电动凝结水回收装置  ELECTRIC CONDENSATION WATER RECOVERY DEVICE

电动凝结水回收装置罐体内部设置汽水分离装置、除污装置、调压装置、汽蚀消除装置、疏水快排装置等；下部配置本厂特制的高温电机泵；同时根据不同工况，并配有水汽引射装置、泵前加压装置、低压输送装置、自动加压器等，从而达到密闭回收。

Electric condensate recovery device is arranged inside the tank water separation device, decontamination device, pressure regulating device, cavitation eliminating device, hydrophobic quick exhaust device; the lower part of the allocation of high temperature motor pump factory special; at the same time according to different working conditions, and is equipped with water vapor ejecting device, pump pressure device, low pressure conveying device, automatic pressurizing device etc. thus, completely closed recovery.

1.自动调压装置

北疏将设备安全和工艺安全分开，用安全阀保证设备结构安全，用调压装置确保生产工艺的系统安全。为确保泵进口处2m以上的正压头，在集水容器内增设自动调压装置，采用多级水封和“U”型管原理。调压装置分两种：一种是无压型，PN=0.01-0.09MPa,常用于采暖、溴化锂制冷的空调等0.1Mpa以下的凝结水回收工程中；一种是压力型，PN=0.1-1.0MPa,常用于石化、钢铁、热电等工业用热系统工程中。在保证正常回水的情况下，压力适当提高，一是有利于二次汽在容器内的二次凝结，是闪蒸回收的重要节能措施；二是二次汽向水面施压，保证水泵防汽蚀必需的正压水头；三是形成闭式系统，保证设备及管道内无氧，不生锈。

1. Automatic voltage regulator

North sparsely separates the equipment safety from the process safety, ensures the safety of the equipment structure with the safety valve, and ensures the safety of the production process by the pressure regulating device. In order to ensure the positive pressure head above 2m at the inlet of the pump, the automatic pressure regulating device is added in the water collector, and the principle of multistage water seal and "U" tube is adopted. The pressure adjusting device is divided into two kinds: one is no pressure, PN=0.01-0.09MPa, condensate recovery project commonly used in heating, refrigerating of central air conditioning in the 0.1Mpa below; a pressure type, PN=0.1-1.0MPa, commonly used in petrochemical, steel, thermal power and other industrial thermal system engineering. To ensure the normal return under the condition of pressure increasing, one is two times to two times the condensation of steam in the container, is an important energy saving measures of flash recovery; two is two times to the surface of the water vapor pressure, to ensure the pump pressure head required anti cavitation; three is the formation of a closed system, and ensure the equipment in the pipeline anaerobic, not rust.

2.除污装置

因集水容器的体积小于被替代的凝水箱体积，早期试验时铁锈等硬块打坏了水泵叶轮。因此，集水容器内增设除油污和杂质的除污装置，用于提高水质纯净度。

2. Decontamination device

Condensate tank volume due to the volume of a container is smaller than the alternative catchment, early test of rust lump broken water pump impeller. Therefore, a decontamination device for oil pollution and impurities is added in the container to improve the pure purity of the water.

3.汽蚀消除装置

多年来的规范认定，将水箱放在水泵上方，让水泵得到一个静水头，用来放置水泵发生汽蚀。研究与实验表明，静水头是在静态下存在的，水泵汽蚀是在动态下发生的。静态和动态不能同一时间存在于同一设备上，所以用静态下的静水头解决动态时的水泵汽蚀是不可能的。高位水箱的水从静止加速至泵前的高速流动过程中（2950转/分），过流段面急速缩小，高温水在负压下瞬间汽化，产生大量汽泡，汽泡入泵受压破裂，水流质点四周的冲击频率达每分钟2万次以上，在极微小的面积上压力常达几十至几百个兆帕，极大的机械破坏力猛烈作用于叶轮，很快造成叶轮的损坏。汽蚀产生刺耳的噪音和强烈的振动。

