Intelligently-regulated mixed-flow type dry-wet combined mechanical draft cooling tower system and using method thereof

Abstract

The invention discloses an intelligently-regulated mixed-flow type dry-wet combined mechanical draft cooling tower system and a using method thereof, and relates to the technical field of circulating water treatment. Comprising a tower body, an air cooling subsystem, a wet cooling subsystem and an intelligent regulation and control subsystem, the tower body is of a shell structure with an inner cavity, a fin air cooler in the air cooling subsystem comprises a fin tube bundle and an air cooler header, a water inlet pipeline is communicated with the air cooler header at the bottom, and a water outlet pipeline is communicated with the air cooler header at the top. The circulating water pump and the water inlet flow adjusting valve group are installed on the water inlet pipeline, the two ends of a wet and cold side inlet pipeline in the wet and cold subsystem are communicated with the water outlet pipeline and the spraying assembly respectively, the wet and cold side flow adjusting valve group is installed on the wet and cold side inlet pipeline, and the spraying assembly and the combined filler are both installed in the middle of an inner cavity of the tower body. The intelligent regulation and control subsystem comprises a data acquisition module, a control module and an execution module. Through an intelligent dynamic adjustment mechanism, the system can adapt to the change of working conditions such as season alternation and day and night temperature difference.

Description

Technical Field

[0001] This invention relates to the field of circulating water treatment technology, specifically to an intelligently controlled mixed-flow dry-wet combined mechanical ventilation cooling tower system and its usage method. Background Technology

[0002] In the field of industrial circulating water treatment, mechanical ventilation cooling towers are the core devices for maintaining the stable operation of circulating cooling water systems and achieving circulating water cooling. Their performance directly affects production efficiency and resource consumption.

[0003] Most existing cooling towers employ a single cooling mode, either wet or dry. While wet cooling towers can achieve cooling through enhanced evaporative heat exchange in hot, low-humidity summer environments, water consumption surges. In cold, high-humidity winter environments, the spray system is prone to freezing, requiring shutdown or costly antifreeze measures, leading to cooling system interruptions. Dry cooling towers rely on sensible heat exchange between air and the heat exchange tube walls; their cooling effect is generally poor at high temperatures, failing to meet the rapid cooling requirements of industrial production. Some cooling towers attempt to combine wet and dry modes, but all employ a "wet cooling priority + air cooling auxiliary" process. The air cooling system only plays a limited role in low-temperature conditions, failing to fully utilize the water-saving advantages of air cooling and lacking a dynamic adjustment mechanism to adapt to seasonal changes and diurnal temperature variations. Summary of the Invention

[0004] The purpose of this invention is to provide an intelligently controlled mixed-flow dry-wet combined mechanical ventilation cooling tower system and its usage method, so as to solve the technical problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: an intelligently controlled mixed-flow dry-wet combined mechanical ventilation cooling tower system and its usage method, comprising a tower body, an air-cooling subsystem, a wet-cooling subsystem, and an intelligent control subsystem. The tower body is a shell structure with an inner cavity. A wind duct is installed at the top of the tower body, and a water collection tank is provided at the bottom. The wind duct and water collection tank are both connected to the inner cavity of the tower body. Air-cooling side louvers and wet-cooling side louvers are embedded in the side walls of the tower body shell. The air-cooling subsystem includes a finned air cooler, an inlet water pipe, an outlet water pipe, a circulating water pump, and an inlet flow... The flow regulating valve assembly includes a finned air cooler comprising a finned tube bundle and an air cooler header installed in the upper part of the tower body cavity. The finned tube bundle is composed of multiple finned tubes and is arranged opposite to the air-cooled side louvers. The air cooler header is installed at the upper and lower ends of the finned tube bundle and is connected to the finned tubes. One end of the inlet pipe is connected to the water collection tank, and the other end passes through the tower body shell and is connected to the air cooler header at the bottom. One end of the outlet pipe is connected to the air cooler header at the top, and the other end passes through the tower body shell and extends into the water collection tank. The circulating water pump and... An inlet flow regulating valve assembly is installed on the inlet pipe. This assembly regulates the amount of circulating water pumped into the tower body. The wet cooling subsystem includes a wet cooling side inlet pipe, a wet cooling side flow regulating valve assembly, a spray assembly, and combined packing. One end of the wet cooling side inlet pipe is connected to the outlet pipe, and the other end is connected to the spray assembly. The wet cooling side flow regulating valve assembly is installed on the wet cooling side inlet pipe and regulates the amount of circulating water entering the spray assembly. Both the spray assembly and the combined packing are installed in the middle of the tower body cavity. Located below the spray assembly and positioned above the humidified side louvers, the intelligent control subsystem includes a data acquisition module, a control module, and an execution module. The control module is electrically connected to both the data acquisition module and the execution module. The data acquisition module collects ambient temperature, ambient humidity, and the outlet water temperature from the outlet pipe and transmits this data to the control module. The control module can control the execution module to adjust the opening of the air-cooled side louvers, the humidified side louvers, and the humidified side flow regulating valve group based on changes in ambient temperature, ambient humidity, and outlet water temperature.

[0006] Based on the above technical features, this invention adopts a dual-system collaborative mode of "air cooling + wet cooling." The circulating cooling water first passes through the air cooling subsystem, and then selectively passes through the wet cooling subsystem by adjusting the opening of the flow regulating valve group. This can be flexibly adjusted according to different operating conditions (ambient temperature and humidity) and the outlet water temperature parameters of the outlet pipe. The air cooling subsystem relies on finned air coolers, while the wet cooling subsystem achieves efficient evaporative heat exchange through a combination of spray components and packing materials. During high temperatures in summer, the circulating water after air cooling enters the wet cooling subsystem. The wet cooling subsystem is opened, and the flow regulating valve group and the wet cooling side louvers are adjusted to a suitable opening to achieve rapid cooling. During low temperatures in winter, the circulating water only passes through the air cooling subsystem, and the flow regulating valve group is closed to prevent spray freezing and reduce energy consumption. In spring and autumn, the amount of circulating water entering the wet cooling subsystem can be adjusted according to changes in ambient temperature and humidity, and the ventilation volume of the wet cooling side louvers can be controlled to ensure that the cooling efficiency does not fluctuate with operating conditions. This invention achieves automatic switching between "air cooling + wet cooling" modes through intelligent control, adapting to ambient temperatures from -10℃ to 45℃, with cooling efficiency fluctuations not exceeding 5%. It solves the problems of "low efficiency at high temperatures and easy icing at low temperatures" in traditional cooling towers. Through a dynamic adjustment mechanism, it can adapt to changes in operating conditions such as seasonal changes and day-night temperature differences, ensuring continuous and stable operation of industrial production.

[0007] Preferably, this technical solution also includes a physical scale prevention and removal device and a frequency control device. The physical scale prevention and removal device is installed on the water inlet pipe and is used to promote the formation of aggregates of calcium and magnesium ions in the circulating water. The frequency control device is electrically connected to the physical scale prevention and removal device and is used to adjust the operating frequency of the physical scale prevention and removal device.

[0008] Based on the aforementioned technical features, the physical scale prevention and removal device, through its special structure and materials, causes calcium and magnesium ions in the circulating water to form aggregates, reducing the chance of forming calcium and magnesium salt molecules or forming loose aragonite crystals with no adhesion (the formed crystals are carried by the water flow to the storage tank for sedimentation and separation), thus playing a role in scale prevention. The adjustable frequency signal output by the frequency control device can gradually break the molecular bonds of the formed calcium and magnesium salt crystals, achieving scale removal.

[0009] Preferably, this technical solution also includes an exhaust fan and a permanent magnet motor. The exhaust fan is installed inside the air duct, and the permanent magnet motor is used to drive the operation of the exhaust fan to enhance the airflow in the internal cavity of the tower. The control module can also control the execution module to adjust the speed of the exhaust fan based on changes in ambient temperature, ambient humidity and the outlet water temperature of the outlet pipe.

[0010] Based on the aforementioned technical features, the exhaust fan is driven by a permanent magnet motor, which can effectively reduce energy consumption by 15%-25% compared to traditional asynchronous motors under the same ventilation requirements. Simultaneously, the finned air cooler, in conjunction with the exhaust fan, accelerates air circulation, further improving the heat exchange efficiency of the air-cooling subsystem.

