM GENERATION
    • F22D—PREHEATING, OR ACCUMULATING PREHEATED, FEED-WATER FOR STEAM GENERATION; FEED-WATER SUPPLY FOR STEAM GENERATION; CONTROLLING WATER LEVEL FOR STEAM GENERATION; AUXILIARY DEVICES FOR PROMOTING WATER CIRCULATION WITHIN STEAM BOILERS
    • F22D1/00—Feed-water heaters, i.e. economisers or like preheaters
    • F22D1/16—Feed-water heaters, i.e. economisers or like preheaters with water tubes arranged otherwise than in the boiler furnace, fire tubes, or flue ways
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F22—STEAM GENERATION
    • F22B—METHODS OF STEAM GENERATION; STEAM BOILERS
    • F22B3/00—Other methods of steam generation; Steam boilers not provided for in other groups of this subclass
    • F22B3/04—Other methods of steam generation; Steam boilers not provided for in other groups of this subclass by drop in pressure of high-pressure hot water within pressure-reducing chambers, e.g. in accumulators
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F22—STEAM GENERATION
    • F22D—PREHEATING, OR ACCUMULATING PREHEATED, FEED-WATER FOR STEAM GENERATION; FEED-WATER SUPPLY FOR STEAM GENERATION; CONTROLLING WATER LEVEL FOR STEAM GENERATION; AUXILIARY DEVICES FOR PROMOTING WATER CIRCULATION WITHIN STEAM BOILERS
    • F22D1/00—Feed-water heaters, i.e. economisers or like preheaters
    • F22D1/32—Feed-water heaters, i.e. economisers or like preheaters arranged to be heated by steam, e.g. bled from turbines

