High-precision low-power-consumption cooling system for chemical reaction furnace

Abstract

The invention discloses a high-precision low-power-consumption cooling system for a chemical reaction furnace, and relates to the technical field of heat exchange in chemical production. The cooling device comprises a cooling circulation pipe, the cooling circulation pipe is used for connecting a reaction furnace and a cooling device, the cooling circulation pipe is communicated with an inner cavity of the reaction furnace, the cooling circulation pipe is used for leading out reactants in the reaction furnace to enter the cooling device to be cooled and circularly flow back into the reaction furnace, and the cooling device comprises an air cooling fan and a liquid cooling cooler. The cooling circulating pipe is directly communicated with the inner cavity of the reaction furnace, so that a traditional jacket or coil indirect cooling mode is abandoned, reactants in the reaction furnace are directly led out to enter the cooling device for cooling, the total thermal resistance of the system is reduced, and the overall cooling efficiency is improved; the thermal hysteresis effect generated when a traditional cooling medium circulates in a long pipeline and an external water chilling unit is effectively eliminated, the real-time monitoring of the cooling controller can make an instantaneous response to the temperature change of reactants, and the problem that the temperature control precision is poor is solved.

Description

Technical Field

[0001] This invention relates to the technical field of heat exchange in chemical production, and in particular to a high-precision, low-power cooling system for chemical reactors. Background Technology

[0002] In the field of modern chemical production, chemical reactors are the core equipment for realizing various chemical synthesis, polymerization, cracking and other processes. Most chemical reactions release a lot of heat during the process, causing the internal temperature of the reactor to rise rapidly. If this excess heat cannot be discharged and cooled down in a timely and accurate manner, it will not only lead to side reactions and reduce the yield and purity of the target product, but may also cause catalyst deactivation, or even cause the reaction to run away from control, resulting in serious overpressure explosions and other safety accidents.

[0003] Existing chemical reactor cooling systems typically employ indirect cooling. Their conventional structure mainly includes an external jacket or internal coil, an external circulating pump, and a separately installed external cooler. In actual operation, the existing cooling process is usually as follows: First, a specific cooling medium is introduced into the reactor's jacket or coil via a circulating pump to absorb the heat released by the materials inside the reactor. Then, the high-temperature cooling medium that has absorbed heat is pumped to the external cooler, where a second cooling medium is used to further cool it. The cooled medium is then pumped back to the reactor, and this cycle repeats continuously.

[0004] First, the existing cooling mechanism is essentially a "secondary cooling heat exchange" process, where the reactor material is cooled once by the cooling medium, and then the cooling medium is cooled a second time by an external cooling medium. This added intermediate step inevitably leads to significant thermal resistance loss, resulting in very low overall cooling efficiency. Second, due to the two cooling processes and the long pipeline circulation, the system suffers from a severe "thermal hysteresis" effect, resulting in poor control accuracy of the reactor's internal temperature and making it difficult to meet the stringent temperature fluctuation requirements of modern fine chemical engineering. Finally, to compensate for the low cooling efficiency, existing systems often require high-power cooling medium circulation pumps and energy-intensive external refrigeration units to force accelerated circulation and cooling, leading to extremely high equipment operating power consumption.

[0005] CN120970158A discloses a boehmite reactor water circulation cooling system, including a reactor, a preheating tank, a water storage tank with an inlet and an outlet, and a heat exchanger. The reactor contains a cooling pipe with one end as a first inlet and the other end as a first outlet. The preheating tank contains a heating pipe with one end as a second inlet and the other end as a second outlet. The second inlet is connected to the first outlet. The water storage tank's inlet is connected to the second outlet. The heat exchanger's hot water inlet is connected to the water storage tank's outlet, and its cold water outlet is connected to the cooling pipe's first inlet. This technology uses a secondary heat exchange cooling device, introducing a cooling medium into the reactor for circulation, and then introducing an external cooling device to cool the medium. However, this method has poor cooling effect and low efficiency, making it unsuitable for situations requiring rapid cooling. Summary of the Invention

[0006] To address the problems of high power consumption and low cooling efficiency in traditional secondary cooling systems, this invention provides a high-precision, low-power cooling system for chemical reactors.

[0007] The present invention provides a high-precision, low-power cooling system for a chemical reactor, which adopts the following technical solution: A high-precision, low-power cooling system for a chemical reactor includes a cooling circulation pipe connecting the reactor and a cooling device. The cooling circulation pipe is connected to the inner cavity of the reactor and is used to guide reactants from the reactor into the cooling device for cooling and then circulate them back into the reactor. The cooling device includes an air cooling fan and a liquid cooler. The air cooling fan cools the reactants in the cooling circulation pipe through circulating air cooling, and the liquid cooler cools the reactants in the cooling circulation pipe through circulating water cooling. The reactor, cooling circulation pipe, air cooling fan, and liquid cooler are connected to a cooling controller via wires. The cooling controller is used to monitor cooling parameters and control the cooling process.

[0008] By directly connecting the cooling circulation pipe to the inner cavity of the reactor, the traditional jacketed or coiled indirect cooling mode is abandoned. This allows the reactants in the reactor to be directly discharged into the cooling device for cooling. Traditional secondary cooling introduces an intermediate cooling medium, which increases the additional convective thermal resistance and pipe wall thermal resistance. This system achieves direct cooling of the reactants, reduces the total thermal resistance of the system, and allows heat to be quickly removed, improving the overall cooling efficiency. It effectively eliminates the thermal hysteresis effect caused by the circulation of the cooling medium in long pipelines and external chillers. Combined with the real-time monitoring and dynamic adjustment of the cooling controller, the system can make instantaneous responses to the temperature changes of the reactants themselves, controlling the temperature fluctuation range within a small error range. This solves the problem of poor temperature control accuracy, effectively avoids the occurrence of side reactions and the danger of temperature loss, and ensures high yield and high purity of fine chemical products.