[0011] Preferably, this technical solution further includes supports and a steel structure. The supports and steel structure are used to fix the relative positions of the finned air coolers. One end of the support is fixed to the top of the tower body, and the other end is suspended from the air cooler header at the top. The steel structure is installed in the internal cavity of the tower body and supports the air cooler header at the bottom. More preferably, along the length of the tower body, air-cooled side louvers are respectively embedded in the left and right side walls of the upper shell of the tower body. The finned air coolers are symmetrically fixed to the left and right sides of the internal cavity of the tower body by the supports and steel structure. Furthermore, the finned air coolers on the left and right sides of the internal cavity of the tower body are respectively positioned opposite to the air-cooled side louvers on the left and right side walls of the shell.

[0012] Based on the above technical features, the finned air cooler is fixed to both sides of the water tower by supports and steel structures, ensuring stable installation and heat exchange. The symmetrical arrangement of the finned air cooler allows cold air to flow evenly through the two sets of finned tube bundles, avoiding local overheating or uneven heat dissipation, thereby improving the overall heat exchange efficiency.

[0013] Preferably, in this technical solution, the spray assembly consists of a spray layer and spray nozzles. The spray layer includes multiple spray pipes arranged in parallel. All spray pipes are arranged opposite to the combined packing material and are connected to the wet and cold side inlet pipe. The spray nozzles are evenly installed at the bottom of each spray pipe.

[0014] Based on the above technical features, the circulating cooling water entering the spray layer is sprayed out through multiple nozzles evenly arranged at the bottom, making full contact with the combined packing material to achieve efficient evaporative heat exchange.

[0015] Preferably, in this technical solution, the wet cooling subsystem further includes a water collector, which adopts a baffle plate structure and is installed on the upper part of the tower cavity to intercept the water mist generated during the spraying process of the nozzles.

[0016] Preferably, in this technical solution, the combined packing includes several plate components and several corrugated components. The plate components are smooth plates with parallel surfaces. The corrugated components are wavy plates with a plate component between each pair of adjacent corrugated components. The corrugated components are detachably connected to the two plate components in each pair of adjacent plate components and their corresponding corrugated components.

[0017] Based on the above technical features, the combined packing adopts a composite structure of "corrugated components + plate components", which increases the contact area with the cooling medium (i.e., atomized water droplets) and improves the cooling effect.

[0018] A method for using a mixed-flow dry-wet combined mechanical ventilation cooling tower system with intelligent control, the method including dynamic monitoring and adaptive adjustment and initial operating condition type determination.

[0019] Dynamic monitoring and adaptive adjustment include the following steps:

[0020] The first step is to start the intelligent control subsystem and set the circulating water outlet temperature threshold to 32℃~35℃, the liquid level threshold to 2m~4m, and the circulating water hardness threshold to ≥300mg / L;

[0021] The second step is to start the circulating water pump and adjust the circulating water flow through the inlet flow regulating valve group until the ventilation cooling tower system can operate stably within the specified time.

[0022] Third, at set intervals, the data acquisition module will collect the outlet water temperature in real time. The control module will compare the collected outlet water temperature with the circulating water outlet temperature threshold to determine the current outlet water temperature status. At set intervals, the data acquisition module will also collect the liquid level height in the collection tank in real time. The control module will compare the collected liquid level height in the collection tank with the liquid level threshold to determine the current liquid level status. At the same time, at set intervals, the hardness of the circulating water will be sampled and analyzed. The control module will compare the sampled circulating water hardness with the circulating water hardness threshold to determine the current circulating water hardness status.

[0023] Fourth, the control module sends instructions based on the determined current outlet water temperature and controls the execution module to adjust the exhaust fan speed and the opening degree of the air-cooled side louvers and the wet-cooled side louvers; the control module also sends instructions based on the determined current liquid level and controls the execution module to replenish or drain water into the collection tank; at the same time, the control module also sends instructions to the frequency control device based on the determined current circulating water hardness and automatically increases the frequency of the physical scale prevention and descaling device.

[0024] The initial operating condition type determination includes the following steps:

[0025] The first step is to start the intelligent control subsystem and set the target thresholds for ambient temperature and ambient humidity under different operating conditions;

[0026] The second step is to collect the external ambient temperature and humidity of the tower in real time through the data acquisition module. The control module compares the ambient temperature and humidity collected by the data acquisition module with the set target threshold to determine the type of working condition.

[0027] The third step involves the control module sending instructions based on the determined operating condition type and controlling the execution module to adjust the fan speed, the opening degree of the air-cooled side louvers, the wet-cooled side louvers, and the wet-cooled side flow regulating valve group, as well as the frequency of the physical anti-scaling and descaling device. Attached Figure Description

[0028] Figure 1This is a flowchart illustrating the intelligent control mechanism of the mechanical ventilation cooling tower system in this embodiment of the invention.

[0029] Figure 2 This is a schematic diagram of the mechanical ventilation cooling tower in an embodiment of the present invention;

[0030] Figure 3 This is a front view of the mechanical ventilation cooling tower in an embodiment of the present invention;

[0031] Figure 4 This is a rear view of the mechanical ventilation cooling tower in an embodiment of the present invention;

[0032] Figure 5 This is a side view of the mechanical ventilation cooling tower in an embodiment of the present invention;

[0033] Figure 6 This is a top view of the mechanical ventilation cooling tower in an embodiment of the present invention;

[0034] Figure 7 This is a schematic diagram of the combined packing structure in an embodiment of the present invention;

[0035] Figure 8 This is a schematic diagram of the structure of the finned air cooler in an embodiment of the present invention.

[0036] In the diagram: 1. Air duct; 2. Permanent magnet motor; 3. Tower body; 4. Air-cooled side louvers; 5. Wet-cooled side louvers; 6. Water outlet pipe; 7. Water inlet pipe; 8. Finned air cooler; 81. Air cooler header; 82. Finned tube bundle; 9. Wet-cooled side flow regulating valve assembly; 91. Wet-cooled side inlet pipe; 10. Spray layer; 11. Spray head; 12. Combined packing; 13. Steel structure; 14. Physical scale prevention and descaling device; 15. Exhaust fan; 16. Water collector; 17. Water collection tank; 171. Liquid level sensor; 18. Circulating water pump; 181. Water inlet flow regulating valve assembly; 182. Temperature sensor; 183. Pressure sensor; 19. Water collection tank flow regulating valve assembly. Detailed Implementation

[0037] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0038] It should be noted that in the description of this invention, the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", and "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0039] Furthermore, it should be understood that, for ease of description, the dimensions of the various components shown in the accompanying drawings are not drawn to actual scale.

[0040] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined or described in one figure, it will not need to be discussed or described in detail in the description of the subsequent figures.

[0041] like Figures 1 to 8 As shown, the present invention provides the following technical solution: an intelligent controllable mixed-flow dry-wet combined mechanical ventilation cooling tower system, wherein the ventilation cooling tower system of the present invention includes the following components:

[0042] I. Tower Body:

[0043] like Figures 1 to 6 As shown, the tower body 3 is a shell structure with an inner cavity. The top of the tower body 3 is equipped with a wind duct 1 and the bottom is equipped with a water collection pool 17. Both the wind duct 1 and the water collection pool 17 are connected to the inner cavity of the tower body 3. The side wall of the shell of the tower body 3 is equipped with air-cooled side louvers 4 and wet-cooled side louvers 5.

[0044] Furthermore, a permanent magnet motor 2 is installed at the top of the tower body 3, and an exhaust fan 15 is installed inside the air duct 1. The exhaust fan 15 can be driven by the permanent magnet motor 2, which is equipped with a frequency converter, enabling stepless speed regulation from 0 to 50 Hz. This allows it to adapt to different ventilation requirements under various working conditions, reducing energy consumption by 15% to 25% compared to traditional asynchronous motors. Air can enter the tower body 3 through the air-cooled side louvers 4 and the wet-cooled side louvers 5. The air entering the inner cavity of the tower body 3 through the air-cooled side louvers 4 flows through the finned tube bundle 82 for sensible heat exchange, while the air entering the inner cavity of the tower body 3 through the wet-cooled side louvers 5 undergoes evaporative heat exchange with water droplets on the combined packing 12. The exhaust fan 2 can accelerate the airflow within the inner cavity of the tower body 3, increasing the contact efficiency between the air and the finned tube bundle 82 and the combined packing 12, improving the heat exchange effect of both the air-cooled and wet-cooled subsystems, and rapidly cooling the circulating water.