当集中容器内的水位降到底部时，原平静的水面立即出现降水漏斗（与龙卷风形状相同），二次汽入泵仍发生“汽蚀”。根据透明玻璃钢和水掺深颜色观察的试验结果，以阿基米德螺线方程为理论依据，用不锈钢做成的多层导流体，在水位下降时，上部导流结构自动闭锁，确保了低水位时无“汽蚀”现象发生。该装置为汽蚀消除装置。

3. Cavitation elimination device

For many years, the water tank is placed above the pump to make the water pump get a static head to keep the water pump cavitation. The research and experiment show that the hydrostatic head exists in the static state, and the cavitation of the water pump occurs in the dynamic condition. Static and dynamic can not exist on the same equipment at the same time, so it is impossible to use static water head in static water to solve the cavitation of water pump in dynamic condition. The high water tank water to accelerate from a standstill to high speed flow in the pump (2950 RPM), rapidly shrinking flow section, high temperature water instantly under negative pressure evaporation, resulting in a large number of bubbles, the bubble burst into the pump pressure, the flow around the particle impact frequency was more than 20 thousａnd times per minute, in the extreme small area pressure often tens to hundreds of MPA, great mechanical damage to violent impeller, soon caused damage of impeller. The cavitation caused a sharp noise and a strong vibration.

   When the water level in the centralized container descends to the bottom, there will be a precipitation funnel (the same shape as the tornado) on the original calm surface, and the cavitation of the two intake pump will still happen. According to the results of observation of transparent glass steel and water with deep color, with the spiral of Archimedes equation as the theoretical basis, the multilayer made of stainless steel by fluid, decline in water level, the upper guide structure to ensure the automatic locking, the low water level without "cavitation" phenomenon. The device is a cavitation elimination device.

4．汽水分离装置

由于高温凝结水为汽液两相流，如不进行处理就会出现带汽入泵，增大水泵气蚀的诱因。可通过内置汽水分离装置将凝结水中的二次汽和部分一次疏水漏汽分离出来，导流到回收罐体上部，分离出来的二次汽在罐体上部形成汽液动态平衡。再通过吸气定压装置将积存的二次汽和一次汽抽吸，并和泵出口凝结水一并输送到下一用户。

通过汽水分离装置确保凝结水在入泵的瞬间为单相的微过冷水，消除凝结水引起水泵气蚀的一大诱因。

4. steam water separation unit

Because the high temperature condensate is a two phase flow of steam and liquid, if it is not treated, it will lead to the suction pump and increase the cavitation of the pump. The two steam and part of the condensate water can be separated from the first part of the condensate by the built-in steam water separating device. The steam can be guided to the upper part of the recovered tank, and the two separated steam will form vapor liquid dynamic balance on the top of the tank. Then through the suction constant pressure device, the accumulated two steam and one steam is sucked, and the condensate of the pump outlet is transported to the next user.

Through the steam water separation device to ensure that the condensate is a single phase micro supercooled water at the moment of entering the pump, so as to eliminate the major cause of the cavitation of the water pump caused by the condensate.

5.水泵改型

为满足集水容器下装配双套电机泵的要求，北疏将现有的单级泵改型，一是将水泵进水管由原来的侧面改到上面，将泵出水管由原来上面改在侧面，形成理想流态；二是将泵体用机械密封，由原耐温80℃-110℃提高到160℃以上，增强泵体耐温耐久性能；三是将泵底座改为轻型，直接固定在设备下部的槽钢上。

从总体结构可以看出，自动调压装置保持了集水容器内特定的压力，凝结水在重力和二次汽压力下，经汽蚀消除装置正压入泵，从根本上消除了高温凝结水对水泵汽蚀发生的条件。

5. pump modification

In order to meet the requirements of assembling two sets of motor pumps under the water collecting container, Beishu changed the existing single-stage pump. First, the water inlet pipe of the pump was changed from the original side to the top, and the water outlet pipe of the pump was changed from the original top to the side to form an ideal flow state. Second, the pump body was sealed mechanically, from the original temperature resistance of 80 ℃ - 110 ℃ to over 160 ℃, so as to enhance the temperature resistance and durability of the pump body. Third, the pump base was changed It is light weight and fixed directly on the channel steel under the equipment.

