Heat exchange equipment for treating impurity-containing heat medium

Abstract

The invention discloses heat exchange equipment for treating an impurity-containing heat medium, and aims to solve the problem of heat exchange of hot sewage as well as the problem that an existing heat exchanger is easy to block and low in heat exchange efficiency. An automatic cleaning system composed of the ball serving water pump, the ball storage device and the like is arranged, cleaning can be started at any time during normal heat exchange of hot sewage, shutdown is not needed, for example, cleaning only needs about one hour after heat exchange by a certain chemical enterprise, production is not stopped, and yield loss is avoided. Meanwhile, the unique hexagonal supporting frame inside the heat exchanger enables a cold medium to flow to the outer wall of the tube bundle in a spiral line mode, the contact time is prolonged, the heat exchange efficiency is greatly improved, and enterprises can save a large amount of heat energy purchasing cost in cases. The heat exchangers can be flexibly connected in series or in parallel, operation is convenient, and the cleaning period is controllable. Through verification of multiple cases, the problem of heat exchange of hot sewage is effectively solved, and economic benefits and environmental protection benefits are achieved.

Description

Technical Field

[0001] This invention relates to the field of heat exchanger technology, and in particular to a heat exchange device for processing heat media containing impurities. Background Technology

[0002] In the daily production processes of chemical enterprises and washing plants, the generation of hot wastewater is an extremely common phenomenon. Due to production process requirements, hot water often comes into direct contact with the products, resulting in hot wastewater with a relatively high calorific value. However, existing conventional heat exchange equipment has revealed serious limitations in dealing with this type of hot wastewater. On the one hand, the sludge components such as wool textiles mixed in the hot wastewater have strong adhesion and sedimentation properties, easily accumulating and condensing inside the heat exchange tubes, thus causing blockage. Whenever the fouling accumulates to a certain extent, in order to restore the heat exchange performance of the equipment, the enterprise has to arrange a shutdown, expending a lot of manpower and resources to disassemble the equipment heads and carry out tedious and time-consuming cleaning work. This not only directly leads to production interruption and reduces production efficiency, but also causes the enterprise to bear high equipment maintenance costs and economic losses caused by the shutdown. On the other hand, the structural design of traditional heat exchangers has inherent deficiencies in heat exchange efficiency. The contact time between the cold medium and the heat tube bundle is short, resulting in insufficient heat transfer. A large amount of heat energy is wasted along with the hot wastewater, causing serious energy waste. This is not only inconsistent with the current environmental protection requirements for energy conservation and emission reduction, but also detrimental to enterprises in reducing production costs and improving economic efficiency. Summary of the Invention

[0003] The purpose of this invention is to provide a heat exchange device for treating heat media containing impurities, so as to overcome the defects in the prior art, realize the efficient recovery and utilization of heat from hot wastewater, and the automatic online cleaning of the heat exchange device.

[0004] To achieve the above objectives, the present invention provides a heat exchange device for processing heat media containing impurities, wherein:

[0005] The system includes an automatic cleaning system comprising a power delivery component, a storage component, a mixing component, a separation component, and a control component; and a media guiding device with a special structure located within the heat exchange area, comprising a support unit with multiple fixed heat exchange channels; the power delivery component is connected to the outlet end of the storage component via rigid or flexible pipelines, and its outlet is connected to a specific inlet of the mixing component; the inlet and outlet structures of the storage component are adapted to the connection end of the power delivery component and the corresponding inlet of the mixing component; the mixing component is located at the front end of the heat medium entering the heat exchange area, and its outlet is connected to the heat medium inlet of the heat exchange area; the separation component is installed at the fluid outlet at the end of the heat exchange area, and is connected to the inlet of the storage component via a sealed pipeline with a suitable diameter, and its structure matches the size and shape of the cleaning element; the manual operation valves, switches, and automatic control units in the control component are electrically connected or mechanically linked to the key nodes of the power delivery component and the connecting pipelines between the components;

[0006] A medium guiding device with a special structure is located in the heat exchange area and includes multiple support units for fixed heat exchange channels. Each support unit is distributed at intervals along the axial direction of the heat exchange channel, and adjacent support units are installed at a specific angle by means of slots and protrusions or welded fasteners.

[0007] As a further improvement to the technical solution of the present invention, the power transmission component is a water pump, which is connected to the storage component and the mixing component through pipelines.

[0008] As a further improvement to the technical solution of the present invention, the storage component is a container with a accommodating space, and is provided with an inlet and outlet and is adapted to be connected to the power transmission component and the mixing component.

[0009] As a further improvement to the technical solution of the present invention, the mixing component is a cavity with an internal turbulence structure, which is placed at the front end of the heat medium entering the heat exchange area.

