Three major innovations in the standard of "heat pump external heating double effect concentrator"
First, the overall technical program
1. The technical principle on which the project is based
The double-effect concentration is to heat and evaporate and concentrate the Chinese medicine extract by steam in a vacuum state in a closed container, and to use the secondary steam generated by the effect to heat and concentrate the second-effect liquid to make the steam be used twice. To achieve the purpose of energy saving. A self-developed thermal energy compressor thermal energy compressor is used to pump a part of the secondary steam generated by the effect into the thermal energy compressor, and the saturated steam is mixed with the boiler which has been depressurized and lowered by the thermal energy compressor Laval nozzle, and the thermal energy compressor is used. After the pump body is heated and boosted, it is used as an effective heat source to further improve the energy-saving effect of the project product. The self-developed condensate equal pressure drainage cascade self-evaporating device reduces the temperature of the saturated condensed water from 90 Â° C to 75 Â° C under the next reduced pressure condition, and flashes. The self-evaporating steam acts as a heat source for this effect, and further achieves the purpose of saving steam, and can generate flash steam accounting for 3% of the condensed water as the second heat source. Due to the adoption of these two energy-saving measures, the products of this project are more than 30% energy-saving and water-saving respectively under the same evaporation conditions as the common Chinese medicine double-effect concentrators used in Chinese medicine factories. The developed thermal energy compressor adopts double-layer composite expansion chamber type muffling technology, which effectively eliminates high frequency and intermediate frequency waves, and has a silencer hole on the wall of the tube to reduce the noise to 75dB (A). First level.
2 , the main technology and performance indicators
Main technical and performance indicators
Steam pressure, Mpa
0.5 to 0.6
Operating noise, dB ( A )
Cooling water consumption ( inlet water temperature 25 Â°C outlet water temperature 35 Â°C )
Heating steam temperature
Evaporation chamber vacuum
Boiling Â point
Heating steam temperature
Evaporation chamber vacuum
Boiling Â point
3. Types of quality standards and standard names realized by the project
The standard is modified according to the enterprise standard Q/Z02-2004 "Double-effect Chinese medicine series concentrating device with thermal energy compressor". Accepted. Entrusted by China Pharmaceutical Equipment Industry Association, our company is the drafting unit of the national pharmaceutical machinery industry standard "heat pump external heating type double effect concentrator". The National Development and Reform Commission has announced that the "heat pump external heating double effect concentrator" will be implemented on December 1, 2006. Since December 01, 2006, the project products have implemented the "" standard.
Through the implementation of this project, the newly obtained relevant certificates of the enterprise
Quality certification system certificate
Norwegian Classification Society ISO9001: 2000 standard
National related industry license
Class I, Class II pressure vessel manufacturing license
External cycle multi-effect concentrating system, a thermal energy compressor
Technology, product identification certificate
Zhejiang high-tech products, Zhejiang high-tech enterprises
Second, the project innovation content
Innovative point 1: In the double-effect evaporation concentration process of traditional Chinese medicine extract, the self-developed low-noise high-pressure ejector steam thermal energy compressor significantly saves energy and water.
