Intelligent online scale removal heat exchanger device

Abstract

The invention discloses an intelligent online scale cleaning heat exchanger device which comprises a heat exchanger body, an online scale cleaning device, a blow-off pipeline and a control system. The heat exchanger body comprises a tube plate, a shell, a heat transfer tube and a water chamber; the on-line scale cleaning device comprises a spiral scraping blade assembly, a guide rail rod, a guide rail sleeve and a connecting plate; the blow-off pipeline comprises a blow-off ball valve, a connecting pipeline and an electric ball valve; the control system comprises a control center, an actuator and a pressure sensor. The device can remove dirt in the pipe online, does not need to stop, improves the heat exchange efficiency and the operation reliability, reduces the maintenance cost, and is suitable for complex medium heat exchange scenes.

Description

Technical Field

[0001] This invention relates to the field of heat exchanger technology, and more specifically to an intelligent online descaling heat exchanger device. Background Technology

[0002] In oil extraction, refining, and urban wastewater treatment systems, the core transport and operating media are mostly crude oil, oily wastewater, or ordinary wastewater, with extremely complex compositions. These media not only contain large amounts of sulfates and carbonates formed by metallic elements such as barium, strontium, magnesium, and calcium, but also contain organic substances such as paraffin and polymers. When the media exchange heat within the heat exchanger, these components come into contact with the pipe walls, gradually condensing and adsorbing onto the surface. As operating time accumulates, these substances continuously precipitate and accumulate, eventually forming a hardened fouling layer on the pipe walls. The longer the time, the more severe the adhesion and hardening of the fouling.

[0003] Current industry-standard descaling methods, including online cleaning, chemical dosing, and manual / mechanical descaling, consistently fail to fundamentally solve the scaling and clogging problems of heat exchangers. This directly leads to frequent clogging failures during equipment operation, significantly increasing the failure rate, reducing system reliability, and forcing increasingly shorter maintenance cycles. The resulting frequent downtime for repairs and replacement of consumables leads to continuously rising costs, severely impacting the economic efficiency of equipment operation and placing a heavy burden on daily maintenance.

[0004] Therefore, developing a high-efficiency and stable sludge removal and descaling device has become an urgent task. By addressing the above-mentioned problems in a targeted manner, the operating status and user experience of the equipment will be effectively improved, providing a strong guarantee for stable production in related fields. Summary of the Invention

[0005] The purpose of this invention is to address the shortcomings of existing technologies by providing an intelligent online descaling heat exchanger device, thereby solving the problem that existing descaling methods need to be improved in terms of efficiency and stability.

[0006] This invention provides an intelligent online descaling heat exchanger device, including a heat exchanger body, an online descaling device, a drain pipe, and a control system.

[0007] The heat exchanger body includes a left tube sheet, a right tube sheet, a shell, heat transfer tubes, a left tube-side water chamber, and a right tube-side water chamber. The shell is welded and fixed between the left and right tube sheets. The heat transfer tubes are fixed between the left and right tube sheets by expansion or welding. The left and right tube-side water chambers are welded and fixed to the outside of the left and right tube sheets, respectively.

[0008] The online descaling device includes a spiral scraper assembly, a guide rail rod, a guide rail sleeve, a scraper connecting plate a, and a scraper connecting plate b. The guide rail sleeve passes through the left tube sheet and is welded to the water chamber side of the tube sheet. A linear bearing is installed inside the guide rail sleeve. The guide rail rod passes through the linear bearing and is fixed to the scraper connecting plate a and scraper connecting plate b by a nut. The spiral scraper assembly includes spiral blades and a central shaft. The spiral scraper assembly is sleeved on the outside of the heat transfer tube and fixed to the scraper connecting plate a and scraper connecting plate b by a nut.

[0009] The sewage pipeline includes a sewage ball valve, connecting pipes, and an electric ball valve. The sewage ball valve is welded to the lower part of the left water chamber of the pipeline and is connected to the electric ball valve through the connecting pipes.

[0010] The control system includes a control center, actuators, and pressure sensors. The pressure sensors are located at the inlet and outlet of the pipe. The actuators are connected to the scraper connecting plate a via a tie rod. The control center is electrically connected to the actuators, pressure sensors, and electric ball valves.

[0011] Furthermore, the left water chamber of the pipeline includes a left cover plate, a water chamber cylinder, and an air vent valve. The left cover plate is connected to the water chamber cylinder through an equipment flange, and the air vent valve is located at the top of the water chamber cylinder.

[0012] Furthermore, the right water chamber of the tube includes a right cover plate, a water chamber cylinder, and a partition plate, with the partition plate welded inside the water chamber cylinder.