[0009] Furthermore, a stirrer is installed inside the reactor, and the stirrer is driven by a stirring motor. The stirrer is a spiral stirrer, which stirs the reactants inside the reactor and guides the reactants to circulate from top to bottom or from bottom to top.

[0010] A spiral stirrer is used inside the reactor, which can achieve an overall axial circulation flow field from top to bottom or bottom to top. This promotes rapid tumbling and mixing of materials in the upper and lower layers of the reactor, reducing material stratification and local temperature gradients that are prone to occur in traditional reaction processes. It effectively ensures the uniformity of the temperature and concentration fields of the materials in the entire reactor. The internal axial circulation driven by the spiral stirrer and the external cooling circulation constructed by the cooling circulation pipe form a highly efficient physical synergy, which accelerates the macroscopic flow of materials in the reactor. This allows materials that need to be cooled to be pumped into the external cooling circulation pipe more quickly. The low-temperature materials that flow back to the reactor after being cooled by the external cooling device can be instantly dispersed and integrated into the overall reaction materials under the strong axial entrainment action of the spiral stirrer, improving the temperature control accuracy and cooling efficiency of the system.

[0011] Furthermore, the reactor is equipped with a sealing cover for sealing the feed inlet. The sealing cover is equipped with a sight glass, which is a transparent plate. A protective shell is wrapped around the outside of the reactor. The reactor and the protective shell are installed and fixed by a support frame.

[0012] The sealing cover installed at the reactor inlet effectively ensures airtightness during the reaction process, preventing the volatilization of reactants, leakage of harmful gases, or intrusion of external impurities, thereby maintaining a pure and safe reaction environment. At the same time, the sealing cover integrates a transparent sight glass, allowing operators to intuitively and in real time observe the liquid level, mixing state, color changes, and reaction intensity of the materials inside the reactor. The protective shell forms a heat insulation layer around the reactor, effectively reducing heat loss or inflow from the reactor body to the external environment, further reducing the overall energy consumption of the system, and improving the occupational safety protection level of the production site.

[0013] Furthermore, the cooling circulation pipe is connected to the bottom and middle of the reactor at both ends, and a circulation pump is connected to and installed on the cooling circulation pipe. The circulation pump drives the reactants in the reactor to flow in the cooling circulation pipe in a directional manner. A shut-off valve is installed at the end of the cooling circulation pipe connected to the bottom of the reactor.

[0014] The cooling circulation pipe is connected to the bottom and middle of the reactor at both ends. By setting the extraction port of the circulation pipe at the bottom and the return port at the middle, materials that are prone to sedimentation and temperature gradients at the bottom can be forcibly extracted and reinjected into the active mixing zone in the middle of the reactor. This process interacts with the axial flow field of the internal spiral agitator, eliminating the mixing dead zone at the bottom and ensuring the homogenization and temperature uniformity of the materials throughout the furnace. The circulation pump installed on the cooling circulation pipe provides a continuous, stable, and directional powerful power source for the external cooling circulation, making the flow rate of the cooling process quantifiable and precisely controllable. This ensures the high efficiency and accurate execution of the temperature control system. A shut-off valve is installed at the end of the cooling circulation pipe that connects to the bottom of the reactor to prevent reactants from flowing into the cooling circulation pipe during the reaction process.

[0015] Furthermore, a liquid one-way valve is installed at one end of the cooling circulation pipe connected to the middle of the reactor. The liquid one-way valve is configured to allow the reaction material in the cooling circulation pipe to flow into the reactor in one direction. A gas pressure balance pipe is connected to the cooling circulation pipe connected to the middle of the reactor. The gas pressure balance pipe is used to connect the cooling circulation pipe and the top of the reactor. A gas one-way valve is installed on the gas pressure balance pipe. The gas one-way valve is configured to allow gas in the reactor to flow into the cooling circulation pipe in one direction.

[0016] After the cooling process is completed, the system needs to reverse the flow of the circulating pump to return the residual reactants in the cooling circulation pipe to the reactor. At this time, the liquid check valve in the middle of the reactor automatically closes due to the reverse negative pressure, cutting off the liquid phase circuit. As the liquid in the pipe is pumped out, a negative pressure trend is generated in the pipe. The gas check valve installed on the gas pressure balance pipe automatically opens, allowing the gas at the top of the reactor to smoothly replenish the cooling circulation pipe. This achieves real-time gas pressure balance between the reactor and the pipeline, ensuring that the reverse discharge process proceeds smoothly under normal pressure difference. Thanks to the gas compensation provided by the gas pressure balance pipe, the circulating pump can completely evacuate the reactants inside the cooling circulation pipe and cooling equipment without resistance when reversing, and safely return them all to the reactor. This avoids the residue of easily crystallized or corrosive materials in the external pipeline, reducing the difficulty of cleaning the subsequent pipelines.

[0017] Furthermore, the air cooling fan blows air towards the cooling circulation pipe, the cooling circulation pipe is fixedly installed by a heat dissipation bracket, and the air cooling fan is fixedly installed by a fan bracket.

[0018] The air cooling fan blows air directly onto the cooling circulation pipe to achieve forced convection cooling. The high-speed airflow can quickly remove heat from the pipe wall surface, allowing the reactants to be rapidly cooled or controlled as they flow through the cooling circulation pipe. This effectively shortens the cooling time required for the process and improves overall production efficiency. The cooling circulation pipe and air cooling fan are installed and fixed by their respective brackets, increasing the heat dissipation area and improving the utilization rate of wind energy and the cooling effect.

[0019] Furthermore, an installation net is installed on the heat dissipation bracket. The installation net is respectively set on both sides of the cooling circulation pipe and fixed in place. An air-cooled heat dissipation plate is provided on the outer surface of the air-cooled part of the cooling circulation pipe. The air-cooled heat dissipation plate is connected and fixed to the installation net.