Definitions

  • steam is often generated in a boiler and transferred through pipework at high temperature and pressure to various industrial processes where the energy in the steam is utilized.
  • condensate can form, and it is common for this condensate to be collected at a lower part of the system and periodically removed by means of steam traps. It is common practice for steam traps to discharge to atmospheric pressure.
  • the condensate is liquid water under the high pressure prevailing within the system, its temperature may be above 100° C. and so it will turn to flash steam when vented to atmospheric pressure. The heat in the condensate is thus lost. This not only represents a waste of energy, but can also incur financial penalties under measures implemented to reduce usage of carbon fuels.
  • an energy recovery unit comprising: a vessel having a condensate inlet and a condensate outlet.
  • the unit may further include a fluid feed line defining a fluid path; and first and second heat exchangers located within the vessel and arranged to transfer heat from flash vapor and condensate respectively, to fluid in the fluid feed line.
  • the first heat exchanger may be located above the second heat exchanger in the vessel.
  • the first and/or second heat exchanger may comprise a plurality of heat transfer fins in thermal contact with the fluid feed line.
  • the plurality of fins may be stacked horizontally.
  • the condensate inlet may be arranged to direct condensate towards the second heat exchanger.
  • the condensate outlet may be located towards the bottom of the vessel.
  • the condensate outlet may be positioned at a location along a vertical axis that is more proximate to the bottom of the vessel than to the top.
  • the terms “above,” “top,” “below,” or “bottom” as used throughout this disclosure refer to the relationship/orientations along a vertical axis for the intended configuration of the condensate energy recovery unit described herein.
  • the condensate outlet may be located no more than 45% of the distance separating a top and a bottom (height).
  • the condensate unit may be about 30%, 25%, 20%, 15%, 10, or 5% of the distance from the bottom.
  • the condensate outlet may be one of two or more condensate outlets disposed at different levels in the vessel.
  • a condensate outlet pipe may connect one or more condensate outlets to a steam trap.
  • the energy recovery unit may further comprise a flash vapor outlet.
  • the flash vapor outlet may be located towards the top of the vessel.
  • a flash vapor outlet pipe may connect the flash vapor outlet to a pressure control valve.
  • the fluid feed line passes through the vessel and the fluid feed path passes through the first and the second heat exchangers.
  • the fluid feed line may be a boiler feed line.
  • a steam utilisation system including a condensate energy recovery unit in accordance with any statement herein.
  • FIG. 1 illustrates an example flash steam and condensate energy recovery unit in accordance with an aspect of the disclosure.
  • the illustrated condensate energy recovery unit 10 (hereinafter referred to as the energy recovery unit) comprises a cylindrical flash vessel 12 , having first and second circular end faces 12 a, 12 b, with first and second heat exchangers 14 , 16 located within the flash vessel 12 .
  • the flash vessel 12 may have a square cross-section and/or may be vertically orientated.
  • the first and second heat exchangers 14 , 16 are shown as finned-tube heat exchangers and the first heat exchanger 14 is located above the second heat exchanger 16 .
  • the first and second heat exchangers 14 , 16 each comprise a plurality of substantially circular fins that are horizontally stacked.
  • references to “horizontal” refer to alignment of the objects along a horizontal axis or plane.
  • the plurality of fins of heat exchangers 14 , 16 in the exemplary embodiment are parallel to one another and each fin lies in a vertical plane.
  • first and second heat exchangers 14 , 16 are finned-tube heat exchangers.
  • the heat exchangers 14 , 16 may be coiled pipes, heat pipes or loop heat pipes.
  • the first and second heat exchangers 14 , 16 may be separate portions of a single heat exchanger.
  • the illustrated energy recovery unit 10 is provided with a fluid feed line in the form of a boiler feed line 18 that defines a fluid path through the flash vessel 12 .
  • the boiler feed line 18 enters the flash vessel 12 through the first end wall 12 a and passes through the second heat exchanger 16 before exiting the flash vessel 12 through the second end wall 12 b.
  • the feed line 18 may be welded to the first and second end walls 12 a, 12 b.
  • the boiler feed line 18 then re-enters the flash vessel 12 through the second end wall 12 b and passes through the first heat exchanger 14 before exiting the flash vessel 12 through the first end wall 12 a .
  • the feed line 18 may be welded to the first and second end walls 12 a, 12 b.
  • the fins (or plates) of the first and second heat exchangers 14 , 16 are directly attached to the boiler feed line 18 and therefore the fluid path passes through the first and second heat exchangers 14 , 16 .
  • the inlet 20 and outlet 22 of the boiler feed line 18 may be provided with a coupling flange.
  • the portion of the boiler feed line 18 between the inlet 20 and the flash vessel 12 may be fitted with an-energy meter 24 , a temperature gauge 26 , an isolation valve 28 and a strainer 29 .
  • the feed line 18 may be provided with other suitable ancillaries.
  • the portion of the boiler feed line 18 between the flash vessel 12 and the outlet 22 is provided with an isolation valve 30 and a temperature gauge 32 .
  • the flash vessel 12 is shown as provided with first and second condensate outlets 34 , 36 .
  • the first condensate outlet 34 is shown as positioned at the bottom of the flash vessel 12 and the second condensate outlet 36 is located as being above the first condensate outlet 34 in the end wall 12 a of the flash vessel 12 .
  • the terms “above” or “below” refer to the relationship along a vertical axis during the intended configuration of the condensate energy recovery unit 10 .
  • second condensate outlet 36 is more distant from the ground or bottom surface than first condensate 34 , thus second condensate outlet is “above” the first condensate outlet 36 .
  • the first and second condensate outlets 34 , 36 are connected by pipe work 38 to a steam trap 39 .
  • the outlet 40 of the steam trap is provided with a coupling flange. As will be readily apparent to one skilled in the art, only one condensate outlet is necessary in certain embodiments.
  • the flash vessel 12 is also provided with a flash steam outlet 42 that is located at the top of the flash vessel 12 .
  • a flash outlet pipe 43 connects the flash steam outlet 42 to a pressure control valve 44 , the outlet 46 of which is provided with a coupling flange.
  • the illustrated energy recovery unit 10 also comprises a condensate inlet pipe 48 , a portion of which extends into the flash vessel 12 through the first end wall 12 a.
  • the portion of the condensate inlet pipe 48 located within the flash vessel 12 has a right-angle bend 49 that is angled downwards. In other embodiments the inlet pipe 48 may be straight.