[0013] Furthermore, the guide rail sleeve is provided with a core and a pressure cap at both ends, which are used to position and fix the linear bearing.

[0014] Furthermore, a threaded tube is welded onto the scraper connecting plate a, and the threaded tube is connected to the actuator via a pull rod.

[0015] Furthermore, the online descaling device also includes a ball valve, which is located at the end of the guide rail sleeve and is used for backwashing and sewage discharge.

[0016] Furthermore, the sewage pipeline also includes a union joint, which is located between the connecting pipeline and the electric ball valve.

[0017] Furthermore, a support plate is provided inside the shell, which is welded and fixed to the shell and used to support the heat transfer tube.

[0018] Furthermore, the central shaft of the spiral scraper assembly is machined with stop and thread at both ends, and is locked to the scraper connecting plate a and scraper connecting plate b by nuts.

[0019] Furthermore, the guide rail rod is threaded and has a stop at both ends. After passing through the guide rail sleeve, it is locked to the scraper connecting plate a and scraper connecting plate b by nuts.

[0020] This invention offers the following advantages: It achieves online mechanical descaling of the inner wall of heat transfer tubes through the reciprocating motion of a spiral scraper assembly. Combined with intelligent linkage between a pressure sensor and the control center, the descaling operation can be automatically initiated based on pressure drop changes or preset cycles, effectively solving the problems of difficult descaling and the need for shutdown maintenance in traditional heat exchangers. The external guide rail design avoids interference with the shell-side tube arrangement, improving heat exchange efficiency and facilitating maintenance. The automatic draining device and backflushing ball valve ensure thorough descaling, preventing residual corrosion or jamming. The overall structure, through the coordinated design of rigid guide rails and spiral scrapers, ensures stable and reliable operation, significantly reducing equipment failure rates and maintenance costs, and improving the economy and continuity of system operation. It is suitable for heat exchange scenarios involving complex media such as crude oil and wastewater. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 This is a schematic diagram of the overall structure of an intelligent online descaling heat exchanger device;

[0023] Figure 2 This is a schematic diagram of the heat exchanger body.

[0024] Figure 3 This is a schematic diagram of the online descaling device;

[0025] Figure 4 This is a structural diagram of the sewage pipeline;

[0026] Figure 5 This is a schematic diagram of the control system.

[0027] Figure 6 This is a schematic diagram of the structure of the left water chamber of the tube side;

[0028] Figure 7 This is a schematic diagram of the structure of the right water chamber of the tube side;

[0029] Figure 8 This is a schematic diagram of the spiral scraper assembly.

[0030] Illustrations: 01-Heat exchanger body; 01-01-Right tube sheet; 01-02-Left tube sheet; 01-03-Heat transfer tubes; 01-04-Left water chamber (tube side); 01-05-Right water chamber (tube side); 01-10-Shell; 01-04-01-Left cover plate; 01-04-02-Equipment flange; 01-04-04-Water chamber shell; 01-04-05-Exhaust valve; 01-05-01-Right cover plate; 01-05-04-Water chamber shell; 01-05-05-Break plate; 01-11-Support plate; 02-Online descaling device; 02-01-Spiral scraper assembly; 02-02-Guide rail sleeve; 02-03- Guide rail rod; 02-04- Linear bearing; 02-05- Compensating core; 02-06- Pressure cap; 02-07- Scraper connecting plate a; 02-08- Scraper connecting plate b; 02-09- Threaded pipe; 02-11- Nut; 02-12- Nut; 02-13- Tie rod; 02-15- Ball valve; 02-01-01- Spiral blade; 02-01-02- Central shaft; 03- Sewage discharge pipe; 03-01- Sewage discharge ball valve; 03-02- Connecting pipe; 03-03- Electric ball valve; 03-04- Union; 04- Control system; 04-01- Control center; 04-02- Actuator; 04-03- Pressure sensor. Detailed Implementation