[0045] Both the air-cooled side louver 4 and the wet-cooled side louver 5 include several sets of blades and rotating shafts. The number of blades and rotating shafts corresponds one-to-one. The blades are rotatably mounted on the outer wall of the tower body 3 via the rotating shafts. Several sets of blades are arranged longitudinally, and the rotating shafts are parallel to the outer wall of the tower body 3. The opening of the louvers can be adjusted according to different operating conditions (such as season, cooling temperature requirements, etc.), flexibly controlling the ventilation volume within the tower body 3, thus improving adaptability to changes in operating conditions such as seasonal changes and fluctuations in cooling temperature requirements, resulting in more stable cooling efficiency. Of course, in other embodiments, ventilators can be used instead of louvers, as long as they promote airflow and maintain and adjust the ventilation volume within the tower body 3. Preferably, in this embodiment of the invention, both the air-cooled side louver 4 and the wet-cooled side louver 5 are electrically adjustable structures. The blade opening is controlled by a stepper motor, with an adjustable range of 0° to 90° and an adjustment accuracy of ±1°, enabling precise control of the ventilation volume within the tower.

[0046] Specifically, such as Figures 1 to 3 As shown, along the length direction of the tower body 3 (i.e., the left-right direction), the air-cooled side louver 4 includes two louvers, which are respectively embedded in the left and right side walls of the upper shell of the tower body 3. Meanwhile, along the width direction of the tower body 3 (i.e., the front-back direction), the wet-cooled side louver 5 is one louver, which is embedded in the front side wall of the lower shell of the tower body 3. The above structure of the air-cooled side louver 4 and the wet-cooled side louver 5 can reduce airflow resistance and increase air intake.

[0047] The water collection tank 17 is equipped with a liquid level sensor 171 and a temperature sensor 182. The liquid level sensor 171 has a measurement range of 0 to 5 m and an accuracy of ±1 mm. The temperature sensor 182 has a measurement range of -20℃ to 100℃ and an accuracy of ±0.1℃. It can monitor the liquid level and temperature of the circulating water in the water collection tank 17 in real time and provide data support for the intelligent control subsystem.

[0048] Tower body and foundation installation:

[0049] Tower body 3 adopts a mixed-flow steel structure frame. Before installation, the levelness of the concrete foundation must be checked to ensure that the horizontal error of the foundation plane is ≤3mm / m. During the assembly of tower body 3, a total station is used to calibrate the verticality. The verticality deviation of each column section is ≤1%, and the diagonal deviation of the overall frame is ≤5mm to avoid affecting air circulation and component compatibility due to structural offset.

[0050] The water collection tank 17 is located at the bottom of the tower. Before installation, it must be treated to prevent leakage, for example, by applying a cement-based penetrating crystalline waterproof coating with a thickness ≥1.5mm inside the water collection tank 17. The liquid level sensor 171 is installed in the middle of the tank wall, 1.5m from the bottom, ensuring the sensor probe is completely submerged and does not touch any debris on the bottom. The temperature sensor 182 is installed on the inner wall of the outlet pipe of the water collection tank, perpendicular to the water flow direction, to avoid direct sunlight affecting measurement accuracy.

[0051] II. Air-cooled subsystem:

[0052] like Figures 1 to 6 , Figure 8 As shown, the air-cooled subsystem includes a finned air cooler 8, an inlet water pipe 7, an outlet water pipe 6, a circulating water pump 18, and an inlet water flow regulating valve group 181.

[0053] like Figure 8 As shown, the finned air cooler 8 includes a finned tube bundle 82 and an air cooler header 81 installed in the upper part of the inner cavity of the tower body 3. The finned tube bundle 82 is composed of multiple finned tubes and is arranged opposite to the air-cooled side louvers 4. The air cooler header 81 is installed at the upper and lower ends of the finned tube bundle 82 and is connected to the finned tubes. The finned tubes are made of copper-aluminum composite material, and the outer surface is provided with serrated fins. The fin spacing is 2mm to 3mm and the fin height is 8mm to 10mm. Compared with ordinary bare tubes, the heat exchange area is increased by 3 to 5 times, which improves the air-cooled heat exchange efficiency.

[0054] like Figure 1 As shown, one end of the inlet pipe 7 is connected to the water collection tank 17, and the other end passes through the outer shell of the tower body 3 and is connected to the air cooler header 81 at the bottom. One end of the outlet pipe 6 is connected to the air cooler header 81 at the top, and the other end passes through the outer shell of the tower body 3 and extends into the water collection tank 17. The circulating water pump 18 and the inlet flow regulating valve group 181 are installed on the inlet pipe 7. The inlet flow regulating valve group 181 is used to regulate the amount of circulating water pumped into the tower body 3.

[0055] Furthermore, the finned air cooler 8 is fixed in the internal cavity of the tower body 3 by a support bracket and a steel structure 13. One end of the support bracket is fixed to the top of the tower body 3, and the other end is suspended from the air cooler header 81 at the top. The steel structure 13 is installed in the internal cavity of the tower body 3 and is used to support the air cooler header 81 at the bottom.

[0056] Preferably, such as Figure 1 and Figure 2 As shown, the finned air cooler 8 is symmetrically fixed to the left and right sides of the internal cavity of the tower body 3 by the support bracket and the steel structure 13. Furthermore, the finned air coolers 8 on the left and right sides of the internal cavity of the tower body 3 are respectively arranged opposite to the air-cooled side louvers 4 on the left and right side walls of the shell.

[0057] Air-cooled subsystem installation:

[0058] The tube-plate finned air cooler 8 consists of an air cooler header 81 and multiple copper-aluminum composite sawtooth finned tubes 82, which are symmetrically fixed to both sides of the tower body by supports and steel structures 13, located inside the louvers 4 on the air-cooled side. During installation, the horizontal deviation of the finned tubes 82 must be ≤2mm / m. The flange connections between the air cooler header 81 and the inlet pipe 7 and outlet pipe 6 must be tightly sealed using graphite gaskets. The bolt tightening torque should be adapted to the pipe diameter (≥300N·m for DN600 pipe bolts) to avoid leakage affecting heat exchange efficiency.

[0059] The air-cooled side louver 4 is an electrically adjustable structure, installed on the side wall of the tower body 3 corresponding to the finned air cooler 8. The louver blade rotation shaft is parallel to the side wall of the tower body 3. The stepper motor (adjustment accuracy ±1°) is fixed on the outside of the louver frame and connected to the blade through a connecting rod. During debugging, it is necessary to ensure that the blade opening can be smoothly adjusted within the range of 0° to 90° without any jamming, and that the air circulation area reaches more than 95% of the design value when fully open.

[0060] III. Wet and Cold Subsystem:

[0061] like Figures 1 to 7 As shown, the wet cooling subsystem includes a wet cooling side inlet pipe 91, a wet cooling side flow regulating valve group 9, a spray assembly, a combined packing 12, and a water collector 16.

[0062] like Figure 1 and Figure 2 As shown, one end of the wet cooling side inlet pipe 91 is connected to the outlet pipe 6, and the other end is connected to the spray assembly. The wet cooling side flow regulating valve group 9 is installed on the wet cooling side inlet pipe 91 and is used to regulate the amount of circulating water entering the spray assembly. The spray assembly and the combined packing 12 are both installed in the middle of the inner cavity of the tower body 3, and the combined packing 12 is located below the spray assembly and is positioned higher than the wet cooling side louvers 5. Preferably, in this embodiment of the invention, to adapt to the intelligent control subsystem, the wet cooling side flow regulating valve group 9 adopts an electric ball valve with a regulation accuracy of ±1%, which can accurately control the amount of circulating water entering the wet cooling subsystem according to the operating conditions.

[0063] Furthermore, the spray assembly consists of a spray layer 10 and nozzles 11. The spray layer 10 includes multiple spray pipes arranged in parallel, all of which are positioned opposite to the combined packing 12 and connected to the wet-cold side inlet pipe 91. The nozzles 11 are evenly installed at the bottom of each spray pipe. The nozzles 11 can be spiral nozzles with a spacing of 300mm to 400mm and an atomization angle of 120°, which can atomize the circulating water into water droplets with a diameter of 0.5mm to 1mm, increasing the contact area with air and improving the evaporative heat exchange efficiency.

[0064] like Figure 7As shown, the combined packing 12 includes several plate components and several corrugated components. The plate components are smooth plates, parallel to each other. The corrugated components are wavy plates, with one plate component between every two adjacent corrugated components. The corrugated components are detachably connected to the two adjacent plate components and their corresponding corrugated components. The combined packing 12 adopts a composite structure of "corrugated components + plate components" and uses modified PVC material (high temperature resistance 80℃, aging resistance ≥5 years) to enhance evaporative heat transfer, increase the contact area with the cooling medium (i.e., atomized water droplets), and improve the cooling effect.