[0010] As a further improvement to the technical solution of the present invention, the separation component is a device that utilizes the principle of filtration and interception, installed at the fluid outlet at the end of the heat exchange zone, and its structure matches the size and shape of the cleaning element, and is connected to the storage component through a pipeline.

[0011] As a further improvement to the technical solution of the present invention, the control components include manually operated valves, switches, and programmable logic controllers.

[0012] As a further improvement to the technical solution of the present invention, the support unit is hexagonal, with some sides fitting against the inner wall of the heat exchange equipment to form an arc-shaped void area, and adjacent support units are rotated and installed at a specific angle.

[0013] As a further improvement to the technical solution of the present invention, the overall structure of the heat exchange device is flexible in its combination form, and can be used independently or in series or in parallel according to the actual heat exchange task requirements.

[0014] As a further improvement to the technical solution of the present invention, the support structure of the heat exchange channel is provided with a channel for the flow of cooling medium in every 60-degree interval in the circumferential direction, and the installation position can be adjusted by rotating the connection structure or by positioning the slot.

[0015] As a further improvement to the technical solution of the present invention, the cleaning element in the automatic cleaning system, with the cooperation of the mixing component and the separating component, forms an internal circulation mode, and the connecting pipeline between the two is smooth and unobstructed.

[0016] Compared with traditional technologies, the present invention has the following significant advantages:

[0017] High-efficiency heat exchange:

[0018] This invention, through its unique support frame design, allows the cold medium to flow in a spiral path towards the outer wall of the tube bundle. Compared with traditional heat exchangers, this significantly extends the contact time between the cold and hot media, greatly improves heat exchange efficiency, and can more fully recover heat from hot wastewater, effectively reducing the energy consumption of enterprises. This aligns with the environmental protection concept of energy conservation and emission reduction, while also saving enterprises a significant amount of thermal energy procurement costs.

[0019] The heat exchange tube bundle support is equipped with medium channels every 60 degrees around its circumference, and the installation angle is precisely adjusted to ensure the spiral direction of the cold medium, which further optimizes the heat exchange process, makes the heat transfer more uniform and efficient, and improves the performance stability of the entire heat exchanger.

[0020] Automatic online cleaning:

[0021] Equipped with an automatic cleaning system, the cleaning program can be started at any time during the normal heat exchange of hot wastewater without stopping production to disassemble the equipment head for cleaning. This avoids production interruptions caused by cleaning, greatly improves production continuity, and ensures the company's production efficiency.

[0022] The cleaning balls operate in a stable internal circulation under the synergistic effect of the cleaning ball mixer and the cleaning ball separator. With the dual pressure drive of the sewage pump and the ball launching pump, it can efficiently remove dirt from the inner wall of the heat exchange tube, maintain the good thermal conductivity of the heat exchange tube, reduce the thermal resistance of dirt, further improve the heat exchange efficiency, and at the same time reduce equipment maintenance costs and extend the service life of the equipment.

[0023] Easy and flexible to operate:

[0024] The cleaning cycle can be automatically controlled by PLC or manually controlled. Users can freely choose the control method according to actual production conditions, dirt accumulation rate and other factors to meet diverse production management needs. Whether it is a large enterprise with a high degree of automation or a small factory that is accustomed to manual monitoring, the heat exchanger of this invention can be easily managed.

[0025] Heat exchangers can be manufactured as individual units for independent use, or they can be flexibly connected in series or in parallel according to actual heat exchange needs. They are suitable for chemical enterprises and washing plants of different sizes and with different process requirements, providing enterprises with more equipment selection options and improving the versatility and adaptability of the equipment. Attached Figure Description

[0026] Other features, objects, and advantages of the present invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings:

[0027] Figure 1 This is one of the structural schematic diagrams of a heat exchange device for processing heat media containing impurities according to an embodiment of the present invention;

[0028] Figure 2 This is a second schematic diagram of the structure of a heat exchange device for processing heat media containing impurities according to an embodiment of the present invention;

[0029] Figure 3 This is a third schematic diagram of the structure of a heat exchanger for processing heat media containing impurities according to an embodiment of the present invention;

[0030] Figure 4 This is a schematic diagram of the heat exchanger according to an embodiment of the present invention;

[0031] Figure 5 for Figure 4 AA section view;

[0032] Figure 6 for Figure 5 BB cross-sectional view;

[0033] Figure 7 for Figure 6 DD sectional view.

[0034] In the attached diagram: 1-Ball launching pump; 2-Ball storage tank; 3-Sewage pump; 4-Cleaning separator; 5-Cleaning ball mixer; 6-Heat exchanger; 7-Hot sewage inlet; 8-Hot sewage outlet; 9-Electrical control box; 11-Valve 1; 12-Valve 2; 13-Valve 3; 61-Tube bundle; 62-Support frame; 63-Outer casing; 64-Flange 1; 65-Flange 2; 66-Tube sheet; 67-Connecting pipe; 68-End cap. Detailed Implementation

[0035] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. The illustrative embodiments and descriptions of the present invention are used to explain the present invention, but are not intended to limit the present invention.