From the overall structure, it can be seen that the automatic pressure regulating device maintains the specific pressure in the collecting container. The condensate under the gravity and the two steam pressure, through the positive pressure pump of the cavitation elimination device, basically eliminates the condition of the high temperature condensate water to the pump cavitation.

6. 控制系统

控制系统采用变频恒液位控制，冷凝水连续输出。

A、凝结水回收器采有PLC微电脑控制，实现整个装置全自动运行。

B、液位传感器设置四个固定液位信号点，从下向上为：超低点、低点、高点、超高点。

C、PLC微电脑根据液位信号控制水泵实现自动间断运行，即实现高点启动水泵泵水，低点停止水泵运行，保证凝结水及时泵走。

D、两台水泵一用一备，自动定时转换运行，保证两台泵同期运行；每台水泵都能手动和自动两种运行方式，可自由转换。

E、控制柜实现水泵过热、过载自动保护并报警，当一台泵出现故障，另一台泵自动投入运行；实现液位到达超高点自动报警，并启动另一台泵，液位低于超低点自动切断控制电源。

6. Control system

The control system adopts variable frequency constant level control and continuous output of condensate water.

A, The condensate recovery device has PLC microcomputer control to realize the whole automatic operation of the device.

B The liquid level sensor sets four fixed level signal points from down to low, low, high, and super.

C The PLC microcomputer controls the pump automatically and intermittently according to the liquid level signal. That is to realize the high point to start the pump water, the low point to stop the operation of the pump, and to ensure the condensate to pump in time.

D The two pumps are operated automatically and regularly at one time, ensuring two pumps running at the same time. Each pump can operate two modes manually and automatically, and it can be converted freely.

E The control cabinet realizes the automatic protection and alarm for the overheating and overload of the pump. When a pump fails, another pump goes into operation automatically. The liquid level reaches the super high point automatically, and the other pump is started. The liquid level is lower than the ultra-low point, and the power is cut off automatically.

7.吸汽定压装置

在闭式回收系统中，由于疏水器一般都有3－5％的疏水漏气，如果不及时处理，漏汽聚积将导致罐体内压力升高，从而使用热设备的背压升高，严重影响用热设备的效率，实际上很多系统的疏水漏汽会更多，罐内压力会升的更高；多路回水时汇集到罐体时由于相对高背压的存在，会形成低压换热装置形成憋压，进一步造成低压凝结水疏水不畅。以上这两点原因都会导致用热设备不能正常密闭运行。一般的闭式系统在运行一段时间后，不得不排放疏水漏气和二次汽，由闭式系统变为开式系统，以保证工艺用热设备的正常运行。从而大大地浪费能源。

为了能够使闭式系统在有较高疏水漏汽率和多路压力不等的凝结水回回到一台回收器的工况下，保证工艺用热设备及凝结水回收器正常运行，我公司科研人员开发出了的吸汽定压装置，它解决了上述问题。通过通过该装置使罐内压力低于凝结水回收器入口压力， 降低背压罐体保证凝结水顺利输出，不影响工艺和前端用热设备的使用效果。

7. Steam absorption constant pressure device

In a closed recycling system, the traps are generally hydrophobic leak 3 - 5%, if not timely treatment will lead to the accumulation of steam leakage in tank pressure increases, thus the use of heat equipment back pressure, seriously affect the efficiency of heat transfer equipment, in fact many hydrophobic system leakage will be more, the pressure in the tank will rise even higher; multiple backwater together to tank due to the relatively high back pressure exists, will form a low pressure heat exchanger formation pressure, low pressure condensate due to poor drainage. The above two reasons will cause the use of thermal equipment to operate normally. When a closed system is running for a period of time, it has to drain the drain and the two steam, and turn the closed system into the open system, so as to ensure the normal operation of the thermal equipment. It is a great waste of energy.