[0031] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments. It should be pointed out that the following detailed description is illustrative and intended to provide further explanation of this application. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0032] Please see Figures 1 to 7This invention provides an intelligent online descaling heat exchanger device, including a heat exchanger body 01, an online descaling device 02, a drain pipe 03, and a control system 04. The heat exchanger body 01 includes a left tube sheet 01-02, a right tube sheet 01-01, a shell 01-10, heat transfer tubes 01-03, a left water chamber 01-04, and a right water chamber 01-05. The shell 01-10 is welded and fixed between the left tube sheet 01-02 and the right tube sheet 01-01, providing support and protection for the internal components and forming a shell-side space to ensure stable flow of the shell-side medium. The heat transfer tubes 01-03 are fixed between the left tube sheet 01-02 and the right tube sheet 01-01 by expansion or welding. They are the core components for heat exchange, and the tube-side medium flows inside the tubes, transferring heat with the shell-side medium. The left water chamber 01-04 and the right water chamber 01-05 are welded and fixed to the outside of the left tube sheet 01-02 and the right tube sheet 01-01, respectively, for distributing and collecting the tube-side medium, ensuring that the medium flows evenly through each heat transfer tube 01-03. The online descaling device 02 includes a spiral scraper assembly 02-01, a guide rail rod 02-03, a guide rail sleeve 02-02, a scraper connecting plate a02-07, and a scraper connecting plate b02-08. The guide rail sleeve 02-02 passes through the left tube sheet 01-02 and is welded to the water chamber side of the tube sheet, providing stable installation support for the guide rail rod 02-03 and avoiding interference with the shell-side tube layout. A linear bearing 02-04 is installed inside the guide rail sleeve 02-02 to reduce the frictional resistance of the guide rail rod 02-03 during movement and ensure smooth sliding. The guide rail rod 02-03 passes through the linear bearing 02-04 and is fixed to the scraper connecting plate a02-07 and scraper connecting plate b02-08 via a nut 02-11, thus serving to... The guide plate a02-07 and b02-08 drive the spiral scraper assembly 02-01 to move stably. The spiral scraper assembly 02-01 includes a spiral blade 02-01-01 and a central shaft 02-01-02. The spiral scraper assembly 02-01 is sleeved on the outside of the heat transfer tube 01-03 and fixed to the scraper connecting plate a02-07 and b02-08 by the nut 02-12. The spiral blade 02-01-01 can scrape off the dirt on the inner wall of the heat transfer tube 01-03 during the movement. At the same time, the central shaft 02-01-02 ensures the structural stability of the spiral blade 02-01-01. Its spiral structure can also generate turbulence in the fluid and enhance the heat transfer effect. The sewage discharge pipeline 03 includes a sewage discharge ball valve 03-01, a connecting pipeline 03-02, and an electric ball valve 03-03. The sewage discharge ball valve 03-01 is welded to the lower part of the left water chamber 01-04 of the pipeline. It is connected to the electric ball valve 03-03 through the connecting pipeline 03-02, so that the removed dirt can be discharged in time to prevent dirt from accumulating in the water chamber.The control system 04 includes a control center 04-01, an actuator 04-02, and a pressure sensor 04-03. The pressure sensor 04-03 is installed at the inlet and outlet of the pipe side to detect the pressure difference of the medium in the pipe side, providing a basis for starting the descaling operation. The actuator 04-02 is connected to the scraper connecting plate a02-07 via a pull rod 02-13, and can provide power to drive the scraper connecting plate a02-07 to move. The control center 04-01 is electrically connected to the actuator 04-02, the pressure sensor 04-03, and the electric ball valve 03-03. It can receive the signal from the pressure sensor 04-03 and control the operation of the actuator 04-02 and the electric ball valve 03-03.