[0036] It should be noted that all directional indicators (such as up, down, left, right, front, back, upper end, lower end, top, bottom, etc.) in the embodiments of the present invention are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicator will also change accordingly.

[0037] In this invention, unless otherwise explicitly specified and limited, the term "connection" should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral part; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0038] Furthermore, in this invention, descriptions involving "first," "second," etc., are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature. Additionally, the technical solutions of various embodiments can be combined with each other, but only on the basis of being achievable by those skilled in the art. If the combination of technical solutions is contradictory or impossible to implement, such a combination should be considered non-existent and not within the scope of protection claimed by this invention.

[0039] The following is in conjunction with the appendix Figure 1 To be continued Figure 7 The present invention will be described in further detail below.

[0040] A heat exchange device for processing heat media containing impurities, wherein the function of automatically cleaning the inner wall of the heat exchange tubes online includes:

[0041] System composition:

[0042] This invention includes key components such as a ball-launching water pump 1, a ball storage tank 2, a wastewater pump 3, a cleaning ball mixer 5, and a cleaning separator 4. It also includes a hot wastewater inlet 7, a hot wastewater outlet 8, and an electrical control box 9.

[0043] Valves 11, 12, and 13 are used to control the water flow and the running path of the cleaning ball.

[0044] Cleaning principle and process:

[0045] When the hot wastewater is passing through the heat exchanger normally, open valve 11, valve 22, and valve 33 to start the ball launching pump 1, which will transport the cleaning balls in the ball storage tank 2 to the cleaning ball mixer 5 at the front end of the heat exchanger, so that they are fully mixed with the hot wastewater.

[0046] Driven by the dual pressure of sewage pump 3 and ball-launching pump 1, hot sewage carrying cleaning balls flows through the inside of the heat exchanger tube bundle. During this process, the cleaning balls continuously collide and rub against the inner wall of the tube bundle, effectively removing dirt and debris adhering to the inner wall of the tube bundle.

[0047] When the cleaning balls reach the outlet of the heat exchanger along with the sewage flow, they are intercepted by the cleaning separator 4 and then returned to the ball storage tank 2 in a circulation manner, waiting for the ball launching pump 1 to send them back into the heat exchanger. This process is repeated to perform the cleaning task.

[0048] After the cleaning task is completed, the opening of valve 13 at the inlet of the ball-launching water pump is reduced to allow water to pass through while intercepting the cleaning balls. Once all the cleaning balls have returned to the ball storage tank 2, the ball-launching water pump 1, valve 11, and valve 12 are closed. The entire operation can be performed manually or automatically using a PLC-controlled electric valve, greatly facilitating users in selecting the operating mode according to actual working conditions.

[0049] Reference Figures 4 to 7 The cooling medium inside the heat exchanger flows in a spiral direction:

[0050] Support frame structure design:

[0051] The heat exchanger 6 is internally equipped with longitudinal support frames 62 for fixing the tube bundle 61, with N frames arranged according to the length of the tube bundle 61. The support frame 62 is designed as a unique hexagon, with three sides being arc-shaped edges that fit tightly against the inner wall of the heat exchanger, and the other three sides being straight edges. The heat exchanger 6 also includes an outer shell sleeve 63, flange one 64, flange two 65, tube sheet 66, nozzle 67, and end cap 68.

[0052] After the support frame 62 is installed inside the heat exchanger, it will naturally form three semi-circular gap spaces A, B, and C between itself and the inner wall of the heat exchanger. These spaces provide special channels for the flow of the cold medium.

[0053] Principle of spiral flow formation:

[0054] Each support frame 62 is installed by rotating 60 degrees relative to the previous support frame 62. For example, if area A of the previous support frame 62 is empty, it becomes area A1 at the next support frame 62. This is equivalent to the arc cross-section of area A being rotated 60 degrees to form the A1 cross-section area. Similarly, areas B and C are successively transformed into areas B1 and C1.

[0055] In this way, the cold medium entering the heat exchanger no longer flows in a straight line through the outer wall of the tube bundle 61, but flows longitudinally along the 60-degree direction. Its route changes from a straight line to a spiral, which significantly increases the contact time between the cold medium and the hot tube bundle, thereby greatly improving the heat exchange efficiency.

[0056] Summary of Invention Features

[0057] The heat exchanger of the present invention has a high degree of flexibility in structural design. It can be manufactured as a single unit for independent use, or multiple heat exchangers can be connected in series or in parallel according to actual heat exchange needs to meet the production requirements of enterprises of different sizes.