[0065] like Figure 1 and Figure 2 As shown, the water collector 16 adopts a baffle plate structure with a water collection efficiency of ≥99.5%. It is installed on the upper part of the cavity of the tower body 3 via a steel structure 13 to intercept the water mist generated during the spraying process of the nozzles 11, thereby reducing water loss. The circulating water formed by the water mist intercepted by the water collector 16, as well as the circulating water after evaporation and heat exchange on the combined packing 12, can all fall into the water collection pool 17 below the tower body 3.

[0066] Installation of the wet cooling subsystem:

[0067] Spray layer 10 is installed in the middle of the tower body, 1.2m directly above the combined packing 12, with a total of 3 layers. Each layer of spray pipes is made of 304 stainless steel with a pipe slope of 0.3% to ensure no water residue remains inside the pipes. Spray heads 11 are evenly installed at the bottom of the spray pipes. After installation, a water pressure test is required. The specific water pressure test is conducted at a pressure of 0.6MPa, held for 30 minutes without leakage. Through adjustments, it is ensured that the diameter of the atomized water droplets is 0.5mm to 1mm, and that there are no dead angles in the coverage area.

[0068] The combined packing material 12 has a filling height of 1.5m and is installed in the middle of the tower body via steel structure 13. The water collector 16 is a baffle structure, installed above the tower body via steel structure 13 with a baffle spacing of 15mm. After installation, the water collection efficiency needs to be tested, specifically by measuring the water mist emission rate using the weighing method, to ensure that the water collection efficiency is ≥99.5%.

[0069] The wet cooling side flow regulating valve group 9 uses an electric ball valve, installed on the wet cooling side inlet pipe 91, at a distance of 5 times the pipe diameter from the inlet of the spray layer 10, to avoid the influence of pipe bends on flow measurement. When connecting the valve to the pipe flange, it is necessary to ensure that the valve core axis coincides with the pipe axis. During commissioning, commands are sent through the control module (PLC controller) to verify that the valve opening adjustment response time from 0% to 100% is ≤2s and the flow control error is ≤3%.

[0070] IV. Physical scale prevention and removal devices:

[0071] like Figures 1 to 5 As shown, the physical scale prevention and removal device 14 is installed on the water inlet pipe 7 to promote the formation of aggregates of calcium and magnesium ions in the circulating water. The frequency control device is electrically connected to the physical scale prevention and removal device 14 to adjust the operating frequency of the physical scale prevention and removal device 14.

[0072] Before understanding the specific structure of physical scale prevention and removal devices, it's important to understand that calcium and magnesium ions in circulating water easily form hard calcite scale on the heat exchange tube walls. For every 1mm increase in scale thickness, heat exchange efficiency decreases by 8%–12%. Simultaneously, scale and impurities in the water exacerbate tube wall corrosion, shorten equipment lifespan, and increase annual maintenance costs by 20%–30%. Existing chemical descaling methods require periodic addition of chemicals, which not only increases operating costs but also easily causes secondary water pollution.

[0073] Specifically, in this embodiment of the invention, the physical scale prevention and removal device 14 can be made of rare earth permanent magnet material. The diameter of the ring body matches the outer diameter of the water inlet pipe 7, and it is wound around the outer ring of the water inlet pipe 7. It can form a gradient magnetic field of 0.5T to 1.2T, causing calcium and magnesium ions in the circulating water to form aggregates, reducing the formation of calcium and magnesium salt molecules, or promoting the formation of loose aragonite crystals (rather than hard calcite) without adhesion. The crystals are carried by the water flow to the collection tank 17 for sedimentation and separation, thus achieving scale prevention and reducing equipment corrosion. The frequency control device can output an adjustable frequency signal of 10kHz to 50kHz. By changing the magnetic field frequency, the working intensity can be adjusted to adapt to circulating water with different hardness. At the same time, it breaks the molecular bonds of the already formed scale to achieve scale removal without the addition of chemical agents, avoiding secondary pollution. The physical scale prevention and removal device can adjust the frequency (10kHz to 50kHz) in real time according to the hardness of the circulating water to adapt to the intelligent control subsystem and achieve continuous scale prevention and removal.

[0074] Installation of physical scale prevention and removal devices:

[0075] The physical scale prevention and removal device 14 is made of rare earth permanent magnet material. The frequency control device is installed in the control cabinet in the control room and is connected to the physical scale prevention and removal device 14 made of rare earth permanent magnet material through a shielded cable. The cable length is ≤50m and the grounding resistance of the shielding layer is ≤4Ω. During commissioning, the frequency output range (10kHz~50kHz) needs to be verified and the frequency adjustment step size is ≤1kHz to ensure that the working intensity can be dynamically adjusted according to the hardness of the circulating water.

[0076] V. Intelligent Control Subsystem:

[0077] The intelligent control subsystem includes a data acquisition module, a control module, and an execution module. The control module is electrically connected to the data acquisition module and the execution module. The data acquisition module is used to collect ambient temperature, ambient humidity, and the outlet water temperature of the outlet water pipe 6, and transmit them to the control module. The control module can control the execution module to adjust the opening degree of the air-cooled side louver 4, the wet-cooled side louver 5, and the wet-cooled side flow regulating valve group 9 based on the changes in ambient temperature, ambient humidity, and outlet water temperature.

[0078] The data acquisition module includes a temperature sensor 182, a humidity sensor, a pressure sensor 183, and a liquid level sensor 171. The temperature sensor 182 is installed on the inlet pipe 7, the outlet pipe 6, the collection tank 17, and the exterior of the tower body 3. Its measurement range is -20℃ to 100℃, with an accuracy of ±0.1℃. The temperature sensor 182 installed on the inlet pipe 7 measures the inlet temperature of the circulating water in the inlet pipe; the temperature sensor 182 installed on the outlet pipe 6 measures the outlet temperature of the circulating water in the outlet pipe; the temperature sensor 182 installed in the collection tank 17 measures the temperature of the circulating water in the collection tank; and the temperature sensor 182 installed on the exterior of the tower body 3 measures the ambient temperature. The humidity sensor is installed on the exterior of the tower body 3, with a measurement range of 0% to 100%RH and an accuracy of ±2%RH, and is used to measure ambient humidity. Pressure sensor 183 is installed in the inlet pipe 7, with a measurement range of 0–1.6 MPa and an accuracy of ±0.5% FS, used to measure the inlet pressure of the circulating water in the inlet pipe 7. Level sensor 171 is installed in the collection tank 17, with a measurement range of 0–5 m and an accuracy of ±1 mm, used to measure the level of the circulating water in the collection tank 17. All sensors (temperature sensor 182, humidity sensor, pressure sensor 183, and level sensor 171) collect data at set intervals and upload it to the control module in real time. Preferably, all sensors update their data every 10 seconds and upload it to the control module.

[0079] The control module uses a PLC controller with built-in operating condition recognition algorithms and cooling mode decision logic. Based on the parameter combination of "inlet water temperature - ambient temperature and humidity - outlet water temperature requirement", it automatically determines the operating condition type.

[0080] In summer, under high temperature conditions, the ambient temperature is ≥30℃ and the ambient humidity is ≤60%RH;

[0081] Winter low-temperature operating conditions: ambient temperature ≤5℃, ambient humidity ≥70%RH;

[0082] Spring and autumn transitional operating conditions: 5℃ < ambient temperature < 30℃, 60%RH < ambient humidity < 70%RH.

[0083] The execution module includes a permanent magnet motor frequency converter, an electric louver stepper motor, a wet cooling side flow regulating valve group 9, and a frequency control device, which performs the following adjustments according to the instructions of the control module:

[0084]

[0085]

[0086] Installation of the intelligent control subsystem:

[0087] In the data acquisition module, temperature sensors 182 are installed on the inlet pipe 7 (3 times the pipe diameter from the inlet of the finned air cooler), the outlet pipe 6 (5 times the pipe diameter from the outlet of the finned air cooler), and the outlet pipe of the water collection tank 17, respectively; humidity sensors are installed at the external ventilation point of the tower body 3, 2m above the ground, to avoid direct sunlight and rain splash; pressure sensors 183 are installed on the inlet pipe 7, vertically connected to the pipe, and adopt a diaphragm structure (temperature resistance ≥100℃), with a measurement range of 0~1.6MPa and an accuracy of ±0.5%FS.

