DESC:FIELD
The present invention relates generally to the field of condensate recovery systems.
DEFINITION
Skid system: The term ‘skid system hereinafter refers to a system including pump, processing units and driving elements contained within a frame. The skid system may have a portable configuration.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
In various industrial applications, particularly in the sugar industry, there is a significant demand for efficient handling of high loads of steam condensate, which is often at elevated temperatures. Currently available solutions predominantly rely on systems comprising centrifugal pumps, that however struggle to accommodate the condensate. This limitation results in a loss of valuable energy content when returning condensate to the boiler feed water tank. Further, high condensate load conditions tend to affect the life of the pumps, which leads to their breakdown, thereby causing the system to shut down, especially during critical load demands. Regular breakdowns not only increase the system downtime required for maintenance, but also affect the efficiency of other components. Moreover, the conventional systems are bulky and have a complex configuration.
There is therefore felt a need for a system that alleviates the aforementioned drawbacks.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
An object of the present invention is to provide a condensate recovery skid system.
Another object of the present invention is to provide a condensate recovery skid system that ensures continuity of process.
Still another object of the present invention is to provide for a condensate recovery skid system that effectively traps steam while effectively removing condensate.
Yet another object of the present invention is to provide a condensate recovery skid system which has a simple and compact configuration.
Still another object of the present invention is to provide a condensate recovery skid system which eliminates breakdown downtime of the overall system.
Another object of the present invention is to provide a condensate recovery skid system which may have a portable configuration.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure envisages a condensate recovery skid system which comprises a receiver, a plurality of steam-operated condensate pumps, a motive steam inlet header, and a set of redundant pumps.
The receiver has a common condensate inlet for receiving high loads of steam condensate at elevated temperatures from a process equipment, and a common condensate outlet for discharging recovered condensate to downstream applications. The steam-operated condensate pumps are configured to fluidly communicate with the receiver to receive the hot condensate from the common condensate inlet, pump the received hot condensate, and discharge it through the common condensate outlet. The motive steam inlet header is fluidly connected with the condensate pumps to supply motive steam to the condensate pumps to power the condensate pumps in their operative configuration. The redundant pumps are provided in fluid communication with the receiver and the motive steam inlet header. The redundant pumps are configured to be selectively be actuated in case of a malfunction of any condensate pump to ensure uninterrupted operation of the system.
The receiver, the plurality of condensate pumps, the motive steam inlet header, and the set of redundant pumps are configured within a skid configuration.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
A condensate recovery skid system of the present disclosure will now be described with the help of the accompanying drawing, in which:
Figure 1 illustrates a top view of the system of the disclosure;
Figure 2 illustrates a front view of the system of Figure 1;
Figure 3 illustrates a side view of the system of Figure 1.
LIST OF REFERENCE NUMERALS
100 condensate recovery skid system
105 common condensate inlet
110 common condensate outlet
115 receiver vent
120 receiver drain
125 condensate outlet header drains
130 common drain
135 motive steam inlet header
140 pump motive steam inlet
150 flash steam outlet
160 condensate sample collection
165 protection device
DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms “a”, “an” and “the” may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms “comprises”, “comprising”, “including”, “includes” and “having” are open-ended transitional phrases and therefore specify the presence of stated features, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, elements, components, and/or groups thereof.
A condensate recovery skid system (100) of the present disclosure will now be described in detail with reference to Figure 1 through Figure 3.
The condensate recovery skid system (100) is configured to manage and recover high-temperature steam condensate from industrial processes, providing a modular, efficient, and reliable solution for condensate handling. This system, organized in a skid configuration, houses a receiver, a series of steam-operated condensate pumps, a motive steam inlet header, a set of redundant pumps, and various sensors and control components to maintain continuous and efficient condensate management. The skid configuration allows the entire system to be compactly assembled in a portable structure, offering flexibility for deployment across various industrial settings. The portability simplifies installation, relocation, and maintenance, making it suitable for dynamic industrial environments with varying condensate recovery needs.