[0058] The heat exchange tube bundle support is cleverly equipped with medium channels every 60 degrees around its circumference, and the installation angle is precisely adjusted to ensure that the cold medium is spirally oriented, which enhances the heat exchange effect. This is one of the key designs of this invention to improve heat exchange efficiency.

[0059] With the combined action of the cleaning ball mixer and the cleaning ball separator, the cleaning balls form a stable internal circulation mode, ensuring the continuous and efficient operation of the cleaning work without frequent manual intervention.

[0060] The cleaning cycle is highly controllable. Users can either achieve automatic control via PLC programming, automatically starting the cleaning program based on preset time, dirt detection data, and other conditions, or choose manual control to start cleaning at any time based on actual observations on the production site, fully meeting diverse production management needs.

[0061] The specific implementation process of the present invention will be described in detail below with reference to the accompanying drawings:

[0062] Equipment assembly

[0063] Materials preparation:

[0064] The ball-launching pump 1, ball storage tank 2, wastewater pump 3, heat exchanger body (including internal support frame 62 and heat exchange tube bundle 61), cleaning ball mixer 5, and cleaning separator 4 are constructed using corrosion-resistant and high-strength materials. For example, the pump bodies of the ball-launching pump 1 and wastewater pump 3 can be made of stainless steel to ensure long-term stable operation in hot wastewater environments and to prevent corrosion. The ball storage tank 2 is made of polyethylene plastic, which provides sufficient strength and prevents damage to the container during storage of cleaning balls, while also reducing overall weight. The outer shell of the heat exchanger body is made of carbon steel, and the internal heat exchange tube bundle is made of copper tubes, balancing thermal conductivity and cost-effectiveness. The cleaning ball mixer 5 and cleaning separator 4 are made of engineering plastics, which are easy to process and mold and are wear-resistant.

[0065] According to the design specifications, connecting pipes with appropriate diameters and wall thicknesses should be prepared. The pipe material must also consider corrosion resistance; for example, using steel pipes lined with plastic can ensure that there is no risk of leakage during the transportation of hot wastewater and cleaning media. Valves 11, 12, and 13 are stainless steel ball valves, which have good sealing performance, flexible operation, and facilitate precise control of water flow and the on / off state of the cleaning ball.

[0066] Assembly steps:

[0067] First, in a clean and dry assembly area, fix the heat exchanger body in the predetermined position, ensuring that its levelness and verticality meet the installation requirements. Anchor bolts can be used for tightening. Next, install the longitudinal support frames 62 sequentially inside the heat exchanger according to the designed angle. Adjacent support frames 62 are precisely rotated and positioned at 60 degrees using a slot and protrusion structure. After installation, check the stability of each support frame 62 to ensure that it can reliably fix the heat exchange tube bundle.

[0068] Next, the cleaning ball mixer 5 is installed on the front-end pipe of the hot wastewater entering the heat exchanger, and a flange connection is used to ensure a seal. Its inlet is connected to the outlet pipe of the ball launching pump 1, and its outlet is directly connected to the hot wastewater inlet of the heat exchanger to ensure that the cleaning balls can be smoothly mixed into the hot wastewater flow. The cleaning separator 4 is installed on the pipe at the end of the heat exchanger outlet, also using a flange connection. Its outlet is connected to the inlet of the ball storage tank 2 through a pipe so that the intercepted cleaning balls can be smoothly returned.

[0069] Next, install the ball-launching water pump 1 and the sewage pump 3 in suitable positions, and reduce operating noise and vibration by using shock-absorbing pads. Connect the two to the ball storage tank 2 and the heat exchanger body respectively through pipes. During the connection process, pay attention to ensuring the slope of the pipes to facilitate drainage and prevent air lock. At the same time, install pressure gauges, thermometers and other monitoring instruments at key parts of the pipes to monitor operating parameters in real time.

[0070] Finally, install valve 11, valve 22, and valve 313 on the corresponding pipeline nodes, and make the correct electrical connections or mechanical linkage control according to the markings to ensure that they can be accurately opened and closed under manual or PLC control, thus completing the assembly of the entire equipment.

[0071] Initial Run Preparation

[0072] Business system inspection:

[0073] Before starting the heat exchanger for the first time, a professional team should conduct a comprehensive and detailed inspection of the entire system. Check that the number of cleaning balls in the ball reservoir 2 is sufficient, that the material and hardness of the cleaning balls meet the requirements, and that there is no surface damage, ensuring that the cleaning balls can function properly. Open the inlet valve of the wastewater pump 3 and slowly introduce a small amount of hot wastewater into the heat exchanger. Simultaneously check all connections for leaks, especially flange connections of pipes, valve seals, and welded seams of the equipment. If any leaks are found, tighten or repair them promptly.