The project product is a double-effect evaporation production equipment using a Chinese medicine extract with a thermal energy compressor (see Figure 1, Figure 2). See Figure 3 and Figure 4 for the traditional double-effect evaporation concentration production equipment and process. The project product adopts a self-developed low-noise thermal energy compressor (also known as a hot-pressure pump), which is a key component for obtaining steam-saving. Its structure is shown in Figure 5. The working principle is that after the high pressure ejector steam (usually 0.55-0.7Mpa) passes through the Laval nozzle, it flows out at supersonic speed, forming a low pressure at the nozzle; and at the same time, because the steam flows in the nozzle, The temperature of the high-pressure ejector steam is also lowered, and the high-temperature high-pressure steam passes through the nozzle and becomes a low-temperature low-pressure (or negative pressure) steam. The nozzle of the thermal energy compressor is a negative pressure, which is the same as the pressure of the one-effect evaporation chamber, so that the secondary steam of the effective portion is sucked into the negative pressure of the nozzle, and mixed with the negative pressure low-temperature steam here, collectively referred to as mixing. steam. The mixed vapor enters the mixing section of the pump body. The supersonic steam flowing from the Laval nozzle and the inhaled subsonic one-effect partial secondary steam are mixed in this section to perform speed equalization. When the mixed steam passes through the throat of the pump body, the speed is equalized and converted into subsonic speed. After the zui is boosted by the expansion section of the pump body, it is used as an effective heat source. It can be seen that, in addition to the original steam, the steam heated by one effect has a large amount of secondary steam introduced into the evaporation chamber of the heat energy compressor as a heat source, so that the steam for heating is greatly reduced, and the steam saving is achieved. effect. As a key component in the double-effect concentrating device, the thermal energy compressor has the advantages of simple structure, no moving parts, low manufacturing cost, etc., but its disadvantage is that it is noisy during operation. The thermal compressor of the project product adopts a double-layer composite expansion chamber type muffling structure, which eliminates high-frequency waves, medium-frequency waves and high-frequency waves and intermediate frequency waves in the supersonic airflow flowing from the Laval nozzle. The thermal energy compressor has only low-frequency waves, which greatly reduces the noise when it is working. At the same time, according to the principle of the expanded silencer, the pump mixing section, the throat and the expansion section of the thermal energy compressor are designed as a double-layered sleeve structure. A sound absorbing hole is arranged on the wall of the cylinder, so that the steam passing through the pipeline of the section passes through the sound absorbing hole of the sleeve structure, and then collides with the outer cylinder wall to return, so that the noise is further reduced. The thermal energy compressor of this structure measures noise of 75.1 dB(A) at the environmental monitoring station of Heilongjiang Land Reclamation Bureau when the high pressure ejector steam pressure is 0.58 MPa. For foreign imports, the noise is 84.5dB(A); the domestic thermal compressor noise is above 90dB(A). The thermal compressor of the project product is at the linger level in terms of noise reduction.
Figure 1 New double-effect concentrating device diagram
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Figure 2 New double effect process flow chart
Figure 3 original double-effect concentrating device diagram
Figure 4 original double-effect process flow chart
Figure 5 Schematic diagram of low noise thermal compressor
Three effects of innovation one:
1. The evaporation of each effect changes: the project product is a double-effect evaporation process with a thermal energy compressor. Due to the use of the thermal energy compressor, according to the working steam pressure of the thermal energy compressor, the pumping coefficient of the thermal energy compressor and the amount of secondary steam injected into the heating steam are calculated, thereby obtaining the *effect evaporation amount, and the project product* effect The evaporation amount is 65% of the total evaporation amount, and the second effect evaporation amount is 35% of the total evaporation amount. The effective double-effect concentrator of Chinese medicine has the same effect as the evaporation of the second effect, which is 50% of the total evaporation. Since the project product adopts the evaporation process with thermal energy compressor, the evaporation rate of the second effect is reduced to 30% compared with that of the ordinary double effect concentrator, so that the cooling water used for cooling the final steam is the same as the cooling water inlet temperature and the outlet temperature. Under the conditions, save 30%.
2. The project product uses a double-effect evaporation process with a thermal energy compressor to greatly reduce the temperature of the heating steam. The traditional double-effect concentrator of Chinese medicine is effective because only the steam supplied by the boiler is used, and the heating temperature is only as low as 105 Â° C, because the heating steam is related to the shell side pressure of the heating chamber. The temperature of the mixed steam formed by the boiler steam generated by the thermal energy compressor and the secondary steam mixed with the *effect part can be determined by the calculation of the structural size of the thermal energy compressor. The temperature of the mixed steam of the project product is about 90 Â°C, realizing the traditional Chinese medicine. Double-effect concentrator* effect low-temperature heating, and *effect evaporation temperature has been determined due to the total temperature difference. According to the principle of heat balance and effective effective temperature difference distribution, the evaporation temperature is 75 Â°C, and the traditional double-effect concentrator of traditional Chinese medicine* The evaporation temperature was 85 Â°C. It can be seen that the double-effect evaporation process with a thermal energy compressor achieves low temperature heating and low temperature evaporation, and is suitable for heat sensitive materials.
