Modularized, superheated steam generators comprise a steam module (46), a thermocouple module (41), and an electrode module (45) assembled within a containment enclosure (66). The multi-stage steam module (46) comprises a plurality of first stage pressure vessels (77) surrounding and feeding a secon
Modularized, superheated steam generators comprise a steam module (46), a thermocouple module (41), and an electrode module (45) assembled within a containment enclosure (66). The multi-stage steam module (46) comprises a plurality of first stage pressure vessels (77) surrounding and feeding a second stage pressure vessel (78). The steam module (46) is coaxially surrounded by insulation (48) disposed within a cylindrical shroud (72). The electrode module (45) radiantly heats the steam module with resistive heating elements (119). The thermocouple module (41) includes thermocouples monitoring first stage temperatures within and between pressure vessels (77). PLC computer SCADA software (600) operates the generators. Thermocouple data is analyzed to control heater temperatures, the water feeding system (340), and outputted steam temperature. PLC software (600) provides operating logic (602) establishing a start up subroutine (602), a ramp up subroutine (603), a steady state subroutine (605), and a shut down subroutine (606).
대표청구항▼
1. A method for producing superheated steam, the method comprising the steps of : providing a plurality of pressure vessels;heating the pressure vessels with a plurality of heating elements;sensing temperatures proximate said vessels;providing water to said pressure vessels through a water distribut
1. A method for producing superheated steam, the method comprising the steps of : providing a plurality of pressure vessels;heating the pressure vessels with a plurality of heating elements;sensing temperatures proximate said vessels;providing water to said pressure vessels through a water distribution manifold connected through individual water delivery lines leading to said pressure vessels;feeding water to said water distribution manifold at selectable pressures with a variable pressure system pump;energizing said heating elements during operation of said generator with a power control circuit;operating said variable pressure system pump, and energizing said power control circuit with a PLC computer system; and,discharging superheated steam. 2. The method as defined in claim 1 including the steps of: obtaining incoming through either a high or low pressure water source;selecting whether a high or low pressure source has been connected with valves;if low pressure water source has been utilized, pumping in the water and providing it to the variable pressure pump;preheating incoming water; and,subjecting water to reverse osmosis treatment prior to delivery to said variable pressure pump. 3. The method as defined in claim 1 wherein said feeding step employs a Variable Frequency Drive pump. 4. The method as defined in claim 3 including the step of driving said pump with a variable-speed drive controller operated by said PLC computer system. 5. The method as defined in claim 3 wherein said step of providing a plurality of pressure vessels comprises the steps of: providing a plurality of first stage pressure vessels and at least one second stage pressure vessel;feeding steam from said first stage pressure vessels to said second stage pressure vessel;delivering water to said first stage pressure vessels from said water distribution manifold through separate water delivery lines. 6. The method as defined in claim 5 including the steps of monitoring the water flow in said water delivery lines and providing flow information to said PLC computer system. 7. The method as defined in claim 5 including the steps of opening or closing the water delivery lines with control valves in response to said PLC computer system. 8. The method as defined in claim 7 including the steps of monitoring the water flow in said water delivery lines and providing flow information to said PLC computer system. 9. The method as defined in claim 5 including the steps of sensing pressure on each of said water delivery lines and providing pressure information to said PLC computer system. 10. The method as defined in claim 5 including the step of preventing backflow with one-way, check valves in said water delivery lines. 11. The method as defined in claim 5 including the steps of providing each water delivery line with: control valves that enable or disable the water flow through said water delivery lines in response to said PLC computer system;pressure sensors that monitor water pressure in said water delivery lines and provide pressure information to said PLC computer system; and,flow indicators that monitor water flow to individual pressure vessels and provide flow information to said PLC computer system. 12. The method as defined in claim 11 further comprising the steps of operating software with the PLC computer system and establishing: a “start-up” subroutine for beginning generator operation;a “ramp up” subroutine for initially checking the water supply, water flow and available electrical power;a “steady state” subroutine for monitoring normal operational parameters and for storing them in a data storage system; and,a “shut down” subroutine, which turns components off in a proper sequence that avoids damage and prevents overheating. 13. The method as defined in claim 12 wherein the “start-up” subroutine performs functions selected from the group consisting of: diagnostic checking, determining available power, determining the availability of a proper ground, establishing electric power connections, providing power to the various circuit breakers and power supplies and transformers, and initialization of said PLC automation system. 14. The method as defined in claim 12 wherein the “ramp up” subroutine performs functions selected from the group consisting of: energizing the power control circuit to activate heating elements, checking for a proper water supply, monitoring heater temperature, opening water control valves, and monitoring water flow and water pressure. 15. The method as defined in claim 12 wherein the “steady state” subroutine performs functions selected from the group consisting of: monitoring operational parameters. storing data in a data storage system, controlling water supplied by said variable pressure pump, and determining temperatures by monitoring thermocouples. 16. A method for producing superheated steam, the method comprising the steps of : providing a plurality of first stage pressure vessels;providing at least one second stage pressure vessel;radiantly heating the first stage and second stage pressure vessels with a plurality of heating elements;delivering steam from said first stage pressure vessels to said at least one second stage pressure vessel;monitoring system temperatures proximate said vessels;providing water to said first stage pressure vessels through a water distribution manifold connected through individual water delivery lines leading to said first stage pressure vessels;feeding water to said water distribution manifold at selectable pressures with a variable pressure system pump;monitoring water pressure;energizing said heating elements during operation of said generator with a power control circuit;operating said variable pressure system pump and energizing said power control circuit with a PLC computer system in response to system temperature and water pressure; and,discharging superheated steam from said at least one second stage pressure vessel. 