[0074] Debug all instruments to ensure that parameters such as temperature and pressure can be monitored and displayed normally. Perform a power-on test on the PLC control system to check whether the communication between each control module, sensor, and actuator is normal, whether the preset control program is loaded correctly, simulate input cleaning commands and operating parameter change signals, and verify whether the PLC system can accurately respond to and control the relevant equipment actions.

[0075] Parameter settings:

[0076] Based on the characteristics of the hot wastewater (such as temperature, flow rate, and solids content) and the temperature requirements of the cold and hot media after heat exchange in the production process, the flow rate and head parameters of wastewater pump 3 and ball-launching pump 1 are reasonably set. For example, if the hot wastewater has a high temperature and a high solids content, the flow rate of wastewater pump 3 is appropriately increased to ensure that the hot wastewater has sufficient flow velocity in the tube bundle and prevents rapid fouling. At the same time, based on the material and size of the cleaning balls, combined with the inner diameter and length of the heat exchanger tube bundle, the flow rate of ball-launching pump 1 is set to ensure that the cleaning balls can form an effective collision and friction cleaning effect in the tube bundle.

[0077] The cleaning cycle parameters for the PLC control system can be set by referring to experience data from similar operating conditions in the past, and dynamically adjusting them in conjunction with real-time data such as changes in heat exchange efficiency and pressure loss. In the initial stage, if accurate prediction is not possible, a more conservative cleaning cycle can be set first, such as starting the automatic cleaning program once every 8 hours of operation, and then gradually optimized based on subsequent operating conditions.

[0078] Automated online cleaning operation (taking PLC automatic control as an example)

[0079] Startup condition monitoring:

[0080] The PLC system monitors the heat exchanger's operating status in real time, collecting data through temperature and pressure sensors installed on the hot wastewater inlet and outlet pipes and the cold medium inlet and outlet pipes, and calculating key indicators such as heat exchange efficiency and pressure loss. When the heat exchange efficiency decreases to a preset threshold (e.g., 10%), or the pressure loss increases beyond a set value (e.g., 15%), or when a preset operating time interval is reached, the PLC determines that a cleaning program needs to be initiated.

[0081] Cleaning process execution:

[0082] After the PLC issues a cleaning command, it first controls the opening of valves 11, 12, and 13, and simultaneously starts the ball-launching pump 1. The ball-launching pump 1 delivers the cleaning balls from the ball storage tank 2 to the cleaning ball mixer 5 according to a preset flow rate curve, where they are thoroughly mixed with the hot wastewater. During this process, the PLC monitors the flow rate of the mixture in real time through a flow sensor installed on the mixer outlet pipe, ensuring that the mixing ratio of the cleaning balls and the hot wastewater meets the requirements and preventing the cleaning balls from accumulating or dispersing unevenly.

[0083] The mixed wastewater containing the ball is pumped through the heat exchanger tube bundle by the combined action of wastewater pump 3 and ball-launching pump 1. The PLC continuously monitors various pressure and flow parameters. Based on preset alarm thresholds, if an abnormal increase in pressure (e.g., exceeding 20% ​​of the normal operating pressure) or a sharp drop in flow (e.g., falling below 30% of the normal flow) is detected, an alarm is immediately issued and corresponding emergency measures are taken, such as suspending ball-launching pump 1, checking whether the cleaning ball is blocking the tube bundle, and resuming cleaning after troubleshooting.

[0084] After the cleaning balls reach the outlet of the heat exchanger and are intercepted by the cleaning separator 4, the PLC controls the relevant valves and water pumps to ensure the cleaning balls return smoothly to the ball storage tank 2, ready for the next round of cleaning. Specifically, the PLC controls the drain valve of the cleaning separator 4 to close briefly and the return valve to open. Using the negative pressure generated by the ball launching pump 1 or by adding a small auxiliary pump on the return pipeline, the cleaning balls are sucked back to the ball storage tank 2. After completing the preset number of cleaning cycles (e.g., 3 times) or reaching the cleaning effect judgment standard (e.g., the heat exchange efficiency recovers to more than 95% of the initial value), the PLC controls the shutdown of the ball launching pump 1, valve 11, and valve 12, and the system returns to normal heat exchange state.

[0085] Manual cleaning operation

[0086] Manual judgment:

[0087] When operators discover signs of needing cleaning during routine inspections, such as a significant decrease in heat exchange efficiency or abnormal pressure, such as an increase in the temperature of hot wastewater at the heat exchanger outlet exceeding the normal fluctuation range (e.g., 5°C) or an increase in the pressure difference between the inlet and outlet (e.g., exceeding 0.2 MPa), manual cleaning can be performed.