[0033] The left water chamber 01-04 of the tube side includes a left cover plate 01-04-01, a water chamber shell 01-04-04, and an air vent valve 01-04-05. The left cover plate 01-04-01 is connected to the water chamber shell 01-04-04 via an equipment flange 01-04-02, which facilitates opening the water chamber for internal inspection and maintenance. The air vent valve 01-04-05 is located at the top of the water chamber shell 01-04-04 and can discharge gas in the tube side to prevent gas from affecting heat exchange efficiency and medium flow. The right water chamber 01-05 of the tube side includes a right cover plate 01-05-01, a water chamber cylinder 01-05-04, and a partition plate 01-05-05. The partition plate 01-05-05 is welded inside the water chamber cylinder 01-05-04, which can divide the right water chamber 01-05 of the tube side into different areas, realize multi-pass flow of the tube side medium, increase heat exchange time, and improve heat exchange efficiency. The guide sleeve 02-02 has a core 02-05 and a pressure cap 02-06 at both ends. The core 02-05 and the pressure cap 02-06 are used to position and fix the linear bearing 02-04, ensuring the stable installation of the linear bearing 02-04 within the guide sleeve 02-02 and preventing displacement during the movement of the guide rod 02-03. A threaded pipe 02-09 is welded to the scraper connecting plate a02-07. The threaded pipe 02-09 is connected to the actuator 04-02 via a pull rod 02-13, transmitting power so that the actuator 04-02 can effectively drive the scraper connecting plate a02-07. The online descaling device 02 also includes a ball valve 02-15, which is located at the end of the guide rail sleeve 02-02 for backwashing and sewage discharge. It can periodically flush the inside of the guide rail sleeve 02-02 to prevent dirt accumulation and avoid jamming or corrosion of the guide rail rod 02-03. The sewage discharge pipeline 03 also includes a union joint 03-04, which is located between the connecting pipeline 03-02 and the electric ball valve 03-03, facilitating the installation, disassembly, and maintenance of the sewage discharge pipeline 03. The housing 01-10 has an internal support plate 01-11, which is welded and fixed to the housing 01-10 and supports the heat transfer tube 01-03. This prevents the heat transfer tube 01-03 from vibrating and deforming during medium flow, ensuring its stable operation. The central shaft 02-01-02 of the spiral scraper assembly 02-01 has locating edges and threads at both ends. It is locked to the scraper connecting plates a02-07 and b02-08 by nuts 02-12, ensuring a secure connection between the spiral scraper assembly 02-01 and the scraper connecting plates a02-07 and b02-08, preventing loosening during operation.The guide rod 02-03 has threads and a stop at both ends. After passing through the guide sleeve 02-02, it is locked to the scraper connecting plate a02-07 and scraper connecting plate b02-08 by the nut 02-11, which ensures the stable connection between the guide rod 02-03 and the scraper connecting plate a02-07 and scraper connecting plate b02-08, so that the guide rod 02-03 can effectively guide the movement of the scraper connecting plate.

[0034] The working process of the device is as follows: When the heat exchanger is running, a relatively dirty medium flows in the tube side, and the control center 04-01 stores the corresponding data of the medium flow rate and pressure drop. After the heat exchanger has been running for a period of time, scale in the medium will deposit on the wall of heat transfer tubes 01-03, resulting in increased flow resistance and pressure drop. When the pressure sensor 04-03 at the inlet and outlet of the tube detects that the pressure difference exceeds the set value for the flow rate, the control center 04-01 sends a start signal to the actuator 04-02. The actuator 04-02 performs reciprocating linear motion, which drives the scraper connecting plate a02-07 to move through the pull rod 02-13. The scraper connecting plate a02-07 and scraper connecting plate b02-08 drive the guide rail rod 02-03 to slide in the linear bearing 02-04 inside the guide rail sleeve 02-02. At the same time, the spiral scraper assembly 02-01 performs reciprocating linear motion outside the heat transfer tubes 01-03. The spiral blades 02-01-01 of the spiral scraper assembly 02-01 scrape away the scale on the wall of the heat transfer tubes 01-03. After a certain period of scraping, when the pressure drop decreases to the set value, the control center 04-01 controls the actuator 04-02 to stop moving, and simultaneously activates the electric ball valve 03-03 and the drain ball valve 03-01 to discharge the remaining dirt through the drain pipe 03 to the medium outlet. In addition, the control center 04-01 can also start the cleaning operation according to a set fixed cycle and cleaning time, or perform the cleaning operation in a fixed cycle manner when the pressure drop does not reach the set value.

[0035] This invention achieves online cleaning of scale on the inner wall of heat transfer tubes 01-03 through the reciprocating motion of the spiral scraper assembly 02-01, without requiring machine shutdown, effectively improving equipment operating efficiency and reducing maintenance costs. The external design of the guide rail sleeve 02-02 avoids interference with the shell-side tube arrangement, ensuring heat exchange effect, and facilitating the maintenance and replacement of the guide rail device. The reciprocating linear small-amplitude motion design of the actuator 04-02 requires only a movement distance greater than or equal to one cycle of the spiral scraper to achieve scale cleaning, with minimal impact on the fluid. The external automatic drain device can drain residual scale in the water chamber with the medium flow, and the ball valve 02-15 can periodically drain and backwash residual scale in the sleeve, preventing scale accumulation in the sleeve from corroding the guide rail rod 02-03 and causing jamming or jamming. Through three control methods—pressure drop control, fixed cycle control, and a combination of both—scale cleaning operations can be flexibly performed according to fluid properties and customer requirements, meeting the scale cleaning needs of media with different levels of scale, and improving the overall stability and economy of equipment operation.