[0020] By installing air-cooled heat dissipation plates on the outer surface of the cooling circulation pipe at the air intake, the effective contact area between the pipe and the cooling air is increased. The air-cooled heat dissipation plates utilize the high thermal conductivity of metal to quickly transfer the heat of the fluid inside the pipe to the plate surface, which is then carried away by the high-speed airflow of the air cooling fan. This effectively reduces the contact thermal resistance between the pipe wall and the air side. The installation mesh is set on both sides of the cooling circulation pipe and sandwiches the pipe section connected to the air-cooled heat dissipation plates in the middle, which improves the rigidity of the structure. When the fluid pulsates through the pipe or the fan vibrates, it can effectively disperse stress. Using the installation mesh as a fixed base, the mesh lines can also cut the airflow, increase the turbulence of the air, and enhance the convective cooling effect.

[0021] Furthermore, the liquid cooler includes a liquid cooling box containing a cooling medium, and the cooling circulation pipe passes through the liquid cooling box and comes into contact with the cooling medium inside the liquid cooling box for cooling.

[0022] The cooling circulation pipes pass directly through the liquid cooling tank and come into physical contact with the liquid medium. They can utilize the liquid's strong heat absorption and conduction capabilities to rapidly remove a large amount of heat from the fluid inside the pipes in a short time, achieving higher power cooling requirements. Pre-cooling is performed by air cooling, followed by liquid cooling to prevent a sudden drop in the temperature of the reactants and the formation of impurities such as crystals. At the same time, the cooling medium stored in the liquid cooling tank also forms a thermal buffer pool with a large thermal inertia. The medium in the liquid cooling tank can absorb and smooth temperature fluctuations. This composite design enables the system to adapt to a wider range of ambient temperatures and more complex thermal load conditions, improving the overall heat dissipation limit and environmental adaptability.

[0023] Furthermore, a water spray head is provided above the liquid cooling tank, and the water spray head sprays water towards the liquid cooling tank. The cooling circulation pipe passes through the water spray area of ​​the water spray head and comes into contact with the cooling medium sprayed by the water spray head for cooling. A guide net is provided on both sides of the cooling circulation pipe in the water spray area of ​​the water spray head. A liquid cooling heat dissipation plate is provided on the outer surface of the water spray cooling part of the cooling circulation pipe. The guide net is connected and fixed to the liquid cooling heat dissipation plate. The air intake side of the air cooling fan faces the guide net.

[0024] The spray nozzles evenly spray the cooling medium onto the cooling circulation pipes and liquid cooling heat sinks, forming a constantly renewing water film on their surface. When the air drawn by the fan flows through, the water film evaporates rapidly. This evaporative cooling mechanism can quickly remove heat from the pipes, improving cooling efficiency and further reducing the load on subsequent cooling. The liquid cooling heat sinks on the outer surface of the cooling circulation pipes expand the water spray contact area, and the guide nets on both sides not only provide stable structural support but also disperse and guide the sprayed water flow, allowing the cooling water to adhere more evenly and distribute on the heat sinks and pipe walls, thus ensuring the overall cooling efficiency and uniformity.

[0025] Furthermore, the reactor is equipped with an in-furnace temperature sensor, the cooling circulation pipe is equipped with a circulation temperature sensor, and the liquid cooler is equipped with a cooling temperature sensor. The in-furnace temperature sensor, the circulation temperature sensor, and the cooling temperature sensor are respectively connected to the cooling controller. The cooling controller dynamically controls the operating parameters of the reactor, the cooling circulation pipe, the air cooling fan, and the liquid cooler based on the temperature sensor data.

[0026] By installing temperature sensors in the reactor, cooling circulation pipes, and liquid cooler, the system can acquire thermodynamic data of each key node in the entire heat exchange chain in real time and accurately, providing reliable data support for subsequent precise control and forming an efficient closed-loop feedback control system. When the reactor heat load fluctuates, the controller can respond instantly and dynamically adjust parameters such as the flow rate of the cooling circulation pipes, the wind speed of the air cooling fan, and the spray volume of the liquid cooler to strictly control the temperature of the reactor and pipelines within the set optimal process range.

[0027] In summary, the present invention has the following beneficial technical effects: 1. The axial entrainment flow field of the internal spiral agitator and the forced directional flow of the external cooling circulation pipe form a seamless combination. The cooling circulation pipe draws out easily deposited materials from the bottom, and after cooling, they are injected into the active zone in the middle by the circulation pump. Combined with the up-and-down tumbling of the agitator, the bottom mixing dead zone is completely eliminated, and the instantaneous unification of the temperature field and concentration field of the material in the whole furnace is achieved.

[0028] 2. The system abandons the traditional jacketed indirect cooling and directly discharges the reactants to the cooling device. This design eliminates the convection and thermal resistance of the pipe wall caused by the intermediate cooling medium. Combined with the real-time monitoring and dynamic closed-loop adjustment of the actual temperature of the reactants by the cooling controller, the thermal hysteresis effect of long pipelines is completely eliminated, and instantaneous response to small error ranges of temperature fluctuations is achieved.

[0029] 3. Under reverse discharge conditions, the liquid check valve, gas check valve and pressure balance pipe in the middle form a gas-liquid linkage compensation mechanism. When the circulating pump reverses to draw in, the liquid check valve cuts off the liquid phase circuit, and the pressure balance pipe automatically introduces gas from the furnace top to replenish the negative pressure in the pipe. This allows all corrosive or easily crystallizing residual materials to be completely sent back to the reactor without resistance under normal pressure difference, greatly reducing the cost of pipeline cleaning and maintenance.

[0030] 4. The air cooling fan, air-cooled heat sink, and mounting mesh form a highly efficient aerodynamic cooling assembly. The heat sink utilizes the high thermal conductivity of metal to dissipate heat from the pipe wall, while the mounting mesh installed on both sides not only enhances the vibration resistance of the pipe, but its mesh lines can also actively cut the high-speed airflow blown out by the fan, increase the local air turbulence, and significantly improve the convective cooling coefficient on the air side.