[0088] Manual startup:

[0089] The operator sequentially opens valves 11, 12, and 13 to start the ball-launching water pump 1, observing the operation of the cleaning balls and the parameters of each instrument. Before starting the ball-launching water pump 1, the outlet valve of the ball storage tank 2 must be opened to ensure that the cleaning balls can smoothly enter the pipeline. During the startup process, listen carefully to the operating sound of the equipment. If there is any abnormal friction sound or increased vibration, stop the machine immediately and check whether the cleaning balls are stuck.

[0090] Cleaning monitoring:

[0091] During the cleaning process, operators closely monitor instrument readings such as pressure, temperature, and flow rate, as well as the flow of cleaning balls within the heat exchanger tube bundle. They ensure the cleaning balls are evenly distributed and free from blockages by observing through a transparent sight glass or a camera installed at a specific location within the tube bundle (if available). If a particular area is found to be poorly cleaned, the cleaning time for that area can be appropriately extended by manually adjusting the flow rate of the ball-launching pump 1 or the valve opening.

[0092] End operation:

[0093] After cleaning, following a similar procedure to automatic cleaning, manually adjust the opening of valve 313 to intercept the cleaning balls back into the ball storage tank 2, and then shut down the relevant equipment. Specifically, gradually close valve 313 to reduce the water flow, causing the cleaning balls to gradually accumulate at separator 4. Once all the cleaning balls have returned to the ball storage tank 2, shut off the ball launching pump 1, valve 11, and valve 212 to complete the manual cleaning operation.

[0094] Heat exchanger heat exchange process

[0095] Cold medium introduction:

[0096] The cold medium enters from the heat exchanger inlet and flows in a spiral path towards the outer wall of the tube bundle, guided by a specially designed internal support frame 62. Operators can flexibly adjust parameters such as the flow rate and temperature of the cold medium using regulating valves installed on the cold medium pipeline, according to production needs. For example, in winter when the temperature is low, the flow rate of the cold medium can be appropriately increased to enhance the heat exchange effect and ensure sufficient heat recovery from the hot wastewater; in summer when the temperature is high, the flow rate of the cold medium can be appropriately reduced to avoid over-cooling the hot wastewater and wasting energy.

[0097] Heat exchange in hot wastewater:

[0098] Hot wastewater flows through the inside of the tube bundle, while the hot and cold media exchange heat through the tube walls. During the heat exchange process, temperature changes are monitored in real time by temperature sensors installed on the inlet and outlet pipes of the hot wastewater, and the heat exchange efficiency is calculated based on the temperature difference. Operators can further optimize the flow matching of the hot and cold media according to the production process requirements and the heat exchange efficiency data. If the heat exchange efficiency is found to be low, the flow rate of the hot wastewater can be appropriately increased or the spiral flow angle of the cold media can be adjusted (achieved by fine-tuning the installation angle of the support frame 62, if the design includes this function) to improve the heat exchange effect.

[0099] Operational monitoring:

[0100] Meanwhile, by monitoring data such as heat exchange efficiency and fouling accumulation over a long period, cleaning cycles are rationally scheduled to ensure the heat exchanger always operates at high efficiency. Regularly recording and analyzing operational data, and plotting curves showing heat exchange efficiency versus time and fouling thermal resistance versus operating time, provides data support for equipment maintenance and operational optimization. For example, if a significant downward trend in heat exchange efficiency and a rapid increase in fouling thermal resistance are observed over a certain period, the cleaning program can be initiated in advance or the cleaning cycle parameters adjusted to promptly restore equipment performance.

[0101] Implementation Cases

[0102] Case 1:

[0103] A chemical company primarily produces synthetic fiber products. Its production process consistently generates approximately 100 cubic meters of hot wastewater daily, with the water temperature maintained between 60°C and 70°C year-round. This wastewater contains a large amount of wool textile sludge and impurities. Before adopting the heat exchanger of this invention, the company used traditional shell-and-tube heat exchangers for heat recovery. However, because impurities in the hot wastewater easily adhere to the inner walls of the heat exchange tubes, severe blockages occurred within a week of operation, leading to a significant decrease in heat exchange efficiency. This forced the company to shut down operations, expending considerable manpower and resources to disassemble and clean the equipment, with each cleaning session taking approximately 12 hours. This not only directly caused production interruptions, resulting in a weekly output loss of up to 10%, but also incurred substantial additional equipment maintenance costs, increasing monthly maintenance expenses by approximately 5,000 yuan.