[0036] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An intelligent online descaling heat exchanger device, characterized in that, include: Heat exchanger body (01), online descaling device (02), drain pipe (03) and control system (04); The heat exchanger body (01) includes a left tube sheet (01-02), a right tube sheet (01-01), a shell (01-10), heat transfer tubes (01-03), a left tube-side water chamber (01-04), and a right tube-side water chamber (01-05). The shell (01-10) is welded and fixed between the left tube sheet (01-02) and the right tube sheet (01-01). The heat transfer tubes (01-03) are fixed between the left tube sheet (01-02) and the right tube sheet (01-01) by expansion or welding. The left tube-side water chamber (01-04) and the right tube-side water chamber (01-05) are respectively welded and fixed to the outside of the left tube sheet (01-02) and the right tube sheet (01-01). The online descaling device (02) includes a spiral scraper assembly (02-01), a guide rail rod (02-03), a guide rail sleeve (02-02), a scraper connecting plate a (02-07), and a scraper connecting plate b (02-08). The guide rail sleeve (02-02) penetrates the left tube sheet (01-02) and is welded to the water chamber side of the tube sheet. A linear bearing (02-04) is installed inside the guide rail sleeve (02-02), and the guide rail rod (02-03) passes through the linear bearing (02-04). 04) and fixed to scraper connecting plate a (02-07) and scraper connecting plate b (02-08) by nuts (02-11); the spiral scraper assembly (02-01) includes a spiral blade (02-01-01) and a central shaft (02-01-02), the spiral scraper assembly (02-01) is sleeved on the outside of the heat transfer tube (01-03) and fixed to scraper connecting plate a (02-07) and scraper connecting plate b (02-08) by nuts (02-12); The sewage discharge pipeline (03) includes a sewage discharge ball valve (03-01), a connecting pipeline (03-02), and an electric ball valve (03-03). The sewage discharge ball valve (03-01) is welded to the lower part of the left water chamber (01-04) of the pipe and is connected to the electric ball valve (03-03) through the connecting pipeline (03-02). The control system includes a control center (04-01), an actuator (04-02), and a pressure sensor (04-03). The pressure sensor (04-03) is located at the inlet and outlet of the pipe. The actuator (04-02) is connected to the scraper connecting plate a (02-07) via a pull rod (02-13). The control center (04-01) is electrically connected to the actuator (04-02), the pressure sensor (04-03), and the electric ball valve (03-03).

2. The intelligent online descaling heat exchanger device according to claim 1, characterized in that, The left water chamber (01-04) of the pipeline includes a left cover plate (01-04-01), a water chamber cylinder (01-04-04), and an air vent valve (01-04-05). The left cover plate (01-04-01) is connected to the water chamber cylinder (01-04-04) through an equipment flange (01-04-02), and the air vent valve (01-04-05) is located on the top of the water chamber cylinder (01-04-04).

3. The intelligent online descaling heat exchanger device according to claim 1, characterized in that, The right water chamber (01-05) of the pipeline includes a right cover plate (01-05-01), a water chamber cylinder (01-05-04), and a partition plate (01-05-05). The partition plate (01-05-05) is welded to the inside of the water chamber cylinder (01-05-04).

4. The intelligent online descaling heat exchanger device according to claim 1, characterized in that, The guide tube (02-02) is provided with a core (02-05) and a cap (02-06) at both ends. The core (02-05) and the cap (02-06) are used to position and fix the linear bearing (02-04).

5. The intelligent online descaling heat exchanger device according to claim 1, characterized in that, A threaded tube (02-09) is welded onto the scraper connecting plate a (02-07), and the threaded tube (02-09) is connected to the actuator (04-02) via a pull rod (02-13).

6. The intelligent online descaling heat exchanger device according to claim 1, characterized in that, The online descaling device (02) also includes a ball valve (02-15), which is located at the end of the guide rail sleeve (02-02) and is used for backwashing and sewage discharge.

7. The intelligent online descaling heat exchanger device according to claim 1, characterized in that, The sewage pipe (03) also includes a union (03-04), which is located between the connecting pipe (03-02) and the electric ball valve (03-03).

8. The intelligent online descaling heat exchanger device according to claim 1, characterized in that, The housing (01-10) is provided with a support plate (01-11) inside. The support plate (01-11) is welded and fixed to the housing (01-10) and is used to support the heat transfer tube (01-03).

9. The intelligent online descaling heat exchanger device according to claim 1, characterized in that, The spiral scraper assembly (02-01) has a central shaft (02-01-02) with both ends machined with a stop and threads, and is locked to the scraper connecting plate a (02-07) and scraper connecting plate b (02-08) by nuts (02-12).

10. The intelligent online descaling heat exchanger device according to claim 1, characterized in that, The guide rod (02-03) has threads and a stop at both ends. After passing through the guide sleeve (02-02), it is locked to the scraper connecting plate a (02-07) and scraper connecting plate b (02-08) by a nut (02-11).

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