[0031] 5. The cooling circulation pipes pass through the air-cooled zone and the liquid-cooled box in sequence, forming a stepped flexible cooling curve. The front fan provides forced convection for pre-cooling, while the liquid medium in the rear provides deep heat exchange. This sequential arrangement of components not only avoids the sudden drop in local temperature and the precipitation of side reactions caused by direct strong cooling, but the liquid-cooled box also acts as a large thermal inertia buffer to smooth out temperature fluctuations in the external environment.

[0032] 6. The spray head, guide net, liquid cooling heat sink and exhaust fan form a composite heat dissipation link. The guide net evenly disperses the spray water on the surface of the heat sink to form a dynamic water film. The high-speed suction of the air cooling fan forces the airflow to sweep across the water film to accelerate its evaporation. The system utilizes the huge latent heat of water phase change to achieve extremely high power heat transfer with extremely low water consumption and power consumption.

[0033] 7. The furnace temperature sensor, circulation temperature sensor and cooling temperature sensor gather data from the three locations in real time to the cooling controller. The components are transformed from physical isolation to data interconnection. The cooling controller dynamically adjusts the pump flow, fan speed and water spray load based on the overall data, making the system a fully automatic active thermal management hub.

[0034] 8. The bottom shut-off valve, circulating pump and cooling controller's abnormal early warning system together form a safety redundancy defense line. During non-cooling periods, the shut-off valve physically isolates materials from entering the pipeline. Under operating conditions, once the multi-node sensor detects local temperature rise abnormality or signs of thermal runaway, the system can instantly activate the maximum cooling power or issue an early warning shutdown to completely prevent extreme thermal damage and extend the service life of core equipment. Attached Figure Description

[0035] Figure 1 This is a schematic diagram of the installation structure of the cooling system of the present invention; Figure 2 for Figure 1 Another perspective structural illustration of retreat; Figure 3 This is a schematic diagram of the cross-sectional structure at the vertical plane of the present invention.

[0036] Explanation of reference numerals in the attached figures: 1. Reactor; 11. Stirrer; 111. Stirring motor; 12. Sealing cover; 121. Sight glass; 13. Protective shell; 131. Support frame; 2. Cooling circulation pipe; 21. Circulation pump; 211. Shut-off valve; 212. Liquid check valve; 22. Pressure balance pipe; 221. Gas check valve; 3. Air cooling fan; 31. Heat dissipation bracket; 311. Mounting net; 312. Air-cooled heat dissipation plate; 32. Fan bracket; 4. Liquid cooler; 41. Liquid cooling box; 411. Liquid replacement pipe; 42. Sprinkler head; 421. Flow guide net; 422. Liquid cooling heat dissipation plate; 5. Cooling controller; 51. Furnace internal temperature sensor; 52. Circulation temperature sensor; 53. Cooling temperature sensor. Detailed Implementation

[0037] The following will be combined with the appendix Figures 1-3The technical solutions in the embodiments of the present invention are clearly and completely described herein. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0038] In the description of this invention, it should be understood that the terms "longitudinal", "lateral", "up", "down", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this invention, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0039] Example 1: This invention discloses a high-precision, low-power cooling system for a chemical reactor, referring to... Figure 1 The system includes a cooling circulation pipe 2, which connects the reactor 1 and the cooling device. The cooling circulation pipe 2 is connected to the inner cavity of the reactor 1. The cooling circulation pipe 2 is used to guide the reactants in the reactor 1 into the cooling device for cooling and then circulate them back into the reactor 1. The cooling device includes an air cooling fan 3 and a liquid cooler 4. The air cooling fan 3 cools the reactants in the cooling circulation pipe 2 through circulating air cooling, and the liquid cooler 4 cools the reactants in the cooling circulation pipe 2 through circulating water cooling. The reactor 1, the cooling circulation pipe 2, the air cooling fan 3, and the liquid cooler 4 are respectively connected to a cooling controller 5 through wires. The cooling controller 5 is used to monitor cooling parameters and control the cooling process.

[0040] Reactor 1, as the sealed main container for the chemical reaction of chemical materials, bears the heat absorption or release during the reaction process, providing the basic physical space for the chemical reaction. Cooling circulation pipe 2 connects directly to the inner cavity of reactor 1 at both ends, forming an external bypass channel. This allows the high-temperature reactants inside the furnace to be directly drawn out and sent to the cooling device for cooling before being returned to the furnace. This eliminates the traditional jacketed or coiled indirect cooling mode, achieving direct cooling between the reactants and the cold source. It eliminates the convection and pipe wall thermal resistance caused by intermediate cooling media, significantly reducing the total thermal resistance of the system and effectively eliminating thermal hysteresis. Air cooling fan 3 uses ambient air as the cooling medium, generating forced convection airflow through fan rotation, which is blown onto the outer wall of cooling circulation pipe 2 for air cooling. As a primary coarse-adjustment cooling method, it makes full use of free natural cold sources without requiring external cooling. High-energy-consuming refrigeration equipment greatly reduces the basic operating power consumption of the system. The liquid cooler 4 utilizes the specific heat capacity advantage of water or other liquid refrigerants to exchange heat with the material flowing through the cooling circulation pipe 2 in this area through circulating water cooling. As a secondary fine-tuning cooling method, liquid cooling has high efficiency and can quickly and deeply cool the material, achieving high-precision control of the reaction temperature. The cooling controller 5, as the intelligent hub of the system, is electrically or communicatively connected to the reactor 1, cooling circulation pipe 2, air cooling fan 3, and liquid cooler 4 through wires. It receives the temperature and flow parameters of each node in real time and outputs control commands to realize the automation and closed-loop regulation of the cooling process. It can make instantaneous responses to the temperature changes of the reactants themselves, controlling their temperature fluctuation range within a small error range to avoid side reactions and the danger of temperature loss.