3. The project products are not only applicable to new plants, but also can be technically modified to the ordinary double-effect concentrators and single-effect concentrators used in the original Chinese medicine factory, and become a three-effect concentrator with heat pump and a double-effect concentrator with heat pump. When the original evaporation amount is constant, the fuel saving is 45% and 67%, and the water saving is 48% and 65%, respectively, compared with the original common double-effect concentrator and single-effect concentrator, which has significant energy saving and water saving effects.
Innovative point 2: In the double-effect concentrator of traditional Chinese medicine water extract, the self-developed condensate equal pressure drainage cascade self-evaporation device is applied, which improves the steam utilization rate and reduces the maintenance workload.
The project product uses a condensed water isobaric drainage cascade self-evaporation device designed by independent proprietary technology in the double-effect concentrator of Chinese medicine water extract liquid. The structure diagram is shown in Figure 6.
The working principle is that the balance water tank is connected to the heating chamber through the balance pipe, so that the pressure of the heating chamber and the balance water tank are equal. The condensate in the heating chamber is discharged into the balance water tank by the pressure of the liquid column; it enters from the condensate inlet at the bottom of the balance water tank and is discharged from the top of the balance water tank. Adjust the ball valve at the condensate outlet pipe, keep the water in the balance water tank in the middle of the sight glass, and use the liquid seal method to prevent the balance water tank from leaking. Since the condensed water is discharged when the pressure in the heating chamber and the pressure in the balanced water tank are equal, it is called equal pressure drainage; and since the condensed water is discharged from one effect to the second effect, and the condensed water is flashed in the second effect, the flash The steaming method is a cascade discharge flash, so it is collectively referred to as an isobaric drainage cascade self-evaporating device. The device adopts the isobaric drainage cascade self-evaporation technology. When the condensed water of each heating chamber is discharged, the steam trap is not used, but the condensed water of the heating chamber is discharged to the second effect heating chamber, and the temperature is lowered from 90 Â° C to 75. Â°C, flashing, * effect condensed water flash steam as a heat source to heat the second effect, can produce 3% of the condensed water discharge flash steam as a heat source, and can avoid the use of steam trap drainage caused by the heating room The leakage of steam also saves the maintenance work of the steam trap, and has the characteristics of simple structure, convenient operation and no maintenance.
A schematic diagram of the isobaric drainage device is shown in Figure 6. The original double-effect drainage device is shown in Figure 4.
Figure 6 isometric diagram of isobaric drainage
Innovative point three: For the first time, a combination of jacket heating and scraper mixing was designed in the final evaporation chamber to obtain a traditional Chinese medicine extract with a specific gravity of 1.4.
For the first time in the country, the project product uses a vacuum-collecting device combining the jacket heating method and the scraper stirring in the final effect evaporation chamber of the Chinese medicine double-effect concentrator. The ordinary double-effect concentrator does not have a liquid collecting device in the final effect evaporation chamber. The liquid can only be concentrated to a specific gravity of 1.2. If a larger specific gravity is required, it should be carried out in a spherical concentrating pot with another device. Because the specific gravity of the common double-effect concentrator exceeds 1.2, the heating chamber heating tube will be cokeed and clogged. In severe cases, the equipment will be scrapped.
When the specific gravity of the liquid of the project is greater than 1.2, the liquid is pumped into the paste removing device of the final effect evaporation chamber to collect the concentrated paste, and the extract having a specific gravity of 1.4 is obtained. Since the collecting paste is not carried out in the heating chamber, the problem that the ordinary double-effect concentrator has a long-term unresolved solution of the condensation of the heating tube and the clogging of the heating tube is solved. A schematic diagram of the new evaporation chamber and the final effect collection device, and a schematic diagram of the original evaporation chamber are shown in Fig. 7 and Fig. 8.
