It can be seen from the landlord's question that your company attaches great importance to the recovery of steam condensate. As the landlord mentioned, the recovery of steam condensate is of great value, which can not only maximize the recovery and reuse of heat energy, but also create considerable economic benefits.
steam from the steam trap
As you can know from the description of the landlord, your company used an open recovery device, that is, the condensed water was first discharged into a soft pool, and then recycled when the water temperature dropped to 71℃ (in order to avoid pumping high-temperature cavitation). During this process, the pressure was reduced from 1.7MPa to 1. Because the temperature of condensed water and air pressure have a one-to-one correspondence, when the pressure was reduced from 1.7MPa to 1, The temperature of condensed water is reduced from 165℃ to 111℃, and the high-temperature condensed water at 65℃ is converted into secondary flash steam to be discharged, which is what the landlord sees as a part of the steam still emitted after recovery.
as we all know, the steam pressure of heat exchange equipment in the oil industry is high, and once one of the steam condensate recovery devices is not considered in person, it is easy to cause problems. Traps all have a leakage rate. Generally, the leakage rate of domestic traps is above 3%-5%, and the leakage rate of imported traps is generally around 1%, but it is also much more expensive than domestic traps. The role of the trap is to drain and block steam. Generally, the trap will not leak under normal operation. When the trap is damaged, if it is closed, the condensate output will be interrupted immediately, and it can be stopped for maintenance (affecting production), or the bypass will be in a normally open state, and some steam heat energy will be discharged without full release. If it is in the fully open or semi-open state, it has no harm to the output, but it is in the state of running "steam". In China, as long as the steam trap can still be used, it will not be replaced immediately, so the steam trap in use is generally in normal operation (that is, the steam leakage rate <: 3%) does not exceed 11%, and the air leakage exceeds the standard (that is, the steam leakage rate >; 5%) accounts for 61%, and the remaining 31% is a serious leak (that is, the air leakage rate is > 11%). This part of the air leakage constitutes another part of the "steaming" seen by the landlord.
some people will say that the leakage of another trap is not serious. In fact, this statement is quite imprecise, because the steam leakage rate is relatively low when the trap is running well at first, but the trap is a vulnerable part, and it will still emit a lot of steam after being used for a period of time.
We have done such a project before, which is also an oil processing enterprise, especially in Inner Mongolia. Before we cooperated with their company, they always used domestic traps, but the air leakage was very serious, and a lot of steam was emitted. Later, the boss was so distressed that he changed to use imported traps, and the cost of replacing each trap was about 311,111-411,111.
About water storage
As for why water is stored in your equipment, the reasons are as follows: The hydrophobic principle of the trap is that under the condition of equal pressure, the condensed water can flow to the trap by gravity. Oil processing enterprises generally use multi-layer heating materials, and the dry humidity and heating time of each layer are different, which leads to different temperature and pressure of each layer, and the pressure is slightly different. The layer with high temperature is difficult to remove against the condensate with low temperature, and the equipment is "water-trapped", resulting in poor heat exchange efficiency. Once the equipment is choked with water, it will not only affect the production itself, but also often open the bypass, resulting in a lot of waste of high-priced steam.
this is also one of the reasons why the boiler evaporation in some enterprises has never reached the design evaporation. A case we did in Jiangsu is that this problem is very serious. Water storage in equipment will inevitably affect the heat transfer efficiency. The most ideal state of a trap is that all the condensed water produced is discharged and there is no air leakage at all, but this trap does not exist so far. Therefore, the use of steam traps will inevitably have some influence on the heat exchange efficiency, which is the contradiction between energy saving and heat exchange in our industry.
once there is a contradiction between energy saving and heat exchange, the energy saving effect will be greatly reduced, which is one of the important reasons why most steam condensate equipment is dismantled and abandoned after installation.
About the reciprocating pump and the strong suction type recovery machine
As for the reciprocating pump and the strong suction type recovery machine, they are both closed steam condensate recovery devices, which are indeed better than the open type recovery device in terms of technology and energy-saving effect, but these two devices still use steam traps, so if these two devices are installed, the above problems still cannot be solved. At the same time, some other problems will be added. For example, the use of reciprocating pump will also produce "virtual pressure phenomenon" and the service life of equipment is short.
Therefore, as long as it is an oil processing enterprise or other enterprises with complicated steam working conditions, it is generally not recommended to choose equipment with steam traps. As long as steam traps are used, there will inevitably be problems such as air leakage and water storage in the equipment, which will further affect production and even make the system paralyzed.
Now, what the landlord is puzzled about is whether energy can be saved on the basis of promoting production, and the answer is yes. Moreover, steam and condensate can be recovered at the same time.
Our company (Yitongda Steam Energy Saving) has rich practical experience and a solid theoretical foundation for the problems existing in the process of steam condensate recovery in the oil industry. Based on years of in-depth research in the oil industry, the steam condensate recovery system without a trap can recover steam and condensate at the same time, and there have been hundreds of successful cases in the oil industry in China, such as Hubei Jianli Jiayi Grain and Oil Technology Co., Ltd. and Hubei Hongkai Industry and Trade. Hunan Zhangjiajie Jinlv Grease Co., Ltd., Jiangsu Dongtai Lanhai Grain and Oil Co., Ltd., Jiangsu Shuang Shan Group, Jiangxi Gaoan Qinghe Grease Co., Ltd. and Shandong Jiaxiang Jinyuan Grease Co., Ltd. all installed our products.
Because our system does not use a steam trap, it effectively avoids the above problems mentioned by the landlord. At the same time, the system insists on achieving the best heat exchange efficiency of the system and ensuring the whole system to run in the best state before design, which can not only maximize the recovery of steam condensate, in other words, you can't see any steaming place after installation, but also solve the problems of insufficient evaporation and steam hardness, and reduce the internal management cost while reducing energy consumption.
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