17. The method as defined in claim 16 including the steps of: obtaining source water through either a high or low pressure water source;selecting whether a high or low pressure source has been connected with valves;if low pressure water source has been utilized, pumping in the water;preheating incoming water; and,subjecting water to reverse osmosis treatment prior to delivery to said variable pressure pump. 18. The method as defined in claim 16 wherein said feeding step employs a Variable Frequency Drive pump. 19. The method as defined in claim 18 including the step of driving said pump with a variable-speed drive controller operated by said PLC computer system. 20. The method as defined in claim 16 including the steps of monitoring the water flow in said water delivery lines, providing flow information to said PLC computer system, and varying said variable frequency drive pump pressure in response to said flow information. 21. The method as defined in claim 16 including the steps of opening or closing the water delivery lines with control valves in response to said PLC computer system. 22. The method as defined in claim 16 including the steps of monitoring water pressure in said water delivery lines, providing said water line pressure information to said PLC computer system, and varying said variable pressure system pump output pressure in response to said water line pressure information. 23. The method as defined in claim 16 including the step of preventing backflow with one-way, check valves in said water delivery lines. 24. The method as defined in claim 16 including the steps of providing each water delivery line with: control valves that enable or disable the water flow through said water delivery lines in response to said PLC computer system;pressure sensors that monitor water pressure in said water delivery lines and provide pressure information to said PLC computer system; and,flow indicators that monitor water flow to individual pressure vessels and provide flow information to said PLC computer system. 25. The method as defined in claim 24 wherein said feeding step employs a Variable Frequency Drive pump, and wherein the PCL computer system adjusts said Variable Frequency Drive pump in response to said pressure sensors and flow indicators. 26. The method as defined in claim 16 further comprising the steps of operating software with the PLC computer system and establishing: a “start-up” subroutine for beginning generator operation;a “ramp up” subroutine for initially checking the water supply, water flow and available electrical power;a “steady state” subroutine for monitoring normal operational parameters and for storing them in a data storage system; and,a “shut down” subroutine, which turns components off in a proper sequence that avoids damage and prevents overheating. 27. The method as defined in claim 26 wherein the “start-up” subroutine performs functions selected from the group consisting of: diagnostic checking, determining available power, determining the availability of a proper ground, establishing electric power connections, providing power to the various circuit breakers and power supplies and transformers, and initialization of said PLC automation system. 28. The method as defined in claim 26 wherein the “ramp up” subroutine performs functions selected from the group consisting of: energizing the power control circuit to activate heating elements, checking for a proper water supply, monitoring heater temperature, opening water control valves, and monitoring water flow and water pressure. 29. The method as defined in claim 26 wherein the “steady state” subroutine performs functions selected from the group consisting of: monitoring operational parameters. storing data in a data storage system, controlling water supplied by said variable pressure pump, and determining temperatures by monitoring thermocouples. 30. A method for producing superheated steam, the method comprising the steps of : providing a plurality of first stage pressure vessels;connecting outputs from said first stage vessels to at least one second stage pressure vessel;radiantly heating the first stage pressure vessels and said at least one second stage pressure vessels with a plurality of heating elements;providing water to said first stage pressure vessels through a water distribution manifold connected through individual water delivery lines leading to each of said first stage pressure vessels;feeding water to said water distribution manifold at selectable pressures with a variable pressure system pump;monitoring system pump water pressure;energizing said heating elements during operation of said generator with a power control circuit;monitoring system temperatures proximate said vessels;operating said variable pressure system pump with a PLC computer system in response to system water pressure; and,energizing said power control circuit with said PLC computer system in response to system temperature; and,discharging superheated steam from said at least one second stage pressure vessel. 31. The method as defined in claim 30 wherein said feeding step employs a Variable Frequency Drive pump. 32. The method as defined in claim 30 including the step of varying said power control circuit with said PLC computer system in response to system pump pressure. 33. The method as defined in claim 30 including the steps of monitoring the water flow in said water delivery lines, providing flow information to said PLC computer system, and varying said variable frequency drive pump pressure in response to said flow information. 34. The method as defined in claim 30 including the steps of opening or closing the water delivery lines with control valves in response to said PLC computer system. 35. The method as defined in claim 30 including the steps of monitoring water pressure in said water delivery lines, providing said water line pressure information to said PLC computer system, and varying said variable pressure system pump output pressure in response to said water line pressure information. 36. The method as defined in claim 30 including the steps of providing each water delivery line with: control valves that enable or disable the water flow through said water delivery lines in response to said PLC computer system;pressure sensors that monitor water pressure in said water delivery lines and provide pressure information to said PLC computer system; and,flow indicators that monitor water flow to individual pressure vessels and provide flow information to said PLC computer system. 37. The method as defined in claim 36 wherein said feeding step employs a Variable Frequency Drive pump, and wherein the PCL computer system adjusts said Variable Frequency Drive pump in response to said pressure sensors and flow indicators.
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