Figure 7 Schematic diagram of the new evaporation chamber and the final effect collection device
Third, the project product features
1, significant steam savings
Because the project uses a thermal energy compressor and an *effect heating chamber condensate heat recovery device, it has a significant steam saving effect compared to the ordinary double effect concentrator. The double-effect concentrating device developed by our company with an evaporation of 2500kg/h was put into use in Jiamusi Morningstar Pharmaceutical Co., Ltd. in January 2004. Tested by Jiamusi City Environmental Monitoring Station in Heilongjiang Province, the high-pressure ejector steam pressure in the thermal energy compressor is 0.58Mpa, the evaporation is 2340kg/h, and the steam consumption is 740kg/h; while the ordinary double-effect concentrating device is in the same evaporation amount. The steam consumption is 1190kg/h, and the former has a steam saving rate of 36.7%. The reduction in steam consumption brings significant economic benefits to the company. The annual average data measured by Chenxing Company during the online use period is taken as an example. The processing volume is 22T/day extract, the proportion of the extract after Zui is 1.20, and the extract is 350kg/day. The evaporation amount was W=22000-350=21650 kg/day, and the evaporation required time was t=21650Ã·2340=9.3h. The double-effect ratio of the heat pump is D=1190-740=450kg/h for the double-effect hourly steam, and D=450Ã—9.3=4185kg=4.2t for the day-saving steam. The annual demand is 300 days, and the steam is 140 yuan per ton. The annual steam saving benefit is 140 Ã— 4.2 Ã— 300 = 177,000 yuan.
Therefore, the heat pump external heating type double-effect concentrating device not only reduces the long-term operating cost of the pharmaceutical factory, but also saves a lot of traditional energy for the country, and has significant economic and social benefits.
2, significant water saving
Since the project uses a thermal compressor, the second effect evaporation is reduced by 30% compared to the conventional double effect concentrator. Therefore, the cooling water used to condense the second-effect secondary steam is saved by 30%. The double effect of Jiamusi Morningstar Pharmaceutical Co., Ltd. with an evaporation of 2500kg/h is as follows: the total evaporation is 2340kg. /h, when the steam pressure is 0.58 MPa and the *effect boiling point is 75 Â° C, the steam consumption coefficient of the thermal compressor is calculated to be 1.16. The heat balance of the whole system is 820kg/h for the second effect, and 1170kg/h for the common double effect second effect. Therefore, under the condition that the second effect boiling point temperature of the thermal energy compressor double-effect concentrator is the same as the ordinary double-effect second-effect boiling point temperature, the evaporation amount of the former is 1170-820=350 kg/h less than the latter, that is, the evaporation amount is small Î· =350Ã·1170=29.92%, when the condensing cooler cooling water inlet temperature, outlet temperature and secondary steam cooling temperature of the two concentrating devices are the same, the cooling water ratio of the double-effect concentrator of the thermal energy compressor The average double-effect concentrator saves 29.92%, which is approximately 30%.
3, one effect heating temperature and low evaporation temperature
Since the project product uses a thermal energy compressor, the mixed steam used for heating is in a vacuum state, and the temperature is lower than the positive pressure heating steam temperature used in the conventional double effect concentrator. According to the environmental monitoring station of Jiamusi City, Heilongjiang Province, the average temperature of one-effect heating is 85 Â°C, and the average evaporation temperature is 72 Â°C. The average temperature of the ordinary double-effect concentrating device is 115 Â°C, and the average evaporation temperature is 85 Â°C. The concentrating device is low-temperature heating and low-temperature evaporation, and is particularly suitable for concentration of heat-sensitive drugs.
Source: HC Network Pharmaceutical Industry Channel
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