[0041] The operator sets the target reaction temperature range and the start-up threshold of each cooling device on the cooling controller 5. When an exothermic reaction occurs in the reactor 1 and the temperature sensor detects that the temperature has reached the preset upper limit, the cooling controller 5 starts the material circulation pump to introduce the reactant into the cooling circulation pipe 2. The material first passes through the coverage area of ​​the air cooling fan 3, and the cooling controller 5 starts the fan for forced air cooling, which removes a large amount of sensible heat. If the temperature still does not drop to the target value after air cooling, the material enters the liquid cooler 4 area, and the cooling controller 5 starts the cooling water circulation for deep and precise cooling. The cooled material flows back into the reactor 1. The cooling controller 5 continuously monitors the parameters and dynamically adjusts the fan speed and cooling water flow until the reaction ends.

[0042] Because chemical reaction materials flow directly through cooling circulation pipe 2, the pipe itself and the supplementary circulation pump must be made of high-grade anti-corrosion materials resistant to strong acids and alkalis, such as 316L stainless steel, Hastelloy, or Teflon lining. If the reaction materials are prone to crystallization or contain solid particles, direct extraction for cooling can easily cause pipe blockage. A filter screen should be installed at the outlet of cooling circulation pipe 2, and backwashing maintenance should be carried out regularly. Direct cooling means that high-risk materials are led to the outside of the reactor. The airtightness and liquid tightness of the pipe connections must be closely monitored to prevent the leakage of toxic or flammable materials that could cause safety accidents.

[0043] Example 2: Based on Example 1, the following is added: Reference Figure 3 The reactor 1 is equipped with a stirrer 11, which is connected to a stirring motor 111. The stirrer 11 is a spiral stirrer. The stirrer 11 stirs the reactants in the reactor 1 and guides the reactants to circulate from top to bottom or from bottom to top.

[0044] Reference Figure 1 and Figure 3 The reactor 1 is provided with a sealing cover 12, which is used to block the feed inlet. The sealing cover 12 is provided with a sight glass 121, which is a transparent plate. The reactor 1 is wrapped with a protective shell 13. The reactor 1 and the protective shell 13 are installed and fixed by a support frame 131.

[0045] The stirrer 11 is located inside the reactor 1 and is connected to the stirring motor 111 outside the furnace via a drive shaft. The stirrer 11 is specifically designed as a spiral structure, such as a ribbon type or a spiral propulsion type. When the stirring motor 111 drives it to rotate, the spiral blades generate axial thrust on the material. Unlike the radial dispersion of ordinary paddle blades, the spiral stirrer 11 can forcefully guide the reactants to form an overall vertical circulating flow field from top to bottom or from bottom to top. This flow field can effectively prevent heavy component materials from settling to the bottom and ensure that the temperature field and concentration field of the upper and lower layers of materials in the furnace are highly uniform. The strong axial flow can accelerate the exchange speed between the material and the interface of the cooling circulation pipe and improve the overall cooling efficiency.

[0046] The sealing cover 12 physically seals the feed inlet of the reactor 1 through a flange or clamp structure. The sight glass 121 is embedded in the center of the sealing cover 12 and is made of high-strength transparent material. The sealing cover 12 effectively prevents the leakage of toxic and harmful gases or the entry of external impurities in the furnace and maintains the pressure stability of the reaction system. The sight glass 121 allows operators to visually monitor the reaction status in the furnace, such as color changes and bubbling, without damaging the sealed environment, thus balancing safety and visibility.

[0047] The protective shell 13 is wrapped around the outer wall of the reactor 1, usually with a gap in the middle or filled with heat insulation cotton. The support frame 131 serves as a rigid base to connect the overall structure. The protective shell 13 not only prevents operators from accidentally touching the high-temperature furnace wall and getting burned, but also reduces the impact of ambient temperature on the reaction heat inside the furnace. The support frame 131 bears the weight of the equipment and the dynamic load generated by stirring, ensuring the mechanical stability of the system during operation.

[0048] Reference Figures 1-3 The cooling circulation pipe 2 is connected to the bottom and middle of the reactor 1 at both ends, and a circulation pump 21 is connected to and installed on the cooling circulation pipe 2. The circulation pump 21 drives the reactants of the reactor 1 to flow in the cooling circulation pipe 2 in a directional manner. A shut-off valve 211 is installed at the bottom end of the cooling circulation pipe 2 connected to the reactor 1.

[0049] Reference Figures 1-3 A liquid one-way valve 212 is installed at one end of the cooling circulation pipe 2 connected to the middle of the reactor 1. The liquid one-way valve 212 allows the reaction material in the cooling circulation pipe 2 to flow into the reactor 1 in one direction. A gas pressure balance pipe 22 is connected to the cooling circulation pipe 2 connected to the middle of the reactor 1. The gas pressure balance pipe 22 is used to connect the cooling circulation pipe 2 and the top of the reactor 1. A gas one-way valve 221 is installed on the gas pressure balance pipe 22. The gas one-way valve 221 allows the gas in the reactor 1 to flow into the cooling circulation pipe 2 in one direction.

[0050] The cooling circulation pipe 2 is connected to the bottom and middle of the reactor 1 at both ends. The circulation pump 21 has forward and reverse rotation functions. When rotating forward, it drives the material to be drawn out from the bottom and flow to the middle. When rotating in reverse, it drives the material in the pipe to flow back to the bottom. This not only realizes the forced external cooling circulation of the material, but also provides reverse power for the pipe to be emptied after the cooling is completed.

[0051] The shut-off valve 211 is installed at the connection end at the bottom of the reactor 1 to control the physical opening and closing of the bottom pipeline. The liquid check valve 212 is installed at the middle connection end, which only allows fluid to flow from the pipeline into the furnace in the forward direction. It opens in the forward direction when cooling. When the circulating pump 21 reverses to draw in, the valve closes quickly due to the reverse pressure difference, cutting off the return path of the material in the middle of the reactor 1 and preventing the material in the furnace from being drawn back into the pipeline.