  • the inlet pipe 48 provides the flash vessel 12 with a condensate inlet 50 (the outlet of the condensate inlet pipe 48 ) that is located towards the top of the stack of fins of the second heat exchanger 16 .
  • the condensate inlet 50 is located above the second condensate outlet 36 .
  • the portion of the condensate inlet pipe 48 located outside of the flash vessel 12 is provided with an isolation valve 52 , the inlet 54 of which is provided with a coupling flange.
  • the energy illustrated recovery unit 10 further comprises a bypass line 56 that provides fluid communication between the inlet 20 and outlet 22 of the boiler feed line 18 , bypassing the flash vessel 12 .
  • the inlet of the bypass line 56 is upstream of the isolation valve 28 and the outlet is downstream of the isolation valve 30 .
  • the bypass line 56 is also provided with its own isolation valve 58 .
  • the bypass line 56 allows the feed water to bypass the heat exchangers 14 , 16 of the energy recovery unit 10 .
  • the unit 10 may be in the form of a module or “skid” which is self-contained and can be assembled off site for connection to an existing system.
  • the components and associated pipework may be mounted on a rigid support so as to be transportable from an assembly facility to the site at which the unit will be utilized.
  • the pipework couplings of the unit are all situated and oriented in the unit so as to make connection to the associated existing pipework relatively simple. Thus they are situated at or close to the outer extremity of the unit and face outwardly, unobstructed by other pipes or ancillaries. Further, provided that the relative locations of existing pipework connectors are known, the unit can be assembled off site and can be installed rapidly once delivered to site by making the appropriate pipe work connections.
  • the coupling flanges of the energy recovery unit 10 may be connected to the existing pipework of a steam utilization system.
  • the illustrated energy recovery unit 10 is connected with the inlet 20 of the boiler feed line 18 connected to a feed tank (not shown) and the outlet 22 of the boiler feed line 18 connected to pipework leading to a boiler (not shown).
  • the outlet 40 of the steam trap 39 is connected to pipework leading to the feed tank (not shown) and the outlet 46 of the pressure control valve 44 is connected to an excess flash steam line (not shown).
  • the inlet 54 of the condensate inlet pipe 48 is connected to the steam utilization system such that condensate can enter the flash vessel 12 through the condensate inlet 50 of the flash vessel 12 .
  • isolation valves 28 , 30 of the boiler feed line 18 are open and the isolation valve 58 of the bypass line 56 is closed. This allows boiler feed water to flow from the feed tank, through the boiler feed line 18 of the energy recovery unit to the boiler.
  • the isolation valve 52 of the condensate inlet pipe 48 is open and therefore condensate enters the flash vessel 12 through the inlet 50 .
  • the pressure is reduced and consequently at least some of the condensate flashes into steam as it enters the flash vessel.
  • the flash steam rises within the flash vessel 12 and passes through the horizontal stack of fins of the first heat exchanger 14 .
  • the first heat exchanger 14 extracts thermal energy from the flash steam and transfers it to the boiler feed water flowing in the boiler feed line 18 .
  • the flash steam condenses and accumulates in the bottom of the flash vessel 12 .
  • the first heat exchanger 14 may thus operate as a vapor condenser.
  • the condensate passes through the horizontal stack of fins of the second heat exchanger 16 which extracts energy from the condensate and transfers it to the boiler feed water flowing in the boiler feed line 18 .
  • the second heat exchanger 16 may thus operates as a condensate cooler.
  • the location and size of the various inlets and outlets may be chosen so as to maintain a predetermined level of condensate within the flash vessel 12 .
  • the first heat exchanger 14 may be designed to transfer the maximum amount of energy from the flash steam to the boiler feed water.
  • the second heat exchanger 16 may be designed to transfer the maximum amount of energy from the condensate to the boiler feed water.
  • the first and second heat exchangers 14 , 16 may be designed differently in order to extract the maximum amount of thermal energy from steam and condensate respectively.
  • the first and second heat exchangers 14 , 16 may have different numbers of fins.
  • the boiler feed water may enter the boiler feed line 18 through the inlet 20 at a temperature of 85° C.
  • the water may be heated to approximately 115° C. by the second heat exchanger 16 , and from 115° C. to approximately 132° C. by the first heat exchanger 14 .
  • the energy meter 24 is capable of measuring the energy gained by the boiler feed water as it flows through the energy recovery unit.
  • the energy meter comprises three main components, namely; a flow meter, a pair of temperature sensors and a display for displaying the energy gained.
  • the temperature gauges 26 , 32 measure the temperature of the boiler feed water as it enters and exits the energy recovery unit 10 .
  • the energy recovery unit 10 can be isolated, without affecting the running of the steam utilizing system which it serves, by closing the isolation valves 28 , 30 of the boiler feed line 18 and opening the isolation valve 58 of the bypass line 56 .
  • the boiler feed water bypasses the first and second heat exchangers 14 , 16 and therefore the feed water is not preheated.
  • the flash vessel 12 can be inspected using an inspection hole 13 .
  • the energy recovery unit recovers energy from both flash steam and condensate and uses this steam to pre-heat boiler feed water. As the boiler feed water is preheated, the energy demand of the boiler is reduced.
  • Certain embodiments of the flash steam and condensate energy recovery unit 10 are designed so as to utilize off-the-shelf components, so that the unit can be constructed at relatively low cost, and so that any component requiring replacement can be replaced rapidly and economically. In practice, it is expected that the cost of the condensate recovery unit will be covered, by the resulting energy savings, in less than two years of standard operation under certain implementations.
  • Locating first and second heat exchangers 14 , 16 within a single vessel 12 reduces the overall size of the energy recovery unit when compared with prior art systems such as that disclosed in U.S. Pat. No. 4,878,457.
  • Embodiments disclosed herein also reduce the requirement for chemical additives that need to be added to any make-up water to maintain the required levels of chemicals in the boiler.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Control Of Steam Boilers And Waste-Gas Boilers (AREA)
  • Waste-Gas Treatment And Other Accessory Devices For Furnaces (AREA)
US13/045,204 2010-03-10 2011-03-10 Energy recovery unit Abandoned US20110220326A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB1003960.0 2010-03-10
GB1003960A GB2478569A (en) 2010-03-10 2010-03-10 Energy recovery unit with flash steam and condensate heat exchangers