The system (100) works on the principles of steam power to handle the high loads. This feature is achieved by utilizing multiple individual steam-operated pumps organized within a common skid system (100) which is capable of accommodating high loads. The system (100) facilitates the optimization of equipment level pressure by incremental steam savings, and enhances condensate recovery, productivity, and product quality.
The system (100) ensures a complete closed-loop operation, eliminating the venting of flash steam and preventing any loss of condensate.
The system (100) comprises a receiver configured to collect and manage condensate inflow. The receiver includes a common condensate inlet (105) for receiving large volumes of high-temperature condensate from process equipment. The configuration of the inlet allows the receiver to accommodate substantial condensate loads, minimizing potential backflow and pressure build-up. To facilitate condensate discharge, the receiver incorporates a common condensate outlet (110) that directs processed condensate to downstream applications, such as boiler feedwater tanks. Positioned on the receiver is a receiver vent (115), which prevents pressure build-up by releasing excess steam or gases from the receiver. This vent feature is crucial for maintaining safe operational pressures and preventing equipment stress, thus extending the lifespan of the system’s components. Additionally, an operative bottom portion of the receiver is fitted with a receiver drain (120), configured to discharge excess condensate and prevent overflow. Equipped with a shut-off valve, the drain provides precise control over condensate discharge, enhancing the receiver's efficiency and ensuring optimal fluid levels within the system.
The system further comprises a plurality of steam-operated condensate pumps configured to fluidly communicate with the receiver to receive condensate from the common condensate inlet (105), pumping it under pressure, and then discharge it through the common condensate outlet (110). Each pump is specifically configured to handle high condensate loads exceeding 30 tons per hour (30TPH) and to operate at temperatures above 100° Celsius, making the pumps well-suited for rigorous industrial applications.
The system further comprises a motive steam inlet header (135) fluidly connected with the condensate pumps to supply motive steam to power the pumps for their operative configuration. By incorporating a pump motive steam inlet (140) for each condensate pump, the system ensures precise control over pump operation, enabling adjustments according to demand. This configuration optimizes energy usage by activating pumps selectively, thereby reducing unnecessary energy consumption.
The system additionally comprises a set of redundant pumps that serve as backup units. These pumps are provided in fluid communication with both the receiver and the motive steam inlet header, to allow automatic activation in case of a primary pump malfunction. The redundant pump setup ensures uninterrupted operation, a feature especially beneficial for high-demand environments where system downtime can lead to significant process disruptions. Engaging the redundant pumps ensures that even in the case of equipment failure, the condensate recovery process remains continuous, improving system reliability and process efficiency.
In an embodiment, the condensate pumps are configured to be operated selectively to allow some condensate pumps to remain in standby mode while others actively manage condensate loads based on demand.
In another embodiment, the receiver includes a receiver vent (115) provided on an operative portion of the receiver. The vent (115) is configured to release excess steam or gases therefrom to prevent pressure build-up in the receiver, and maintain optimal operating conditions.
In another embodiment, the receiver includes a receiver drain (120) provided on an operative bottom portion of the receiver. The drain (120) is configured to facilitate controlled discharge of excess condensate from the receiver, to maintain the desired level of condensate in the receiver and prevent overflow.
In yet another embodiment, the drain (120) includes a shut-off valve to regulate the flow of discharge through the drain (120).
In still another embodiment, the system includes at least one steam trap positioned upstream of the common condensate inlet (105) to remove non-condensable gases and condensate from process equipment before entry into the receiver.
In a further embodiment, the system includes a steam recovery line provided upstream of the steam trap, and a protective device (165) provided on the steam recovery line to release excess pressure from the steam recovery line to maintain optimal differential pressure across the steam traps. The protective device, as shown in Figure 2, functions by permitting the excess pressure in the line which is meant for recovering steam that is created during the loss of pressure of the condensate as it moves from the inlet of the reservoir as described in a previous embodiment (105) into the main body of the reservoir. This can cause the build-up of pressure in the reservoir, which is not desirable due to it interfering with the normal differential pressure of the system. The protective device releases this excess pressure, maintaining optimal differential pressure across traps.