[0052] The furnace top is connected to the cooling circulation pipe 2. The gas check valve 221 only allows gas to flow into the pipe from the furnace top in one direction. When the circulation pump 21 reverses to empty the pipe, a negative pressure is generated in the pipe. The gas check valve 221 opens automatically due to the forward pressure difference, and the gas from the furnace top is introduced into the pipe to fill the vacuum generated by the drop in liquid level. This allows the residual material in the pipe to be smoothly pushed back to the bottom of the reactor, achieving complete self-emptying of the pipe.

[0053] Cooling cycle stage: Open the shut-off valve 211 and control the circulation pump 21 to start in the forward direction. The material is drawn out from the bottom of the reactor 1, flows through the cooling circulation pipe 2 for cooling, opens the liquid check valve 212 and is conveyed in the forward direction, flowing back into the furnace from the middle of the reactor 1 to form a closed-loop cooling.

[0054] Pipeline purging stage: After the cooling process is completed, the circulating pump 21 is reversed. At this time, a reverse suction force is generated in the cooling circulation pipe 2. The liquid check valve 212 is immediately closed by the reverse negative pressure to block the backflow of material in the middle. At the same time, the gas check valve 221 is automatically opened by the forward pressure difference. The gas at the top of the furnace enters the cooling circulation pipe 2 through the gas pressure balance pipe 22. With the suction force of the circulating pump 21, all the remaining material in the pipe is transported back into the furnace from the bottom of the reactor 1.

[0055] After all the material in the pipeline has been emptied, stop the circulating pump 21 and quickly close the shut-off valve 211 to complete the entire cooling and emptying operation.

[0056] Reference Figure 1 and Figure 3 The air cooling fan 3 blows air towards the cooling circulation pipe 2. The cooling circulation pipe 2 is fixed by a heat dissipation bracket 31 at the air cooling part. The air cooling fan 3 is fixed by a fan bracket 32.

[0057] Reference Figure 1 and Figure 3 The heat dissipation bracket 31 is equipped with an installation net 311. The installation net 311 is respectively set on both sides of the cooling circulation pipe 2 and fixed. The outer surface of the cooling circulation pipe 2 where it is cooled by air is provided with a wind-cooled heat dissipation plate 312. The wind-cooled heat dissipation plate 312 is connected and fixed to the installation net 311.

[0058] The air cooling fan 3, as the power source for active cooling, blows air directly onto the cooling circulation pipe 2 to form forced convection. The fan bracket 32 ​​is used to physically fix the cooling fan in space. By forcing airflow, the heat on the pipe wall and the surface of the heat dissipation components is quickly removed, which significantly improves the cooling efficiency. The fan bracket 32 ​​ensures the stability of the cooling fan during operation and the precise air delivery angle, and avoids airflow deviation.

[0059] The heat dissipation bracket 31 is fixedly installed on the external frame of the cooling circulation pipe 2 at the air-cooled part, providing a solid mechanical support for the pipe in the air-cooled area and preventing the pipe from deforming or displacing under fluid impact and strong wind.

[0060] The mounting mesh 311 is installed on the heat dissipation bracket 31 and is arranged on both sides of the cooling circulation pipe 2. Its mesh structure has both a connection function and a very high air permeability. While providing sufficient structural strength, the mesh hollow design minimizes wind resistance and ensures that the cold air blown out by the air cooling fan 3 can smoothly penetrate and wrap around the entire cooling pipe, avoiding the formation of heat dissipation dead corners.

[0061] The air-cooled heat sink 312 is attached to the outer surface of the cooling circulation pipe 2 where it is cooled by air and is connected and fixed to the mounting mesh 311 on both sides. This greatly increases the heat conduction area of ​​the outer surface of the cooling circulation pipe 2. After the heat of the high-temperature material inside is conducted to the pipe wall, it is quickly conducted and dispersed to the outside by the air-cooled heat sink 312. With the help of the cold air from the cooling fan, the heat is quickly stripped and dissipated. At the same time, the fixed connection with the mounting mesh 311 enhances the structural rigidity of the heat sink and prevents it from vibrating and falling off under the wind.

[0062] First, install and fix the heat dissipation bracket 31 in the predetermined position. Then, fix the cooling section of the cooling circulation pipe 2 in the heat dissipation bracket 31. Tightly wrap or weld the air-cooled heat sink 312 to the outer surface of the air-receiving section of the cooling circulation pipe 2. Next, assemble the mounting mesh 311 on the heat dissipation bracket 31 on both sides of the pipe and fasten the mounting mesh 311 to the edge of the air-cooled heat sink 312 to form an integrated heat dissipation mesh frame. Use the fan bracket 32 ​​to fix the air cooling fan 3 on the windward side of the heat dissipation bracket 31. Adjust the air blowing angle so that it faces the air-cooled heat sink 312. When high-temperature materials are introduced into the pipe and need to be cooled, start the air cooling fan 3. The cold air passes through the mounting mesh 311 on the windward side, blows over the air-cooled heat sink 312 and takes away the heat. Finally, it is discharged from the mounting mesh 311 on the leeward side, completing the efficient air heat exchange.

[0063] Reference Figures 1-3 The liquid cooler 4 includes a liquid cooling box 41, which contains a cooling medium. The cooling circulation pipe 2 passes through the liquid cooling box 41 and comes into contact with the cooling medium inside the liquid cooling box 41 for cooling.

[0064] Reference Figure 3 A water spray head 42 is provided above the liquid cooling tank 41, and the water spray head 42 sprays water toward the liquid cooling tank 41. The cooling circulation pipe 2 passes through the water spray area of ​​the water spray head 42 and comes into contact with the cooling medium sprayed by the water spray head 42 for cooling. A guide net 421 is provided on both sides of the cooling circulation pipe 2 in the water spray area of ​​the water spray head 42. A liquid cooling heat dissipation plate 422 is provided on the outer surface of the water spray cooling part of the cooling circulation pipe 2. The guide net 421 is connected and fixed to the liquid cooling heat dissipation plate 422. The air intake side of the air cooling fan 3 faces the guide net 421.