[0088] The control module uses a Siemens S7-1200 PLC controller, installed in the control cabinet in the control room. It communicates with the sensors of the data acquisition module via the Modbus-RTU protocol (communication baud rate 9600bps, 8 data bits, 1 stop bit). The permanent magnet motor frequency converter in the execution module (adapted to a 75kW permanent magnet synchronous motor) is installed in the fan control cabinet and communicates with the PLC controller via the Profinet protocol. During commissioning, it was verified that the frequency converter output frequency range is 0-50Hz, and the speed control error of the pumping motor is ≤1%.

[0089] The human-machine interface uses a 10-inch touch screen, which is installed on the control panel in the control room. It can display operating parameters (ambient temperature and humidity, circulating water inlet and outlet temperatures, liquid level, pressure, and operating status of each component) and control commands in real time. It supports parameter setting (outlet temperature threshold, hardness threshold, liquid level threshold) and historical data query (storage period ≥ 1 year, data can be exported in Excel format).

[0090] Under high-temperature conditions in summer, the air-cooled circulating water enters the wet cooling subsystem through the wet cooling side inlet pipe 91. The wet cooling subsystem is then turned on, the wet cooling side louvers 5 are opened and adjusted to a suitable opening degree, and the flow rate of the circulating water entering the wet cooling subsystem is controlled by the wet cooling side flow regulating valve group 9. This allows the circulating water to enter the spray layer 10 and be sprayed out through multiple evenly arranged nozzles 11 at the bottom, ensuring full contact with the combined packing 12 and achieving efficient evaporative heat exchange. Above the air duct 1, the exhaust fan 15, driven by the permanent magnet motor 2, operates to enhance the airflow speed inside the tower, accelerate the contact efficiency between the air and the combined packing 12, improve the wet cooling heat exchange effect, and quickly cool the circulating water.

[0091] In low-temperature winter conditions, circulating water only passes through the air-cooled subsystem, while the wet-cooled subsystem is shut down and spraying is stopped to prevent ice formation inside the tower. At this time, the opening of the louvers 4 on the air-cooled side can be adjusted according to actual conditions to control ventilation volume, thereby reducing energy consumption while meeting cooling requirements.

[0092] In spring and autumn, the amount of circulating water entering the wet cooling subsystem can be flexibly adjusted according to changes in temperature and humidity through the wet cooling side flow regulating valve group 9. Combined with the ventilation volume control of the air cooling side louvers 4 and the wet cooling side louvers 5, the cooling efficiency is ensured to remain stable regardless of operating conditions.

[0093] A method for using a mixed-flow dry-wet combined mechanical ventilation cooling tower system with the above-mentioned intelligent control includes initial operating condition type determination and dynamic monitoring and adaptive adjustment.

[0094] The initial operating condition type determination includes the following steps:

[0095] The first step is to start the intelligent control subsystem and set the target thresholds for ambient temperature and ambient humidity under different operating conditions;

[0096] The second step involves real-time collection of external ambient temperature and humidity using temperature sensor 182 and humidity sensor outside the tower body 3. The control module compares the collected ambient temperature and humidity with the set target threshold to determine the operating condition type (high temperature operating condition in summer, low temperature operating condition in winter, and transitional operating condition in spring and autumn).

[0097] The third step involves the control module sending instructions based on the determined operating condition type, controlling the permanent magnet motor frequency converter to adjust the speed of the exhaust fan 15, controlling the electric louver stepper motor to adjust the opening of the air-cooled louver 4 and the wet-cooled louver 5, controlling the wet-cooled side flow regulating valve group to adjust the opening of the wet-cooled side flow regulating valve group 9, and controlling the frequency control device to adjust the frequency of the physical anti-scaling and descaling device 14.

[0098] Dynamic monitoring and adaptive adjustment include the following steps:

[0099] The first step is to start the intelligent control subsystem and set the circulating water outlet temperature threshold to 32℃~35℃, the liquid level threshold of the collection tank 17 to 2m~4m, and the circulating water hardness threshold to ≥300mg / L.

[0100] The second step is to start the circulating water pump 18 and adjust the circulating water flow rate through the inlet flow regulating valve group 181 until the ventilation cooling tower system can operate stably within the specified time.

[0101] Third, at set intervals, the temperature sensor 182 installed on the outlet pipe will collect the outlet water temperature in real time. The control module will compare the collected outlet water temperature with the circulating water outlet temperature threshold to determine the current outlet water temperature status. At set intervals, the liquid level sensor 171 will also collect the liquid level height in the collection tank 17 in real time. The control module will compare the collected liquid level height in the collection tank 17 with the liquid level threshold to determine the current liquid level status. At the same time, at set intervals, the hardness of the circulating water will be sampled and analyzed. The control module will compare the sampled and analyzed circulating water hardness with the circulating water hardness threshold to determine the current circulating water hardness status.

[0102] Fourth, the control module sends instructions based on the determined current outlet water temperature status and controls the permanent magnet motor frequency converter to adjust the speed of the exhaust fan 15, and controls the electric louver stepper motor to adjust the opening degree of the air-cooled side louver 4 and the wet-cooled side louver 5; the control module also sends instructions based on the determined current liquid level status and controls the water supply valve in the water collection tank flow regulating valve group 19 to supply water to the water collection tank 17 or controls the drain valve in the water collection tank flow regulating valve group 19 to drain water; at the same time, the control module also sends instructions to the frequency control device based on the determined current circulating water hardness status and automatically increases the frequency of the physical anti-scaling and descaling device 14.

[0103] Specifically, when the control module determines the operating conditions to be high-temperature conditions in summer (T0≥30℃, RH≤60%):

[0104] ① Circulating cooling water enters the tower body 3 through the inlet pipe 7 and the physical scale prevention and removal device. At the same time, the physical scale prevention and removal device 14 is set to work at a frequency of 30kHz to 50kHz to prevent scale from entering the circulating water.

[0105] ② The treated circulating water enters the finned air cooler 8 and exchanges sensible heat with the air entering through the air-cooled side louvers 4 (the opening is set to 30% to 50% under high-temperature conditions in summer), and the water temperature drops to the set threshold.

[0106] ③ The circulating water after initial cooling enters the spray layer 10 through the wet cooling side inlet pipe 91 and is controlled by the wet cooling side flow regulating valve group 9 (the opening degree is set to 60% to 100% under the high temperature condition in summer). After being atomized by the nozzle 11, it is sprayed onto the combined packing 12.

[0107] ④ The permanent magnet motor 2 drives the exhaust fan 15 to run at 80% to 100% speed to accelerate air flow. The air enters the tower body 3 through the louver 5 on the wet and cold side (set to 80% to 100% opening under high temperature conditions in summer) and exchanges heat with the water droplets on the combined packing 11 through evaporation. The water temperature drops to the set threshold.

[0108] ⑤ After heat exchange, the misty air is intercepted by the water collector 16 (water collection efficiency ≥99.5%). After the water mist condenses, it falls back into the water collection pool 17, and the air is discharged through the air duct 1.

[0109] ⑥ The circulating water in the water collection tank 17 flows back to the water collection tank 17 through the water outlet pipe 6, and is then transported back to the industrial production system to complete the circulation.

[0110] When the control module determines the operating condition to be low temperature in winter (T0≤5℃, RH≥70%):

[0111] ① The control module closes the louvers 5 on the wet cooling side and the flow regulating valve group 9 on the wet cooling side, stopping the operation of the wet cooling subsystem to prevent icing;

[0112] ② The circulating cooling water enters the finned air cooler 8 after being treated by the physical anti-scaling and descaling device 14 (with a frequency set to 10kHz~30kHz under high-temperature conditions in winter).

[0113] ③ The permanent magnet motor 2 drives the exhaust fan 15 to run at 30% to 50% speed to accelerate air flow. The opening of the air-cooled side louver 4 is adjusted to 50% to 70%. The exhaust fan 15 determines whether to run based on the circulating water temperature. The air and the circulating water in the finned tube exchange sensible heat, and the water temperature drops to the set threshold.

[0114] ④ The cooled circulating water flows back to the collection tank 17 through the outlet pipe 6, and then is transported back to the production system.

[0115] When the control module determines the operating condition to be in transition between spring and autumn (5℃ < T0 < 30℃, 60% < RH < 70%):

[0116] ① The control module dynamically adjusts the following based on real-time parameters (T0, RH, outlet water temperature): opening of the wet cooling side flow regulating valve group 9 is 10% to 50%, opening of the air cooling / wet cooling louvers is 50% to 70% / 30% to 60%, and fan speed is 50% to 80%.