[0104] After replacing the heat exchanger with the one of this invention, the automatic cleaning system allows the cleaning program to be started at any time during normal heat exchange of hot wastewater without requiring shutdown and disassembly of the equipment head. For example, when the operating time reaches the preset 8 hours, the PLC control system automatically detects that the heat exchange efficiency has decreased by nearly 10% and quickly starts the cleaning program. Valves 11, 12, and 13 are opened, and the ball launching pump 1 transports the cleaning balls from the ball storage tank 2 to the cleaning ball mixer 5 for thorough mixing with the hot wastewater. Driven by the dual pressure of the wastewater pump 3 and the ball launching pump 1, the hot wastewater carrying the cleaning balls flows within the heat exchanger tube bundle. The cleaning balls continuously collide and rub against the inner wall of the tube bundle, effectively removing dirt. After the cleaning balls reach the heat exchanger outlet and are intercepted by the cleaning separator 4, they are smoothly returned to the ball storage tank 2 by the PLC controlling the relevant valves and pumps, ready for the next cycle of cleaning. The entire cleaning process takes only about 1 hour, and production continues to operate normally during the cleaning period, greatly improving production continuity and ensuring the company's production efficiency.

[0105] Meanwhile, the unique support frame design of this invention causes the cold medium to flow in a spiral path towards the outer wall of the tube bundle. Compared with traditional heat exchangers, this significantly extends the contact time between the cold and hot media, increasing heat exchange efficiency by approximately 30%. This means that enterprises can more fully recover heat from hot wastewater, effectively reducing energy consumption and saving approximately 8,000 yuan in heat energy procurement costs per month. Furthermore, the support frame of the heat exchange tube bundle is equipped with medium channels every 60 degrees circumferentially, and the installation angle is precisely adjusted to ensure the spiral direction of the cold medium, further optimizing the heat exchange process. This makes heat transfer more uniform and efficient, improving the overall performance stability of the heat exchanger and reducing equipment damage caused by uneven heat exchange.

[0106] Case 2:

[0107] A wastewater treatment plant generates approximately 80 cubic meters of hot wastewater daily, with a temperature between 55℃ and 65℃, containing a significant amount of fibrous impurities. Previously, ordinary plate heat exchangers were used, which also faced frequent clogging problems, requiring a shutdown for cleaning every 5 days. Each cleaning session took about 8 hours, severely impacting production schedules and increasing labor costs. Furthermore, traditional plate heat exchangers have low heat exchange efficiency, resulting in a large amount of heat energy being discharged with the wastewater, leading to energy waste.

[0108] With the introduction of the heat exchanger of this invention, manual cleaning becomes simple and easy. When operators find a significant decrease in heat exchange efficiency during routine inspections, such as an increase in the outlet hot wastewater temperature exceeding the normal fluctuation range of 5°C, or an increase in the pressure difference between the inlet and outlet exceeding 0.2 MPa, manual cleaning can be performed. Operators sequentially open valve 11, valve 22, and valve 13, start the ball-launching pump 1, and observe the operation of the cleaning ball and the parameters of each instrument to ensure a smooth cleaning process. After cleaning, the opening of valve 313 is manually adjusted to intercept the cleaning ball back into the ball storage tank 2, and the relevant equipment is shut down. Once the entire operation is mastered, it can be completed within 1.5 hours, significantly reducing downtime compared to before.

[0109] In terms of heat exchange performance, the cold medium flows spirally towards the outer wall of the tube bundle under the guidance of a special support frame. Combined with the medium channels in 60-degree intervals along the circumference of the support frame, the heat exchange efficiency is increased by approximately 25% compared to the original plate heat exchanger. This allows for better recovery of heat from wastewater, reducing the hot water heating cost for the washing plant and saving approximately 6,000 yuan per month. Furthermore, the cleaning balls operate stably in internal circulation under the synergistic action of the cleaning ball mixer and cleaning ball separator. Driven by the dual pressure of the wastewater pump and the ball launching pump, they efficiently remove scale from the inner wall of the heat exchange tubes, maintaining good thermal conductivity, reducing scale thermal resistance, further improving heat exchange efficiency, and significantly extending the equipment's service life, saving approximately 15,000 yuan in equipment replacement costs annually.

[0110] Case 3:

[0111] A medium-sized chemical company generates a large volume of hot wastewater during its production process, approximately 150 cubic meters per day. The water temperature fluctuates between 65℃ and 75℃, and the wastewater has a complex composition, containing various organic and inorganic impurities. The shell-and-tube heat exchangers they previously used experienced a reduction in heat exchange efficiency of over 20% after about three days of operation due to fouling buildup, necessitating a shutdown for cleaning. Each cleaning session took 10 hours, and the frequent shutdowns severely hampered the company's capacity expansion and resulted in significant economic losses.

[0112] After adopting the heat exchanger of this invention, enterprises can connect three heat exchangers of this invention in series according to their own production characteristics. Regarding automatic online cleaning, the PLC control system comprehensively judges multiple parameters, including preset operating time (every 6 hours), changes in heat exchange efficiency (decreased by 15%), and changes in pressure loss (increased by 10%), to accurately start the cleaning program. After startup, all valves and water pumps work together, and the cleaning balls efficiently complete the cleaning task and circulate back to the ball storage tank 2, ensuring that the heat exchanger always maintains a high heat exchange efficiency. Production continues during cleaning, avoiding production losses caused by shutdowns.