In order to make the closed system with high leakage rate and hydrophobic multi-channel pressure ranging from condensate return to a recovery condition, ensure that the process of heat equipment and condensate recovery device normal operation, our company researchers developed a unique steam pressure setting device, it thoroughly solves the above the problem. Through the device, the pressure in the tank is lower than the inlet pressure of the condensate recovery unit, and the back pressure tank can be reduced to ensure the condensate output smoothly, without affecting the application effect of the hot equipment in the process and front-end.

 8.低压输送装置

在闭式回收系统中，多路凝结水回到凝结水回收装置时，由于有相对背压的存在，压力较低的高低压凝结水会形成相互干扰，低压凝结水管路会形成憋压，造成疏水不畅，进一步影响前端换热设备的换热。当多路共网时一路压力远远低于其他路压力，而该路凝结水量又较小，另加一台回收器浪费时；当用压力低于 0.2MPa ，且用热点很分散，而且用热负荷较小，导致凝结水压力很低，回收困难时，采用低压输送装置。

工作原理：我厂采用的水水引射装置通过节流变径，所产生的相对负压，将低压凝结水顺利输送到罐体内。该装置效率高，稳定性好为了解决低压管路输水不畅的问题。

8. low pressure conveyor

In the closed type condensed water recovery system, multi-channel to condensate recovery device, due to the relative pressure of the existence of low pressure high pressure condensate will form a mutual interference, low pressure condensate line formation pressure, causing hydrophobic sluggish, further influence the heat exchanger design front-end preparation. When a road network multi-path pressure is far lower than other road pressure, and the way the condensation of water and small, plus a waste recovery device; when the pressure is lower than 0.2MPa, and the hot spots are scattered, and the heat load is small, resulting in condensation of water pressure is very low, difficult recovery, mining and conveying device low pressure.

Working principle: our factory adopts a unique water water ejection device to transfer the low pressure condensate to the tank through the rheological diameter of the joint and the relative negative pressure produced. The device has high efficiency and good stability in order to solve the problem of poor water transport in low pressure pipeline.

9.泵前增压装置

在换热首站、采暖换热等系统中所产生的凝结水压力很低，进行密闭回收，在水泵启动运行时罐体出水口会出现相对负压，泵入口的压力小于水泵的气蚀余量，水泵会发生气蚀。利用该装置可以解决该问题，达到闭式回收。

9. pre pump booster

The condensate pressure produced in the first heat exchange system, heating and heat exchange system is very low, and it is closed recycling. When the pump starts and runs, the outlet of the tank will have relative negative pressure. The pressure of the pump inlet is smaller than the pump's cavitation allowance, and the pump will cavitation. The device can completely solve the problem and achieve complete closed recovery.

 10.多路共网器

用于多路不同压力凝结水回到同一管网或凝结水回收器，消除各路凝水间相互影响。利用高压凝水的动能，通过射吸原理来平衡各路凝结水的压力，保证各种压力凝结水都能顺畅回到管网或凝结水回收器。该设备为非标设备，根据每路凝结水的水量，凝结水的压力进行系统设计，以便能更好得适应具体工况

安装简单，自调节能力强，适用范围广。

10. multichannel common network

It is used to return different pressure condensate back to the same pipe network or condensate recovery device to eliminate the mutual influence of all kinds of condensate water. By using the kinetic energy of high-pressure condensate, the pressure of condensate is balanced by the principle of suction, so that all kinds of pressure condensate can smoothly return to the network or condensate recovery unit. The equipment is a non standard equipment. The system is designed according to the water volume of the condensate per road and the pressure of condensate, so that it can be better adapted to the specific working conditions.

Simple installation, strong self-regulation, wide range of application.