[0117] ② The permanent magnet motor 2 drives the exhaust fan 15 to run at 50% to 80% speed to accelerate air flow. The circulating cooling water is first cooled by the air cooling subsystem, and then partially enters the wet cooling subsystem to supplement the cooling as needed, so as to ensure the outlet water temperature is stable.

[0118] ③ The physical scale prevention and removal device 14 adjusts the frequency (10kHz~50kHz) in real time according to the hardness of the circulating water to continuously prevent and remove scale.

[0119] Dynamic monitoring and adaptive adjustment: The control module compares the outlet water temperature with the circulating water outlet temperature in real time to set a threshold.

[0120] If the water temperature is ≥2℃ higher than the threshold: increase the exhaust fan speed by 15 (+10%), the opening of the wet and cold side flow regulating valve group 9 (+10%), and the opening of the wet and cold side louvers by 5 (+10%) until the water temperature drops.

[0121] If the water temperature is below the threshold ≤ -2℃: reduce the exhaust fan speed by 15 (-10%), the flow regulating valve group 9 on the wet and cold side by 9 (-10%), and the opening degree of the louvers on the wet and cold side by 5 (-10%) to avoid energy waste;

[0122] Liquid level monitoring: When the liquid level in the collection tank is <2m, the water replenishment valve in the water collection tank flow regulating valve group 19 will be automatically opened to replenish water; when the liquid level is >4m, water replenishment will be stopped, and the drain valve in the water collection tank flow regulating valve group 19 will be automatically opened to drain water appropriately.

[0123] Hardness monitoring: When the hardness of the circulating water changes by more than 300 mg / L, the frequency control device automatically increases the frequency of the physical scale prevention and descaling device 14 by 5 kHz to 10 kHz to enhance the descaling effect and triggers an audible and visual alarm to remind the user to check the water replenishment system.

[0124] System debugging process

[0125] 1. Standalone debugging

[0126] Each component was started one by one to verify its operating status: the permanent magnet motor 2 drove the exhaust fan 15 to run, and the fan speed was tested to ensure its stability from 30% to 100%, with the fan vibration speed ≤4.5mm / s and noise ≤85dB; the electric louvers (4, 5) were adjusted from 0° to 90° under the control of the PLC controller, and the ventilation volume corresponding to each opening was recorded (the ventilation volume was calculated by measuring the wind speed inside the tower with an anemometer); after the circulating water pump 18 was started, the flow control accuracy of the inlet flow regulating valve group 181 was tested to ensure that the circulating water flow rate was stable at 3000m³. 3 / h±5%.

[0127] Commissioning of physical scale prevention and removal device: Inject simulated water with a hardness of 350 mg / L (calculated as CaCO3) into the circulating water system, turn on the physical scale prevention and removal device 14 (frequency 45 kHz), and run it continuously for 72 hours. Then, take samples to analyze the changes in calcium and magnesium ion concentration in the circulating water to ensure that the calcium and magnesium ion polymerization rate is ≥60%. At the same time, check the heat exchange tube wall (finned tube) to ensure that no new scale is formed.

[0128] 2. Linkage debugging

[0129] Simulating high-temperature summer conditions (the inlet water temperature is raised to 42℃ via an electric heating device, and the ambient temperature and humidity are controlled at 40℃ and 50%RH via air conditioning), the PLC controller automatically determines the operating condition type and sends commands: exhaust fan 15 speed 100% (75kW), air-cooled side louver 4 opening 40%, wet-cooled side louver opening 590%, wet-cooled side flow regulating valve group 9 opening 80%, physical anti-scaling and descaling device 14 frequency 45kHz; after continuous operation for 2 hours, the circulating water outlet temperature is recorded to be stable at 31.5℃±0.5℃, meeting the requirement of ≤32℃, and the hourly water consumption is ≤5 tons (daily average water consumption is 120 tons).

[0130] Simulating low-temperature winter conditions (inlet water temperature 25℃, ambient temperature and humidity controlled at -8℃, 80% RH), the PLC controller commands were: exhaust fan 15 speed 40% (30kW), air-cooled side louver 4 opening 60%, wet-cooled side louver 5 and wet-cooled side flow regulating valve group 9 fully closed, physical anti-scaling and descaling device 14 frequency 25kHz; after running for 2 hours, the circulating water outlet temperature stabilized at 30℃±0.5℃, with no spray water consumption and no ice formation inside the tower.

[0131] Simulating the transitional working conditions between spring and autumn (inlet water temperature 35℃, ambient temperature and humidity controlled at 25℃ and 70%RH), the PLC controller dynamically adjusts the following parameters: exhaust fan 15 speed 60% (45kW), air-cooled side louver 4 opening 60%, wet-cooled side louver 5 opening 50%, wet-cooled side flow regulating valve group 9 opening 30%, and physical scale prevention and descaling device 14 frequency 30kHz. After running for 2 hours, the circulating water outlet temperature fluctuation range is ≤1℃, verifying the system's adaptability to changes in working conditions.

[0132] Operation under different working conditions

[0133] 1. Operation under high-temperature conditions in summer (ambient temperature ≥30℃, humidity ≤60%)

[0134] ① Pre-start checks

[0135] Check the circulating water system: the water level in the collection tank 17 is between 2.5m and 3.5m (water level threshold 2m to 4m), the inlet valve of the circulating water pump 18 is fully open, and the inlet flow regulating valve group 181 is open at 50%; the air-cooled side louvers 4 and the wet-cooled side louvers 5 are closed, and the wet-cooled side flow regulating valve group 9 is fully closed; the frequency control device is in standby mode, and the physical anti-scaling and descaling device 14 has no fault alarm.

[0136] Check the intelligent control subsystem: the PLC controller, touch screen and sensors are all powered on and functioning normally, and there are no communication faults; the circulating water outlet temperature threshold is set to 32℃~35℃, the circulating water hardness threshold is 300mg / L (calculated as CaCO3), and the liquid level threshold is 2m~4m.

[0137] ②Startup Operation

[0138] Start the circulating water pump 18 and adjust the circulating water flow rate to 3000 m³ / h using the inlet flow regulating valve assembly 181. 3 After running stably for 5 minutes, observe the reading of pressure sensor 183 (normal range 0.4MPa~0.6MPa) and check for pressure fluctuations.

[0139] Turn on the physical scale prevention and removal device 14, set the frequency control device to 45kHz (because the hardness of the circulating water is 350mg / L≥300mg / L), run for 10 minutes, and observe the aggregation of calcium and magnesium ions through the online water quality monitoring instrument to ensure that the aggregation rate is ≥60%.

[0140] The PLC controller automatically identifies the high-temperature operating conditions in summer and sends instructions: turn on the exhaust fan 15, gradually increase the speed of the permanent magnet motor 2 to 100% (75kW), and at the same time, slowly adjust the opening of the air-cooled side louvers 4 to 40% and the opening of the wet-cooled side louvers 5 to 90%; after the fan runs stably (vibration speed ≤4.5mm / s), slowly open the wet-cooled side flow regulating valve group 9 to 80% to ensure that the nozzles 11 on the spray layer 10 atomize evenly and without interruption of flow.

[0141] ③ Operation monitoring and adjustment

[0142] Real-time monitoring parameters: View inlet water temperature (inlet 42℃±1℃, outlet must be stable at ≤32℃), ambient temperature and humidity (updated every 10 seconds), fan speed, louver opening, wet and cold water volume, and physical scale prevention and descaling device frequency via touch screen; record data once per hour to form an operation log.

[0143] Adaptive adjustment: If the outlet water temperature is higher than 32℃ by ≥2℃ (e.g., rising to 34℃), the PLC controller automatically increases the fan speed by 10% (to 110%, but not exceeding the rated speed), the opening of the wet cooling side flow regulating valve group 9 by 10% (to 90%), and the opening of the wet cooling side louver 5 by 10% (to 100%), until the outlet temperature drops back to 32℃ ±0.5℃; if the outlet temperature is lower than 32℃ ≤-2℃ (e.g., dropping to 30℃), the above parameters are reduced by 10% to avoid energy waste.

[0144] Water quality maintenance: Daily sampling and analysis of circulating water hardness (using EDTA titration method). If the hardness is ≥300mg / L, the frequency control device automatically increases the frequency of the physical scale prevention and removal device 14 by 5kHz-10kHz (e.g., from 45kHz to 50kHz) and triggers an audible and visual alarm to remind operators to check the water replenishment system (whether high-hardness water has been mixed in). If the water level in the collection tank 17 is below 2m, the water replenishment valve in the collection tank water replenishment flow regulating valve group 19 will be automatically opened to replenish water. If the water level is above 4m, the drain valve in the collection tank water replenishment flow regulating valve group 19 will be opened to drain water to ensure stable water level.