In an embodiment, the system includes a common drain (130) configured to collect residual condensate from the receiver to prevent condensate build-up within the system. The system also includes a plurality of flash steam outlets (150) connected to the receiver to release any flash steam generated during the recovery process. These features help in optimizing the condensate recovery process, as flash steam release maintains balanced pressure, thus improving the system’s overall efficiency.
In an embodiment, the system includes a control system having a plurality of first sensors configured to monitor the operational status of each condensate pump. The first sensors are configured to generate at least one first sensed signal if malfunctions are detected in the condensate pumps. The control system also has an actuator configured to actuate at least one redundant pump based on the first sensed signal.
In another embodiment, the actuator includes a plurality of valves configured to fluidly communicate with both condensate pumps and the redundant pumps, and with the receiver and the motive steam inlet header. The valves are configured to direct the motive steam to the redundant pump to actuate the redundant pump.
In yet another embodiment, the system includes a plurality of second sensors configured to monitor condensate flow rate, pressure, and temperature within the system (100), and generate a plurality of second sensed signals.
In still another embodiment, the system includes a performance monitoring unit configured to communicate with the second sensors to receive the second sensed signals and process them by analysing flow rate, pressure, temperature, and steam consumption data to identify performance trends. The performance monitoring unit is further configured to facilitate adjustment of system parameters, including pump operation, steam flow, and pressure settings, to maintain optimal energy efficiency and condensate recovery rates.
In an embodiment, the system includes a plurality of flash steam outlets (150) connected to the receiver. The flash steam outlets (150) are configured to release flash steam generated during the condensate recovery process.
In another embodiment, each condensate pump includes a pump motive steam inlet (140) connected to the motive steam inlet header (135), enabling individual control of each condensate pump in response to load conditions.
In yet another embodiment, the skid configuration is portable, allowing the system to be deployed in various industrial settings and simplifying relocation and installation.
In still another embodiment, the common condensate outlet (110) is configured to direct condensate to a condensate recovery unit, such as a boiler feedwater tank.
In a further embodiment, the receiver comprises a plurality of condensate outlet header drains (125) configured to maintain consistent flow toward the common condensate outlet (110) and prevent stagnation in the receiver.
The combination of all the components, of the system, integrated within a single skid configuration maximizes the system’s functionality while minimizing its footprint, making it a compact, efficient, and versatile solution for industrial condensate recovery needs.
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCEMENTS
The present disclosure described hereinabove has several technical advantages including, but not limited to a condensate recovery skid system, which:
• ensures continuity of process;
• eliminates breakdown downtime of the overall system;
• effectively traps steam while effectively removing condensate;
• ensures normal differential pressure in system by using a protection device;
• may have a portable configuration; and
• has a simple and compact configuration.
The foregoing disclosure has been described with reference to the accompanying embodiments which do not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
Any discussion of materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation. ,CLAIMS:WE CLAIM:
1. A condensate recovery skid system (100) comprising:
• a receiver having a common condensate inlet (105) for receiving high loads of steam condensate at elevated temperatures from a process equipment, and a common condensate outlet (110) for discharging recovered condensate to downstream applications;
• a plurality of steam-operated condensate pumps configured to fluidly communicate with the receiver to receive the hot condensate from the common condensate inlet (105), pump the received hot condensate, and discharge it through the common condensate outlet (110);
• a motive steam inlet header (135) fluidly connected with the condensate pumps to supply motive steam to the condensate pumps to power the condensate pumps in their operative configuration; and
• a set of redundant pumps provided in fluid communication with the receiver and the motive steam inlet header, the set of redundant pumps configured to be selectively be actuated in case of a malfunction of any condensate pump to ensure uninterrupted operation of the system;
wherein the receiver, the plurality of condensate pumps, the motive steam inlet header (135), and the set of redundant pumps are configured within a skid configuration.