[0065] The liquid cooling box 41 serves as the basic liquid cooling carrier, and is filled with water or special coolant or other cooling media. The cooling circulation pipe 2 passes directly through the interior of the liquid cooling box 41, so that the pipe wall comes into direct contact with the liquid medium. By utilizing the large specific heat capacity of the liquid, the high-temperature material flowing through the pipe is subjected to basic, large-capacity contact-type rapid cooling, thus achieving efficient heat transfer in the first stage.

[0066] The spray head 42 is arranged above the liquid cooling box 41 and continuously sprays the cooling medium in an umbrella or mist shape toward a specific area of ​​the liquid cooling box and the cooling circulation pipe 2. A dynamically flowing liquid film is formed on the surface of the cooling circulation pipe 2. The flowing water can continuously remove heat from the pipe wall and avoid local heat accumulation. It has a higher surface heat transfer coefficient than static water immersion.

[0067] The liquid cooling heat sink 422 is attached to the outer surface of the cooling circulation pipe 2 in the area where the water spray head 42 sprays water, which greatly expands the surface area of ​​the pipe in the spray area. The sprayed water can fully adhere to and flow on the liquid cooling heat sink 422, significantly increasing the contact area between the water and the heating pipe wall, thereby multiplying the spray cooling efficiency.

[0068] The guide net 421 is set on both sides of the cooling circulation pipe 2 in the spray area and is connected and fixed to the liquid cooling heat sink 422. On the one hand, it guides and prevents splashing of the sprayed water flow, so that the water flow can be more evenly gathered and flow through the heat sink. On the other hand, the fixed connection with the heat sink enhances the structural rigidity of the entire water spray cooling assembly.

[0069] The air intake of the air cooling fan 3 faces the air guide net 421 and the spray area. When the fan starts, it will forcefully draw in the air passing through the water spray area and the air guide net. The fan's air intake not only accelerates the evaporation of the spray water on the surface of the liquid cooling heat sink 422, but also utilizes the water vaporization to absorb a large amount of latent heat, achieving efficient evaporative cooling. At the same time, the air that has passed through the water mist and moistened the air guide net is pre-cooled, becoming a cold air with low temperature and high humidity. This pre-cooled air is drawn out by the fan and then blown to the subsequent air-cooled area, which greatly improves the overall cooling efficiency of the system.

[0070] The cooling circulation pipe 2 is passed sequentially through the liquid cooling tank 41 and the spray area above it. The liquid cooling heat dissipation plate 422 is welded or clipped onto the pipe wall of the spray section. Then, the guide net 421 is installed on both sides and fastened to the heat dissipation plate. The air cooling fan 3 is installed on the corresponding bracket and its direction is strictly calibrated to ensure that its air inlet side negative pressure exhaust surface is facing the guide net 421. Sufficient cooling medium is injected into the liquid cooling tank 41 to submerge the cooling circulation pipe 2 at the bottom. When high-temperature material is introduced into the pipe, the water spray head 42 and the air cooling fan 3 are turned on simultaneously. The water spray head sprays liquid film downwards, and the air cooling fan forces air out from the guide net, forming a triple high-efficiency cooling state of water immersion, spray cooling and exhaust evaporation cooling.

[0071] Reference Figure 3 The reactor 1 is equipped with an in-furnace temperature sensor 51, the cooling circulation pipe 2 is equipped with a circulation temperature sensor 52, and the liquid cooler 4 is equipped with a cooling temperature sensor 53. The in-furnace temperature sensor 51, the circulation temperature sensor 52, and the cooling temperature sensor 53 are respectively connected to the cooling controller 5. The cooling controller 5 dynamically controls the operating parameters of the reactor 1, the cooling circulation pipe 2, the air cooling fan 3, and the liquid cooler 4 based on the temperature sensor data.

[0072] The furnace temperature sensor 51 probe extends deep into the reactor 1 to collect temperature data in the core reaction area of ​​the reactor in real time. This provides the most basic process temperature reference for the entire control system, ensuring that the temperature of the material before being drawn out for circulation and after reflux meets the process requirements of the core reaction, and preventing the reaction from getting out of control or heat from accumulating.

[0073] The circulating temperature sensor 52 is installed inside the cooling circulation pipe 2 or attached to the pipe wall to monitor the temperature change of the flowing material in the circulation pipe in real time, accurately assess the heat load carried by the material flowing through the pipe, and the actual cooling effect after passing through the cooling mechanism, providing direct data feedback for adjusting the intensity of air cooling and liquid cooling.

[0074] The cooling temperature sensor 53 is immersed in the liquid cooling box 41 of the liquid cooler 4 to monitor the temperature of the cooling medium in real time. It is used to assess the remaining cooling capacity of the current liquid cooling system. When the temperature of the cooling medium is too high, the system can respond in time to avoid the cooling efficiency from decreasing due to the temperature rise of the medium.

[0075] The cooling controller 5 is connected to the three temperature sensors mentioned above to receive real-time temperature data. It uses a built-in PID or fuzzy control algorithm to perform comprehensive analysis and comparison, and outputs control commands. It can dynamically and steplessly adjust the heating power of the reactor 1, the material flow rate of the cooling circulation pipe 2, the speed of the air cooling fan 3, and the operating parameters of the liquid cooler 4 according to the actual heat load, so as to maximize the reduction of system energy consumption while ensuring process safety.