[0145] 2. Operation under low-temperature conditions in winter (ambient temperature ≤ 5℃, humidity ≥ 70%)

[0146] ① Pre-start checks

[0147] Check the wet cooling system: there should be no water accumulation in the spray layer 10, spray head 11, and wet cooling side pipes (if there is water accumulation, drain it through the drain valve) to avoid freezing and damaging the components; there should be no snow accumulation or ice accumulation in the air-cooled side louvers 4 and exhaust fan 15, and the fan bearing lubricating oil temperature should be ≥-5℃ (if it is lower than this temperature, turn on the electric heating device to preheat).

[0148] The intelligent control subsystem is set as follows: the outlet temperature threshold remains at 32℃~35℃, the hardness threshold is 300mg / L, and the liquid level threshold is 2m~4m; the PLC controller mode is switched to "winter low temperature" mode, and the start command of the wet and cold system is disabled.

[0149] ②Startup Operation

[0150] Start circulating water pump 18 and adjust the flow rate to 3000 m³ / h. 3 / h, stable operation for 5 minutes, pressure sensor 183 reading is normal (0.4MPa~0.6MPa).

[0151] Turn on the physical scale prevention and removal device 14. Since the hardness of the circulating water is slightly lower in winter (about 280mg / L), the frequency is set to 25kHz and run for 10 minutes to verify the scale prevention effect.

[0152] The PLC controller identifies the low-temperature operating conditions in winter and sends the following instructions: the speed of the exhaust fan 15 is increased to 40% (30kW), and the opening of the air-cooled side louver 4 is adjusted to 60%; the louver 5 on the wet-cooled side and the flow regulating valve group 9 on the wet-cooled side remain fully closed, and the wet-cooled system is prohibited from starting through interlock control (it cannot be opened even if there is a misoperation).

[0153] ③ Operation monitoring and adjustment

[0154] Anti-freeze monitoring: Check the four louvers on the air-cooled side every 2 hours to see if they are icy (observed by camera or on-site inspection). If icing occurs, the PLC controller will automatically reduce the louver opening by 10% to 20% to reduce the amount of cold air entering, while increasing the fan speed by 10% to generate heat through the fan operation to melt the ice layer. If the icing is severe, stop the fan operation and turn on the hot air device (standby) to blow away the ice layer.

[0155] Temperature regulation: The inlet water temperature is approximately 35℃ in winter. After cooling by the air-cooled subsystem, the outlet water temperature needs to be stabilized at 32℃±1℃. If the outlet water temperature is below 30℃ (due to low ambient temperature), reduce the fan speed by 10% (e.g., from 40% to 30%) and the opening degree of the air-cooled side louvers by 10% (e.g., from 60% to 50%) to reduce heat exchange. If the outlet temperature is above 35℃, increase the above parameters by 10%.

[0156] Equipment maintenance: Check the magnetic field strength of the physical anti-scaling and descaling device 14 weekly (as low temperature may affect the performance of the permanent magnet). If the magnetic field strength is lower than 0.5T, replace the physical anti-scaling and descaling device 14 in time. Replenish the fan bearings with low-temperature lubricating oil (viscosity grade ISO VG32) every two weeks to ensure lubrication effect.

[0157] 3. Operation under transitional conditions in spring and autumn (5℃ < ambient temperature < 30℃, 60% < humidity < 70%)

[0158] ① Pre-start checks

[0159] Check the wet cooling and air cooling systems: the nozzles 11 on the spray layer 10 are not blocked (unblocked by high-pressure water flushing), and there is no dust accumulation on the finned tubes of the air cooler (if there is, turn on compressed air to purge); the parameters of the intelligent control subsystem are set normally, and the "operating condition identification algorithm" is in automatic mode.

[0160] ②Startup Operation

[0161] Start circulating water pump 18 and adjust the flow rate to 3000 m³ / h. 3 / h, running stably.

[0162] Turn on the physical scale prevention and removal device 14, with the initial frequency set to 30kHz, and then dynamically adjusted according to the hardness of the circulating water (e.g., keep it at 30kHz when the hardness is 290mg / L, and increase it to 35kHz when the hardness is 320mg / L).

[0163] The PLC controller automatically identifies the transitional operating conditions between spring and autumn. Based on the real-time ambient temperature and humidity (such as 25℃, 70%RH), it sends commands: fan speed 60% (45kW), air-cooled side louver 4 opening degree 60%, humidified side louver 5 opening degree 50%, and humidified side flow regulating valve group 9 opening degree 30%, to achieve coordinated cooling of "air cooling + partial humidified cooling".

[0164] ③ Dynamic Adaptation: Every 30 minutes, based on changes in ambient temperature and humidity (e.g., ambient temperature rises from 25℃ to 28℃, humidity drops from 70% to 65%), the PLC controller automatically adjusts operating parameters: the fan speed increases from 60% to 70% (45kW→52.5kW), the opening of the wet cooling side flow regulating valve group 9 increases from 30% to 40%, and the opening of the wet cooling side louver 5 increases from 50% to 60%, ensuring that the circulating water outlet temperature remains stable at 32℃±0.5℃; if the ambient temperature drops to 20℃ and the humidity rises to 68%, the parameters are adjusted in the opposite direction to reduce wet cooling input and lower energy consumption.

[0165] Intermittent operation optimization: In spring and autumn when the ambient temperature is low at night (e.g., 15℃), the "intermittent operation mode" can be enabled. The PLC controller will automatically start and stop the wet cooling system according to the outlet water temperature. When the outlet temperature is ≤31℃, the wet cooling side flow regulating valve group 9 and the louvers will be closed, and only the air cooling system will be kept running. When the outlet temperature is ≥33℃, the wet cooling subsystem will be restarted to achieve "cooling on demand".

[0166] Water quality and equipment monitoring: Monitor the hardness of circulating water daily. If the hardness fluctuation exceeds ±20mg / L, adjust the frequency of the physical scale prevention and removal device 14 through the frequency control device. Check the atomization effect of the spray nozzles 11 on the spray layer 10 weekly. If uneven atomization occurs (e.g., water droplet diameter >1.5mm due to impurities clogging), close the corresponding spray layer and backwash with high-pressure water (0.8MPa) to clear the blockage.

[0167] 4. System Fault Handling

[0168] ① Common Faults and Solutions

[0169]

[0170]

[0171]

[0172] ② Emergency Fault Handling Procedure

[0173] In case of sudden power outage: Immediately shut off the power to the circulating water pump 18 and the exhaust fan 15 to prevent the equipment from starting under load when power is restored; close the flow regulating valve group 9 on the wet cooling side and drain the water accumulated in the spray layer 10 pipe (through the drain valve) to prevent the pipe from freezing and cracking (in winter) or microbial growth (in summer); after power is restored, start the system step by step in the following order: "circulating water pump → physical anti-scaling and descaling device → intelligent control subsystem → exhaust fan → wet cooling subsystem", with a 5-minute interval between each step to ensure stable system operation.

[0174] Circulating water pump failure shutdown: The PLC controller triggers a "water pump failure" alarm, automatically shutting off the flow valve and exhaust fan on the wet cooling side to prevent damage to the air cooler finned tubes due to dry burning; immediately start the backup circulating water pump (if available) and adjust the flow rate to 3000 m³ / h. 3 / h, restore cooling; if there is no backup pump, contact maintenance personnel to repair the faulty pump (such as replacing the damaged mechanical seal). During the repair, open the emergency drain valve of the water collection tank to prevent circulating water from overflowing.

[0175] The present invention has the following beneficial effects:

[0176] ① Adopting the process of "air cooling pre-cooling + wet cooling on demand", it relies entirely on air cooling in winter, reduces the amount of wet cooling water in spring and autumn, and operates at full load in summer, reducing the overall circulating water discharge by more than 30%. A single large cooling tower saves an average of 100,000 to 180,000 tons of water per year, while reducing wastewater treatment costs by 40% to 50%, which is in line with national water conservation and environmental protection policies.

[0177] ② Through intelligent control, the "air cooling-wet cooling" mode can be automatically switched, adapting to ambient temperatures of -10℃ to 45℃ and circulating water hardness range of 50-500mg / L. The cooling efficiency fluctuation does not exceed 5%, solving the problems of "low efficiency at high temperatures and easy freezing at low temperatures" of traditional cooling towers, and ensuring continuous and stable operation of industrial production.