2. The system (100) as claimed in claim 1, wherein the condensate pumps are configured to be operated selectively to allow some condensate pumps to remain in standby mode while others actively manage condensate loads based on demand.
3. The system (100) as claimed in claim 1, wherein the receiver includes a receiver vent (115) provided on an operative portion of the receiver, the vent (115) configured to release excess steam or gases therefrom to prevent pressure build-up in the receiver, and maintain optimal operating conditions.
4. The system (100) as claimed in claim 1, wherein the receiver includes a receiver drain (120) provided on an operative bottom portion of the receiver, the drain (120) configured to facilitate controlled discharge of excess condensate from the receiver, to maintain the desired level of condensate in the receiver and prevent overflow.
5. The system (100) as claimed in claim 4, wherein the drain (120) includes a shut-off valve to regulate the flow of discharge through the drain (120).
6. The system (100) as claimed in claim 1, which includes at least one steam trap positioned upstream of the common condensate inlet (105) to remove non-condensable gases and condensate from process equipment before entry into the receiver.
7. The system (100) as claimed in claim 6, which includes a steam recovery line provided upstream of the steam trap, and a protective device (165) provided on the steam recovery line to release excess pressure from the steam recovery line to maintain optimal differential pressure across the steam traps.
8. The system (100) as claimed in claim 1, wherein each steam-operated condensate pump is configured to handle condensate loads exceeding 30 tons per hour at temperatures above 100° Celsius.
9. The system (100) as claimed in claim 1, which includes a common drain (130) configured to collect residual condensate from the receiver to prevent condensate build-up within the system.
10. The system (100) as claimed in claim 1, which includes a control system having a plurality of first sensors configured to monitor the operational status of each condensate pump, the first sensors configured to generate at least one first sensed signal if malfunctions are detected in the condensate pumps, the control system having an actuator configured to actuate at least one redundant pump based on the first sensed signal.
11. The system (100) as claimed in claim 10, wherein the actuator includes a plurality of valves configured to fluidly communicate with both condensate pumps and the redundant pumps, and with receiver and the motive steam inlet header, the valves configured to direct the motive steam to the redundant pump to actuate the redundant pump.
12. The system (100) as claimed in claim 1, which includes a plurality of second sensors configured to monitor condensate flow rate, pressure, and temperature within the system (100), and generate a plurality of second sensed signals.
13. The system (100) as claimed in claim 12, which includes a performance monitoring unit configured to communicate with the second sensors to receive the second sensed signals and process them by analysing flow rate, pressure, temperature, and steam consumption data to identify performance trends, the performance monitoring unit further configured to facilitate adjustment of system parameters, including pump operation, steam flow, and pressure settings, to maintain optimal energy efficiency and condensate recovery rates.
14. The system (100) as claimed in claim 1, which includes a plurality of flash steam outlets (150) connected to the receiver, the flash steam outlets (150) configured to release flash steam generated during the condensate recovery process.
15. The system (100) as claimed in claim 1, wherein each condensate pump includes a pump motive steam inlet (140) connected to the motive steam inlet header (135), enabling individual control of each condensate pump in response to load conditions.
16. The system (100) as claimed in claim 1, wherein the skid configuration is portable, allowing the system to be deployed in various industrial settings and simplifying relocation and installation.
17. The system (100) as claimed in claim 1, wherein the common condensate outlet (110) is configured to direct condensate to a condensate recovery unit, such as a boiler feedwater tank.
18. The system (100) as claimed in claim 1, wherein the receiver comprises a plurality of condensate outlet header drains (125) configured to maintain consistent flow toward the common condensate outlet (110) and prevent stagnation in the receiver.

Dated this 06th Day of November, 2024

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
OF R. K. DEWAN & CO.
AUTHORIZED AGENT OF APPLICANT

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, AT MUMBAI