11.自力增压器

蒸汽经过用热设备产生的凝结水回收流程中，常有回收管道在地下或者向上弯曲，跨越马路障碍物等需要爬升时，在管道的处安装自力增压器。利用自身的特殊结构使冷凝水的余压和二次汽凝结时的能量得到释放，提高冷凝水的爬高能力，消除水阻、汽阻和撞管等问题。该配套装置占地面积小、安装方便，且不需增加任何动力源。

1）在如下图所示凝结水回收系统中，有增压器和没加增压器的效果演示图： 

    没有安装自力增压器水流示意图                           安装了自力增压器后水流示意图

2）自力增压器工作原理：
自力增压器作用在于以下两点：一是在有水的情况下只走水不走汽；二是防止在拱形管道顶部产生汽阻；三是利用管线泄漏和自身闪蒸的蒸汽产生压力来推动凝结水爬高。

下图是自力增压器的工作原理图，从图中可以看出，凝结水在绝大部分管道中是半管水而不是满管水，也就是说在管道中是汽水共存状态，汽在上层，水在下层，在通常的管道系统的爬高处，通常管道中的汽是先于水上升到高处，容易在高处形成汽阻，而在管道爬高处安装一台自力增压器，自力增压器大致结构是顶部出水管延伸到自力增压器底部，水是从底往上走，当凝结水、汽进入加压器时，水在增压器底部，汽则在上部对水面施加一定压力，推动凝结水爬高，特别是疏水器泄漏的新蒸汽对凝结水的推动力更大，加压器上部的汽通过做功消耗、自然散热、管道背压的作用，也是不断凝结成水被送走。

由于凝结水在增压器内存在扩容降压，所以通过增压器后的凝结水压力比进增压器前的凝结水的压力要高一些，从这个方面来说也提高了凝结水的爬高能力，重要的是它具有一定的阻汽通水作用，特别是在闭式系统的拱形管道中对汽阻的消除效果十分明显。这也是闭式系统与开式系统相比必须多考虑的问题之一。

11. self powered turbocharger

After recovering steam from the condensate water generated by the thermal equipment, the recovery pipe often is bent underground or upwards, crossing the road obstacle and so on. When it is necessary to climb, the self pressurizing device is installed at the lowest part of the pipeline. With its special configuration to residual pressure of condensed water and two condensing energy release, improve the ability of the condensed water, eliminate water resistance, steam resistance and impact pipe etc.. The equipment is small in area, convenient to install, and does not need to increase any power source.

1) a demonstration of the effect of a supercharger and no supercharger in the condensate recovery system as shown in the following figure:

No water flow diagram of a self powered supercharger is installed             Flow schematic after installing a self powered supercharger

Self booster role lies in the following two points: one is in the presence of water vapor only water does not go; two is to prevent the generation of steam resistance in the conduit top; three is the utilization of steam pipeline leakage and its flash vaporization pressure to push up condensate.

2) the working principle of self powered turbocharger:

This is independent of turbocharger working principle diagram, it can be seen from the figure, the vast majority of condensed water in the pipeline is half pipe water instead of water filled pipe, that is to say in the pipeline is the soda coexistence of steam in the upper water in the lower layer, in climbing at the pipeline system usually, usually pipeline the steam is before the water rises to the height, easy to form steam resistance on high, but in the pipeline to climb high installation of a self independent turbocharger turbocharger, general structure is the top outlet pipe extends to the bottom of the water is independent of the supercharger, walked up from the bottom, when the condensation of water and steam into the pressurizer, water in the supercharger bottom steam in the upper pressure of water, promote the condensation of water climbing, especially the driver of new steam trap leakage of the condensed water is larger, the upper part of the steam pressurizer through consumption, natural cooling, pipe work The function of the back pressure is also continuously condensed into water to be sent away.

Because the condensed water exists in the turbocharger expansion, so the turbocharger condensate pressure is higher than that in the supercharger before the condensed water pressure, in this respect also improves the condensate climb ability is the most important, it has a certain role in water vapor resistance, especially in the conduit closed system of steam resistance elimination effect is obvious. This is also one of the problems that must be taken into consideration in the closed system compared with the open system.

电动凝结水回收流程图  Electric condensate recovery flow chart