[0178] ③ Adopting the process of "air cooling pre-cooling + wet cooling on demand", it relies entirely on air cooling in winter, reduces the amount of wet cooling water in spring and autumn, and operates at full capacity for wet cooling in summer, reducing the overall circulating water discharge by more than 30%. A single large cooling tower saves an average of 100,000 to 180,000 tons of water per year, while reducing wastewater treatment costs by 40% to 50%, which is in line with national water conservation and environmental protection policies.

[0179] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A smart, controlled mixed-flow dry-wet combined mechanical ventilation cooling tower system, characterized in that, include: The tower body (3) is a shell structure with an inner cavity. A wind duct (1) is installed on the top of the tower body (3), and a water collection pool (17) is provided at the bottom. The wind duct (1) and the water collection pool (17) are connected to the inner cavity of the tower body (3). Air-cooled side louvers (4) and wet-cooled side louvers (5) are embedded on the shell side wall of the tower body (3). The air-cooling subsystem includes a finned air cooler (8), an inlet pipe (7), an outlet pipe (6), a circulating water pump (18), and an inlet flow regulating valve group (181). The finned air cooler (8) includes a finned tube bundle (82) installed on the upper part of the inner cavity of the tower body (3) and an air cooler header (81). The finned tube bundle (82) is composed of multiple finned tubes and is arranged opposite to the air-cooling side louvers (4). The air cooler header (81) is installed at both ends of the finned tube bundle (82) and is connected to the finned tubes. The water inlet pipe (7) is connected to the water collection tank (17) at one end and penetrates into the outer shell of the tower body (3) and is connected to the air cooler manifold (81) at the bottom. The water outlet pipe (6) is connected to the air cooler manifold (81) at the top at one end and penetrates out of the outer shell of the tower body (3) and extends into the water collection tank (17) at the other end. The circulating water pump (18) and the water inlet flow regulating valve group (181) are installed on the water inlet pipe (7). The water inlet flow regulating valve group (181) is used to regulate the amount of circulating water pumped into the tower body (3). The wet cooling subsystem includes a wet cooling side inlet pipe (91), a wet cooling side flow regulating valve group (9), a spray assembly, and a combined packing (12). One end of the wet cooling side inlet pipe (91) is connected to the outlet pipe (6), and the other end is connected to the spray assembly. The wet cooling side flow regulating valve group (9) is installed on the wet cooling side inlet pipe (91) and is used to regulate the amount of circulating water entering the spray assembly. The spray assembly and the combined packing (12) are both installed in the middle of the inner cavity of the tower body (3). The combined packing (12) is located below the spray assembly and is positioned higher than the wet cooling side louvers (5). The intelligent control subsystem includes a data acquisition module, a control module, and an execution module. The control module is electrically connected to the data acquisition module and the execution module. The data acquisition module is used to collect ambient temperature, ambient humidity, and outlet water temperature of the outlet pipe (6) and transmit them to the control module. The control module can control the execution module to adjust the opening degree of the air-cooled side louvers (4), the wet-cooled side louvers (5), and the wet-cooled side flow regulating valve group (9) based on the changes in ambient temperature, ambient humidity, and outlet water temperature.

2. The intelligent controllable mixed-flow dry-wet combined mechanical ventilation cooling tower system according to claim 1, characterized in that, It also includes a physical scale prevention and removal device (14) and a frequency control device, wherein, The physical scale prevention and descaling device (14) is installed on the water inlet pipe (7) to promote the formation of aggregates of calcium and magnesium ions in the circulating water. The frequency control device is electrically connected to the physical scale prevention and descaling device (14) to adjust the working frequency of the physical scale prevention and descaling device (14).

3. The intelligent controllable mixed-flow dry-wet combined mechanical ventilation cooling tower system according to claim 1, characterized in that, It also includes an exhaust fan (15) and a permanent magnet motor (2), wherein, The exhaust fan (15) is installed inside the air duct (1). The permanent magnet motor (2) is used to drive the operation of the exhaust fan (15) to enhance the air flow in the inner cavity of the tower body (3). The control module can also control the execution module to adjust the speed of the exhaust fan (15) based on the changes in ambient temperature, ambient humidity and water outlet temperature of the water outlet pipe (6).

4. The intelligent controllable mixed-flow dry-wet combined mechanical ventilation cooling tower system according to claim 1, characterized in that, It also includes supports and a steel structure (13) for fixing the relative position of the finned air cooler (8), wherein, One end of the support bracket is fixed to the top of the tower body (3), and the other end is suspended on the air cooler header (81) at the top. The steel structure (13) is installed in the internal cavity of the tower body (3) and is used to support the air cooler header (81) at the bottom.

5. The intelligent controllable mixed-flow dry-wet combined mechanical ventilation cooling tower system according to claim 1, characterized in that, The spray assembly consists of a spray layer (10) and nozzles (11), wherein, The spray layer (10) includes multiple spray pipes arranged in parallel. All spray pipes are arranged opposite to the combined packing (12) and connected to the wet and cold side inlet pipe (91). The nozzles (11) are evenly installed at the bottom of each spray pipe.

6. The intelligent controllable mixed-flow dry-wet combined mechanical ventilation cooling tower system according to claim 5, characterized in that, The wet cooling subsystem also includes a water collector (16), which adopts a baffle plate structure and is installed on the upper part of the cavity of the tower body (3) to intercept the water mist generated during the spraying process of the nozzle (11).

7. The intelligent controllable mixed-flow dry-wet combined mechanical ventilation cooling tower system according to claim 1, characterized in that, The combined packing (12) includes several plate-type components and several corrugated components, wherein, The plate assembly is a plate with a smooth surface, and the plate assemblies are parallel to each other; The corrugated component is a wave-shaped plate. A plate component is provided between each pair of adjacent corrugated components, and the corrugated component is detachably connected to the two plate components between each pair of adjacent plate components and the corresponding corrugated component.

8. A method of using a mixed-flow dry-wet combined mechanical ventilation cooling tower system with intelligent control as described in any one of claims 1 to 7, characterized in that, The ventilation duct (1) is equipped with an exhaust fan (15), which can be driven by a variable frequency permanent magnet motor (2). The method of use includes dynamic monitoring and adaptive adjustment, which includes the following steps: The first step is to start the intelligent control subsystem and set the circulating water outlet temperature threshold to 32℃~35℃; The second step is to start the circulating water pump (18) and adjust the circulating water flow through the inlet flow regulating valve group (181) until the ventilation cooling tower system can operate stably within the specified time. The third step involves the data acquisition module collecting the outlet water temperature in real time at set intervals. The control module then compares the collected outlet water temperature with the circulating water outlet temperature threshold to determine the current outlet water temperature status. In the fourth step, the control module sends a command based on the determined current outlet water temperature status and controls the execution module to adjust the speed of the exhaust fan (15), the opening degree of the air-cooled side louvers (4) and the wet-cooled side louvers (5).

9. The method of use according to claim 8, characterized in that, The method of use also includes initial operating condition type determination, which includes the following steps: The first step is to start the intelligent control subsystem and set the target thresholds for ambient temperature and ambient humidity under different operating conditions; The second step is to collect the external ambient temperature and humidity of the tower body (3) in real time through the data acquisition module. The control module compares the ambient temperature and humidity collected by the data acquisition module with the set target threshold, and then determines the working condition type. The third step is for the control module to send instructions based on the determined working condition type and control the execution module to adjust the speed of the exhaust fan (15), the opening degree of the air-cooled side louvers (4), the wet-cooled side louvers (5) and the wet-cooled side flow regulating valve group (9), and the frequency of the physical anti-scaling and descaling device (14).

10. The method of use according to claim 8, characterized in that, The dynamic monitoring and adaptive adjustment also include the following: In the first step, after starting the intelligent control subsystem, it is also necessary to set the liquid level threshold of the collection tank (17) to 2m~4m and the hardness threshold of the circulating water to ≥300mg / L; In the third step, at each set time interval, the data acquisition module will also collect the liquid level height in the water collection tank (17) in real time. The control module compares the collected liquid level height in the water collection tank (17) with the liquid level threshold to determine the current liquid level status. At the same time, at each set time interval, the hardness of the circulating water will be sampled and analyzed. The control module compares the sampled and analyzed hardness of the circulating water with the hardness threshold of the circulating water to determine the current hardness status of the circulating water. In the fourth step, the control module will send an instruction based on the determined current liquid level status and control the execution module to replenish or drain water to the water collection tank (17); at the same time, the control module will also send an instruction to the frequency control device based on the determined current circulating water hardness status and automatically increase the frequency of the physical scale prevention and descaling device (14).

Images