[0076] Connect all sensor signal lines to the input terminals of the cooling controller 5. Connect the output terminals of the cooling controller 5 to the reactor heating components, the circulating pump frequency converter, the cooling fan motor, and the liquid cooling water pump control circuit, respectively. In the interactive interface of the cooling controller 5, input the target temperature range, alarm threshold, and PID control parameters for each monitoring point. Switch the system to automatic mode, and the cooling controller 5 will start to continuously monitor the temperature of each point and dynamically allocate the load of air cooling and liquid cooling in real time according to the built-in logic to achieve unattended automatic temperature control.

[0077] The above description is merely an example and illustration of the structure of the present invention. Those skilled in the art can make various modifications or additions to the specific embodiments described, or use similar methods to replace them, as long as they do not deviate from the scope defined by the structure of the invention, and all such modifications and additions should fall within the protection scope of the present invention.

Claims

1. A high-precision, low-power cooling system for a chemical reactor, comprising a cooling circulation pipe (2), wherein the cooling circulation pipe (2) is used to connect the reactor (1) and a cooling device, characterized in that: The cooling circulation pipe (2) is connected to the inner cavity of the reactor (1). The cooling circulation pipe (2) is used to export the reactants in the reactor (1) into the cooling device for cooling and to circulate them back into the reactor (1). The cooling device includes an air cooling fan (3) and a liquid cooler (4). The air cooling fan (3) cools the reactants in the cooling circulation pipe (2) by circulating air cooling. The liquid cooler (4) cools the reactants in the cooling circulation pipe (2) by circulating water cooling. The reactor (1), cooling circulation pipe (2), air cooling fan (3) and liquid cooler (4) are respectively connected to a cooling controller (5) by wires. The cooling controller (5) is used to monitor the cooling parameters and control the cooling process.

2. The high-precision, low-power cooling system for a chemical reactor according to claim 1, characterized in that: The reactor (1) is equipped with a stirrer (11), which is connected to a stirring motor (111). The stirrer (11) is a spiral stirrer. The stirrer (11) stirs the reactants in the reactor (1) and guides the reactants to circulate from top to bottom or from bottom to top.

3. The high-precision, low-power cooling system for a chemical reactor according to claim 2, characterized in that: The reactor (1) is provided with a sealing cover (12), which is used to block the feed inlet. The sealing cover (12) is provided with a sight glass (121), which is a transparent plate. The reactor (1) is wrapped with a protective shell (13). The reactor (1) and the protective shell (13) are installed and fixed by a support frame (131).

4. The high-precision, low-power cooling system for a chemical reactor according to claim 1, characterized in that: The cooling circulation pipe (2) is connected to the bottom and middle of the reactor (1) at both ends respectively. The cooling circulation pipe (2) is connected to and equipped with a circulation pump (21). The circulation pump (21) drives the reactants of the reactor (1) to flow in the cooling circulation pipe (2). A shut-off valve (211) is installed at one end of the cooling circulation pipe (2) connected to the bottom of the reactor (1).

5. The high-precision, low-power cooling system for a chemical reactor according to claim 4, characterized in that: The cooling circulation pipe (2) is connected to the middle end of the reactor (1) and a liquid check valve (212) is installed. The liquid check valve (212) allows the reaction material in the cooling circulation pipe (2) to flow into the reactor (1) in one direction. The circulation pump (21) is connected to the cooling circulation pipe (2) in the middle of the reactor (1) and a gas pressure balance pipe (22) is connected. The gas pressure balance pipe (22) is used to connect the cooling circulation pipe (2) and the top of the reactor (1). A gas check valve (221) is installed on the gas pressure balance pipe (22). The gas check valve (221) allows the gas in the reactor (1) to flow into the cooling circulation pipe (2) in one direction.

6. The high-precision, low-power cooling system for a chemical reactor according to claim 1, characterized in that: The air cooling fan (3) blows air toward the cooling circulation pipe (2), and the cooling circulation pipe (2) is fixed by a heat dissipation bracket (31). The air cooling fan (3) is fixed by a fan bracket (32).

7. A high-precision, low-power cooling system for a chemical reactor according to claim 6, characterized in that: The heat dissipation bracket (31) is equipped with an installation net (311). The installation net (311) is respectively set on both sides of the cooling circulation pipe (2) and fixed. The outer surface of the cooling circulation pipe (2) under air cooling is provided with a wind-cooled heat dissipation plate (312). The wind-cooled heat dissipation plate (312) is connected and fixed to the installation net (311).

8. The high-precision, low-power cooling system for a chemical reactor according to claim 1, characterized in that: The liquid cooler (4) includes a liquid cooling box (41), which contains a cooling medium. The cooling circulation pipe (2) passes through the liquid cooling box (41) and comes into contact with the cooling medium inside the liquid cooling box (41) for cooling.

9. A high-precision, low-power cooling system for a chemical reactor according to claim 8, characterized in that: A water spray head (42) is provided above the liquid cooling box (41). The water spray head (42) sprays water towards the liquid cooling box (41). The cooling circulation pipe (2) passes through the water spray area of ​​the water spray head (42) and comes into contact with the cooling medium sprayed by the water spray head (42) for cooling. A guide net (421) is provided on both sides of the cooling circulation pipe (2) in the water spray area of ​​the water spray head (42). A liquid cooling heat dissipation plate (422) is provided on the outer surface of the water spray cooling area of ​​the cooling circulation pipe (2). The guide net (421) is connected and fixed to the liquid cooling heat dissipation plate (422). The air intake side of the air cooling fan (3) faces the guide net (421).

10. A high-precision, low-power cooling system for a chemical reactor according to claim 1, characterized in that: The reactor (1) is equipped with an in-furnace temperature sensor (51), the cooling circulation pipe (2) is equipped with a circulation temperature sensor (52), and the liquid cooler (4) is equipped with a cooling temperature sensor (53). The in-furnace temperature sensor (51), circulation temperature sensor (52) and cooling temperature sensor (53) are respectively connected to the cooling controller (5). The cooling controller (5) dynamically controls the operating parameters of the reactor (1), cooling circulation pipe (2), air cooling fan (3) and liquid cooler (4) according to the temperature sensor data.

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