[0113] In terms of improved heat exchange efficiency, the unique support frame structure and spiral flow design of the cold medium extend the contact time between the cold and hot media. The heat exchange efficiency of each heat exchanger is increased by approximately 35% compared to the original shell-and-tube heat exchanger. When used in series, the overall heat exchange effect is even more significant, greatly improving the company's energy recovery and utilization rate, saving more than 10,000 yuan in energy costs per month. At the same time, the heat exchangers' ability to be flexibly connected in series or in parallel adapts to the production needs of the company at different stages, providing convenience for subsequent capacity expansion or process adjustments, demonstrating the equipment's versatility and adaptability.

[0114] As can be seen from the above implementation cases, the heat exchanger of the present invention effectively solves the problem of heat exchange in hot wastewater in practical application scenarios such as chemical enterprises and washing plants. It performs excellently in terms of automatic online cleaning, high-efficiency heat exchange and convenient and flexible operation, bringing significant economic and environmental benefits to enterprises.

[0115] The technical solutions provided by the embodiments of the present invention have been described in detail above. Specific examples have been used to illustrate the principles and implementation methods of the embodiments of the present invention. The descriptions of the embodiments above are only for helping to understand the principles of the embodiments of the present invention. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the embodiments of the present invention. Therefore, the content of this specification should not be construed as a limitation of the present invention.

Claims

1. A heat exchange device for processing heat media containing impurities, characterized in that: The system includes an automatic cleaning system comprising a power delivery component, a storage component, a mixing component, a separation component, and a control component; and a media guiding device with a special structure located within the heat exchange area, comprising a support unit with multiple fixed heat exchange channels; the power delivery component is connected to the outlet end of the storage component via rigid or flexible pipelines, and its outlet is connected to a specific inlet of the mixing component; the inlet and outlet structures of the storage component are adapted to the connection end of the power delivery component and the corresponding inlet of the mixing component; the mixing component is located at the front end of the heat medium entering the heat exchange area, and its outlet is connected to the heat medium inlet of the heat exchange area; the separation component is installed at the fluid outlet at the end of the heat exchange area, and is connected to the inlet of the storage component via a sealed pipeline with a suitable diameter, and its structure matches the size and shape of the cleaning element; the manual operation valves, switches, and automatic control units in the control component are electrically connected or mechanically linked to the key nodes of the power delivery component and the connecting pipelines between the components; A medium guiding device with a special structure is located in the heat exchange area and includes multiple support units for fixed heat exchange channels. Each support unit is distributed at intervals along the axial direction of the heat exchange channel, and adjacent support units are installed at a specific angle by means of slots and protrusions or welded fasteners.

2. A heat exchange device for processing heat media containing impurities according to claim 1, characterized in that: The power transmission component is a water pump, which is connected to the storage component and the mixing component through pipelines.

3. A heat exchange device for processing heat media containing impurities according to claim 1, characterized in that: The storage component is a container with a holding space, and is equipped with an inlet and outlet and is adapted to connect with the power transmission component and the mixing component.

4. A heat exchange device for processing heat media containing impurities according to claim 1, characterized in that: The mixing component is a cavity with an internal turbulence structure, located at the front end of the heat medium entering the heat exchange area.

5. A heat exchange device for processing heat media containing impurities according to claim 1, characterized in that: The separation component is a device that utilizes the principles of filtration and interception. It is installed at the fluid outlet at the end of the heat exchange zone. Its structure matches the size and shape of the cleaning element and is connected to the storage component through pipelines.

6. A heat exchange device for processing heat media containing impurities according to claim 1, characterized in that: The control components include manually operated valves, switches, and programmable logic controllers.

7. A heat exchange device for processing heat media containing impurities according to claim 1, characterized in that: The support unit is hexagonal, with some sides fitting against the inner wall of the heat exchange equipment to form an arc-shaped void area. Adjacent support units are rotated and installed at a specific angle.

8. A heat exchange device for processing heat media containing impurities according to claim 1, characterized in that: The overall structure of the heat exchange equipment is flexible in its combination form. It can be operated independently or multiple heat exchange equipment can be connected in series or in parallel according to the actual heat exchange task requirements.

9. A heat exchange device for processing heat media containing impurities according to claim 1, characterized in that: The support structure of the heat exchange channel is provided with channels for the flow of cooling medium in every 60-degree interval in the circumference, and the installation position can be adjusted by rotating the connection structure or by positioning slots.

10. A heat exchange device for processing heat media containing impurities according to claim 1, characterized in that: The cleaning elements in the automatic cleaning system, with the cooperation of the mixing and separating components, form an internal circulation mode, and the connecting pipeline between the two is smooth and unobstructed.

Images