Publications (1)

Publication Number Publication Date
US20110220326A1 true US20110220326A1 (en) 2011-09-15

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ID=42136751

Family Applications (1)

Application Number Title Priority Date Filing Date
US13/045,204 Abandoned US20110220326A1 (en) 2010-03-10 2011-03-10 Energy recovery unit

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US (1) US20110220326A1 (enExample)
EP (1) EP2369228B1 (enExample)
JP (1) JP2011185594A (enExample)
CN (1) CN102679317A (enExample)
GB (1) GB2478569A (enExample)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN107741010A (zh) * 2017-11-16 2018-02-27 陕西西咸新区博源能源工程有限公司 一种锅炉排污水余热与水资源回收再利用系统

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US2812164A (en) * 1953-09-17 1957-11-05 Lummus Co Heat exchanger
US2995341A (en) * 1959-01-08 1961-08-08 Griscom Russell Co Feed water heater sub-cooling zone
US3390722A (en) * 1965-12-16 1968-07-02 Worthington Corp Vertical feedwater heater drain coolers
US3795273A (en) * 1972-06-12 1974-03-05 Foster Wheeler Corp Feedwater heater
US3938588A (en) * 1973-10-18 1976-02-17 Westinghouse Electric Corporation Deaerating feedwater heater
US4224981A (en) * 1978-05-12 1980-09-30 Bbc Brown Boveri & Company Limited Feed-water heater for steam power plants
US4370949A (en) * 1979-11-21 1983-02-01 Ardell Beckett Waste heat recovery system
US4393816A (en) * 1982-02-10 1983-07-19 Bock Paul A Thermodynamic method for steam-water separation
US4462339A (en) * 1983-08-29 1984-07-31 Texaco Development Corporation Gas cooler for production of saturated or superheated steam, or both
US4679529A (en) * 1985-04-24 1987-07-14 Electricite De France Service National Steam generator feed water heater
US4878457A (en) * 1988-10-17 1989-11-07 Martin Bekedam Zero flash closed condensate boiler feedwater system

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1790306A (en) * 1931-01-27 hudson
US2060078A (en) * 1936-02-07 1936-11-10 James C Hobbs Heat exchanger
US2812164A (en) * 1953-09-17 1957-11-05 Lummus Co Heat exchanger
US2995341A (en) * 1959-01-08 1961-08-08 Griscom Russell Co Feed water heater sub-cooling zone
US3390722A (en) * 1965-12-16 1968-07-02 Worthington Corp Vertical feedwater heater drain coolers
US3795273A (en) * 1972-06-12 1974-03-05 Foster Wheeler Corp Feedwater heater
US3938588A (en) * 1973-10-18 1976-02-17 Westinghouse Electric Corporation Deaerating feedwater heater
US4224981A (en) * 1978-05-12 1980-09-30 Bbc Brown Boveri & Company Limited Feed-water heater for steam power plants
US4370949A (en) * 1979-11-21 1983-02-01 Ardell Beckett Waste heat recovery system
US4393816A (en) * 1982-02-10 1983-07-19 Bock Paul A Thermodynamic method for steam-water separation
US4462339A (en) * 1983-08-29 1984-07-31 Texaco Development Corporation Gas cooler for production of saturated or superheated steam, or both
US4679529A (en) * 1985-04-24 1987-07-14 Electricite De France Service National Steam generator feed water heater
US4878457A (en) * 1988-10-17 1989-11-07 Martin Bekedam Zero flash closed condensate boiler feedwater system

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN107741010A (zh) * 2017-11-16 2018-02-27 陕西西咸新区博源能源工程有限公司 一种锅炉排污水余热与水资源回收再利用系统

Also Published As

Publication number Publication date
GB2478569A (en) 2011-09-14
GB201003960D0 (en) 2010-04-21
EP2369228A3 (en) 2014-08-27
CN102679317A (zh) 2012-09-19
EP2369228A2 (en) 2011-09-28
EP2369228B1 (en) 2017-04-05
JP2011185594A (ja) 2011-09-22

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AS Assignment

Owner name: SPIRAX-SARCO LIMITED, UNITED KINGDOM

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:AMINI, AMIR;REEL/FRAME:026316/0587

Effective date: 20110404

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION