Spheroidizing furnace circulating cooling water system based on dynamic regulation and control of heat exchange requirements

Abstract

The invention relates to the field of circulating cooling water systems, in particular to a spheroidizing furnace circulating cooling water system based on dynamic regulation and control of heat exchange requirements. Comprising a cooling tower, a circulating pump, a heat exchanger, a DCS controller, a flow acquisition module, a temperature acquisition module, a feedback calibration module and a circulating water main pipeline, the flow acquisition module continuously monitors the flow of circulating water, the temperature acquisition module continuously monitors the temperature of each inlet and outlet of the heat exchanger, and the DCS controller calculates the real-time heat exchange requirement of the spheroidizing furnace, dynamically adjusts the flow of the circulating water, quickly matches heat load changes, eliminates idle work in a low-load state, avoids invalid energy consumption, and improves the heat exchange efficiency of the spheroidizing furnace. The feedback calibration module monitors the adjusting effect in real time, dynamically corrects control parameters, ensures long-term operation stability, greatly stabilizes the temperature of a heat medium outlet of the heat exchanger, provides stable cooling conditions for the spheroidizing furnace technology, and directly improves the product sphericity degree and batch consistency.

Description

Technical Field

[0001] This invention relates to the field of circulating cooling water systems, and in particular to a circulating cooling water system for a spheroidizing furnace based on dynamic control of heat exchange demand. Background Technology

[0002] Spherical silica is an important material for high-end industries such as aerospace, aviation, and electronics, and is also widely used in new coatings, special ceramics, and high-end cosmetics. Currently, the most widely used preparation method is the high-temperature melting method, in which silica raw materials are instantly melted at extremely high temperatures and then cooled, spheroidized, and solidified in a very short time. This process occurs in a spheroidizing furnace, and its cooling rate and uniformity directly determine the sphericity, particle size distribution, crystal form, and internal stress of the final product, which are core factors affecting product quality and grade.

[0003] To ensure the stable operation of the spheroidizing furnace, a high-efficiency and reliable circulating cooling water system is required to continuously and stably remove the massive amounts of waste heat generated in the furnace and process. Commonly used circulating cooling water systems in the industry include... Figure 1 As shown, its basic components are: cooling tower (1), circulating pump (2), heat exchanger (3) and corresponding pipelines and valves. The circulating water absorbs heat from the heat medium of the spheroidizing furnace (such as high-temperature heat transfer oil, molten salt, etc.) in the heat exchanger and its temperature rises, becoming hot water. The hot water is transported to the cooling tower, cooled by evaporation and sensible heat exchange, and then becomes cold water again. It is then sent back to the heat exchanger by the circulating pump to complete the cycle.

[0004] Traditional systems often employ fixed circulating water flow rates, manual flow rate adjustments, or DCS flow control based on a single temperature parameter (such as return water temperature). Fixed flow rates result in pumps performing significant unproductive work under low heat load conditions (such as at night or in winter), leading to substantial energy waste. Manual operation is slow to respond and lacks precision, failing to match flow demands promptly, resulting in decreased heat exchange efficiency. Reliance on operator experience also makes them prone to excessive temperature fluctuations, impacting product quality or production safety. While simple DCS control offers flow rate adjustment, it often relies on single temperature parameter feedback, lacking a dynamic correlation model between heat exchange demand and flow rate, resulting in insufficient adjustment precision and adaptability. Meanwhile, the cooling effect of open cooling towers depends on ambient wet-bulb temperature. In hot and humid summer weather, their outlet water temperature rises significantly, causing a decrease in the overall cooling capacity of the circulating water system. To maintain process temperatures, the only options are often to blindly increase the circulating water flow rate or activate standby chillers. The former drastically increases pump energy consumption, while the latter drastically raises operating costs.

[0005] Therefore, there is an urgent need for a spheroidizing furnace circulating cooling water system that dynamically adjusts based on heat exchange demand to solve the above-mentioned technical problems. Summary of the Invention

[0006] The purpose of this invention is to solve the problems in the background art and provide a spheroidizing furnace circulating cooling water system based on dynamic control of heat exchange demand.

[0007] The above-mentioned technical objective of the present invention is achieved through the following technical solution: A circulating cooling water system for a spheroidizing furnace based on dynamic control of heat exchange demand includes a cooling tower, a circulating pump, a heat exchanger, a DCS controller, a flow acquisition module, a temperature acquisition module, a feedback calibration module, and a main circulating water pipeline. The outlet of the cooling tower is connected to the cold medium inlet of the heat exchanger via the main circulating water pipeline, and the outlet of the heat exchanger's cold medium is connected to the inlet of the cooling tower via the main circulating water pipeline. The circulating pump and the flow acquisition module are installed on the main circulating water pipeline. The inlet and outlet of the heat exchanger's cold and hot medium are both equipped with temperature acquisition modules. The DCS controller contains a heat exchange efficiency calculation module and a PID control algorithm, receives real-time data from the flow acquisition module and the temperature acquisition module, calculates the target flow value, and outputs a control signal to the circulating pump. The feedback calibration module receives the adjusted flow and temperature data, compares it with the target value, and dynamically corrects the PID parameters.

[0008] Preferably, the flow acquisition module acquires the actual flow rate of circulating water in real time, the temperature acquisition module acquires the medium temperature at each port of the heat exchanger in real time, and the DCS controller calculates the target flow rate of circulating water based on the temperature difference and outputs a control signal to the circulating pump. The DCS controller receives the actual flow rate Q1 of circulating water and the temperatures T1, T2, T3, and T4 at each port of the heat exchanger, calculates the target flow rate Q2 of circulating water required to match the current heat load through a built-in algorithm, and outputs a control signal to the circulating pump to precisely adjust its speed and change the output flow rate, so that the actual flow rate Q1 quickly and accurately approaches the target flow rate Q2, realizing the dynamic matching of cooling water supply and process heat load, avoiding energy waste caused by low heat load and constant supply, significantly reducing pump energy consumption, and greatly stabilizing the outlet temperature (i.e., T2) of the heat exchanger process side through precise flow control, providing stable cooling conditions for the spheroidizing furnace process, and directly improving the sphericity and batch consistency of the product.

[0009] Preferably, the DCS controller calculates the target flow rate of circulating water based on the temperature difference using the formula Q2=(C1×m1×|T1-T2|) / (C2×|T4-T3|), where Q2 is the target flow rate of circulating water, C1 is the specific heat capacity of the heat medium, m1 is the mass flow rate of the heat medium, T1 is the inlet temperature of the heat medium, T2 is the outlet temperature of the heat medium, C2 is the specific heat capacity of the cold medium, T3 is the inlet temperature of the cold medium, and T4 is the outlet temperature of the cold medium. The DCS controller presets basic parameters such as the design heat exchange efficiency of the heat exchanger, the specific heat capacity of the hot and cold media, and the allowable temperature range, and sets the initial values ​​of the proportional coefficient, integral time, and derivative time of the PID control. In this formula, the numerator (C1×m1×|T1-T2|) calculates the instantaneous heat power released by the heat medium in the heat exchanger (i.e., the heat exchange demand), and the denominator (C2×|T4-T3|) represents the theoretical heat carrying capacity of a unit of cold medium under the current operating conditions, thereby obtaining the circulating water flow rate required to meet the heat exchange demand at this moment.

[0010] Preferably, when the actual heat exchange efficiency is lower than 90% of the design value, the DCS controller issues an alarm signal and records fault data; thereby improving operation and maintenance efficiency and reducing manual maintenance costs.

[0011] Preferably, the cooling tower includes a tower body, an air outlet at the top of the tower body, and a water collection tank at the bottom of the tower body. Between the air outlet and the water collection tank, a large-particle spray device, an atomizing spray device, a packing layer, and an air inlet are sequentially arranged from top to bottom on the tower body. The outlet of the water collection tank is connected to the cold medium inlet of the heat exchanger, the cold medium outlet is connected to the inlet of the large-particle spray device, and a circulating water auxiliary pipe is formed between the cold medium outlet and the inlet of the atomizing spray device. An auxiliary regulating valve is installed on the circulating water auxiliary pipe. The working principle of a classic open counter-flow cooling tower is that the circulating water flowing down from top to bottom and the ambient cold air flowing up from bottom to top come into counter-current contact, achieving cooling through heat exchange. The large-particle spray device... The continuous, large water droplets uniformly and thoroughly wet the packing layer below, forming a water film that allows for continuous and efficient latent heat exchange with the ambient air. Simultaneously, the large water droplets undergo sensible heat exchange during their descent. The atomizing spray device atomizes the incoming circulating water into lightweight, slow-settling fine water mist, enabling intense and sustained latent heat exchange with the ambient air. This significantly reduces the temperature of the circulating water entering the packing layer while enhancing the sensible heat exchange between the large water droplets and the air above, greatly improving cooling performance. An auxiliary regulating valve allows the atomizing spray device to be started and stopped according to actual heat exchange needs. During periods of high temperature and humidity in summer or when process heat exchange demands increase, the auxiliary circulating water pipe can be opened to enhance the overall cooling capacity of the cooling tower.

[0012] Preferably, a temperature regulating pipe is also provided between the outlet of the circulating pump and the outlet of the cold medium, and a temperature regulating pump is installed on the temperature regulating pipe; the temperature regulating pipe and the main circulating water pipe are connected in parallel, and after the circulating water flows out of the water collection tank, part of it bypasses the heat exchanger and is directly pumped to the inlet of the large particle spray device, where it mixes with the heated circulating water flowing out of the cold medium outlet of the heat exchanger, directly reducing the inlet water temperature of the cooling tower and improving the cooling efficiency.

[0013] Preferably, both the auxiliary regulating valve and the temperature regulating pump are controlled by the DCS controller to start / stop or adjust their opening degree. By connecting both the auxiliary regulating valve and the temperature regulating pump to the DCS controller, precise control of the cooling tower's cooling capacity can be achieved. By controlling the opening and closing of the auxiliary regulating valve, the start / stop of the atomizing spray device can be controlled. By adjusting the speed of the temperature regulating pump, the inlet water temperature of the cooling tower can be controlled. The system can accurately adjust the cooling intensity according to the real-time heat load fluctuations of the spheroidizing furnace, ensuring stable process temperature while completely avoiding insufficient or excessive cooling capacity, and meeting cooling requirements with minimal total energy consumption.

[0014] Preferably, a temperature equalization mixer is provided at the junction of the cold medium outlet and the temperature regulating pump outlet. The temperature equalization mixer includes a mixing chamber, a circulating water inlet, a temperature regulating water inlet, and a mixed water outlet. The circulating water inlet and the mixed water outlet are located at both ends of the mixing chamber. The temperature regulating water inlet is located on the side wall of the mixing chamber. The circulating water inlet is connected to the cold medium outlet of the heat exchanger, the temperature regulating water inlet is connected to the outlet of the temperature regulating pump, and the mixed water outlet is connected to the inlet of the large particle spraying device and the circulating water auxiliary pipeline. This forcibly merges the high-temperature circulating water from the heat exchanger and the low-temperature circulating water from the water collection tank, preventing uneven heating and cooling of the spray water, ensuring that the water temperature falling into the packing layer is uniform, and improving the stability of the cooling operation.

[0015] Preferably, a diversion mechanism is fixedly installed in both the circulating water inlet and the temperature-regulating water inlet. The diversion mechanism is a diversion plate extending axially along the water inlet direction. The diversion plate has multiple diversion blades extending radially from the center of the circulating water inlet and the temperature-regulating water inlet to the pipe wall. A fluid channel is formed between two adjacent diversion blades. When the water flows in through the inlet, it directly impacts the central intersection point of the diversion plate and is then forcibly divided and guided, evenly dispersed into multiple independent fluid channels. This disperses a water flow with uneven velocity distribution into multiple streams with equal velocity and flow rate, improving the efficiency of initial mixing in the mixing chamber and providing a basis for subsequent thorough mixing.

[0016] Preferably, a mixing mechanism is fixedly installed in the mixing chamber near the outlet of the mixed water. The mixing mechanism consists of at least two mixing plates perpendicular to the water flow direction. Each mixing plate has several guide holes, and the guide holes on adjacent mixing plates are staggered. After the initially mixed water flow impacts the first mixing plate, it is divided into multiple jets by the guide holes. Due to the staggered arrangement of the guide holes on adjacent mixing plates, the multiple jets undergo violent turning, kinetic energy dissipation, and turbulent mixing when they impact the second mixing plate, and are then divided again. This process is repeated to ensure sufficient and rapid heat transfer at the molecular scale between the hot and cold fluids, resulting in a highly uniform outlet water temperature.

[0017] In summary, the present invention has the following beneficial effects: This invention employs high-frequency data acquisition and a PID adjustment algorithm to continuously monitor the circulating water flow rate and the inlet and outlet temperatures of the heat exchanger. It accurately calculates the real-time heat exchange requirements of the spheroidizing furnace, dynamically adjusts the circulating water flow rate, quickly matches changes in heat load, eliminates wasted effort under low load conditions, and avoids ineffective energy consumption. The feedback calibration module monitors the adjustment effect in real time, dynamically corrects control parameters, ensures long-term operational stability, greatly stabilizes the outlet temperature of the heat medium in the heat exchanger, provides stable cooling conditions for the spheroidizing furnace process, and directly improves the sphericity and batch consistency of the product.

[0018] This invention improves heat dissipation efficiency and cooling uniformity by setting up the temperature-regulating pipe and atomizing spray device. Under the premise of ensuring stable process temperature, it completely avoids insufficient or excessive cooling capacity, meets cooling requirements with minimal total energy consumption, and controls its start and stop according to actual heat exchange requirements, ensuring that the cooling tower can stably output low-temperature circulating water under various operating conditions.

[0019] The DCS controller of this invention supports multiple communication protocols, making it applicable to different industrial heat exchange scenarios. It intelligently schedules the collaborative work of various devices, ensuring that the overall operating energy efficiency is always at its best, minimizing global energy consumption, and reducing manual maintenance costs through fault alarms and feedback calibration. It also improves the continuity and safety of the production process and reduces the risk of downtime. Attached Figure Description

[0020] Figure 1 This is a structural diagram of existing technology; Figure 2 This is a schematic diagram of the overall structure of the present invention; Figure 3 This is a schematic diagram of the cooling tower structure of the present invention; Figure 4 This is a schematic diagram of the temperature equalization mixer structure of the present invention; Figure 5 This is a cross-sectional schematic diagram of the uniform temperature mixer structure of the present invention; In the diagram, 1. Cooling tower; 11. Tower body; 12. Air outlet; 13. Water collection tank; 14. Large particle spray device; 15. Atomizing spray device; 16. Packing layer; 17. Air inlet; 2. Circulating pump; 3. Heat exchanger; 31. Hot medium inlet; 32. Hot medium outlet; 33. Cold medium inlet; 34. Cold medium outlet; 4. DCS controller; 5. Flow acquisition module; 6. Temperature acquisition module; 7. Feedback calibration module; 8. Main circulating water pipeline; 81. Auxiliary circulating water pipeline; 82. Auxiliary regulating valve; 9. Temperature regulating pipeline; 91. Temperature regulating pump; 92. Temperature equalization mixer; 93. Mixing chamber; 94. Circulating water inlet; 95. Temperature regulating water inlet; 96. Mixed water outlet; 97. Flow splitting mechanism; 971. Flow splitting plate; 972. Flow splitting blade; 973. Fluid channel; 98. Mixing mechanism; 981. Mixing plate; 982. Guide hole. Detailed Implementation

[0021] The present invention will be further described in detail below with reference to the accompanying drawings.

[0022] Example

[0023] according to Figure 2 As shown, a spheroidizing furnace circulating cooling water system based on dynamic control of heat exchange demand includes a cooling tower 1, a circulating pump 2, a heat exchanger 3, a DCS controller 4, a flow acquisition module 5, a temperature acquisition module 6, a feedback calibration module 7, and a circulating water main pipeline 8. The outlet of the cooling tower 1 is connected to the cold medium inlet 33 of the heat exchanger 3 through the circulating water main pipeline 8, and the cold medium outlet 34 of the heat exchanger 3 is connected to the inlet of the cooling tower 1 through the circulating water main pipeline 8. The circulating pump 2 and the flow acquisition module 5 are installed on the circulating water main pipeline 8. Temperature acquisition modules 6 are installed at both the inlet and outlet of the cold and hot medium of the heat exchanger 3. The DCS controller 4 contains a heat exchange efficiency calculation module and a PID control algorithm, receives real-time data from the flow acquisition module 5 and the temperature acquisition module 6, calculates the target flow value, and outputs a control signal to the circulating pump 2. The feedback calibration module 7 receives the adjusted flow and temperature data, compares them with the target value, and dynamically corrects the PID parameters.

[0024] according to Figure 2 As shown, the flow acquisition module 5 collects the actual flow rate of the circulating water in real time, the temperature acquisition module 6 collects the medium temperature at each port of the heat exchanger 3 in real time, and the DCS controller 4 calculates the target flow rate of the circulating water based on the temperature difference and outputs a control signal to the circulating pump 2. The flow acquisition module 5 uses a high-precision electromagnetic flow meter or vortex flow meter, the temperature acquisition module 6 uses a high-precision temperature sensor, and the circulating pump 2 is motor controlled. The motor frequency is adjusted according to the control signal given by the DCS controller 4. The DCS controller 4 supports multiple communication protocols and can be seamlessly integrated with existing DCS systems, making it suitable for different industrial heat exchange scenarios.

[0025] according to Figure 2 As shown, the formula for calculating the target flow rate of circulating water based on the temperature difference by the DCS controller 4 is Q2=(C1×m1×|T1-T2|) / (C2×|T4-T3|), where Q2 is the target flow rate of circulating water, C1 is the specific heat capacity of the heat medium, m1 is the mass flow rate of the heat medium, T1 is the temperature of the heat medium inlet 31, T2 is the temperature of the heat medium outlet 32, C2 is the specific heat capacity of the cold medium, T3 is the temperature of the cold medium inlet 33, and T4 is the temperature of the cold medium outlet 34. The heat medium is the intermediate heat transfer fluid that absorbs heat from the furnace and carries it to the external heat exchanger 3, such as heat transfer oil, molten salt, etc., and the cold medium is circulating cooling water.

[0026] according to Figure 2 As shown, when the actual heat exchange efficiency is lower than 90% of the design value, the DCS controller 4 issues an alarm signal and records the fault data.

[0027] according to Figure 3 As shown, the cooling tower 1 includes a tower body 11, with an air outlet 12 at the top and a water collection tank 13 at the bottom. Between the air outlet 12 and the water collection tank 13, a large particle spraying device 14, an atomizing spraying device 15, a packing layer 16, and an air inlet 17 are arranged sequentially from top to bottom on the tower body 11. The outlet of the water collection tank 13 is connected to the cold medium inlet 33 of the heat exchanger 3, and the cold medium outlet 34 is connected to the inlet of the large particle spraying device 14 and the inlet of the atomizing spraying device 15, forming a circulating water auxiliary pipe 81. An auxiliary... Regulating valve 82; Cold air in the environment enters from the air inlet 17, flows upward, and finally exits from the air outlet 12. Circulating water is sprayed downward by the large particle spray device 14 and the atomizing spray device 15. The large particle spray water exchanges sensible heat with the ambient air humidified and heated by the packing layer 16 and the atomizing spray water. The atomizing spray water exchanges intense latent heat with the ambient air humidified and heated by the packing layer 16. After two stages of cooling, the circulating water continues to flow downward and forms a stable water film in the packing layer 16 to fully and continuously exchange latent heat with the ambient cold air, thus being significantly cooled. Finally, it flows into the water collection tank 13 for the next round of circulation.

[0028] according to Figure 2 As shown, a temperature regulating pipe 9 is also provided between the outlet of the circulating pump 2 and the outlet of the cold medium 34, and a temperature regulating pump 91 is installed on the temperature regulating pipe 9. In traditional methods, in order to improve the cooling capacity, the main circulation flow rate is usually increased or an external chiller is used. The former increases energy consumption and the latter increases cost. The temperature regulating pipe 9 only needs a small-power temperature regulating pump 91 to effectively reduce the inlet water temperature of the cooling tower 1, and the energy saving benefits are significant.

[0029] according to Figure 2As shown, the auxiliary regulating valve 82 and the temperature regulating pump 91 are both controlled by the DCS controller 4 to start, stop or open; at night or in winter when the temperature is low, the output speed of the temperature regulating pump 91 is reduced or turned off; in summer when the temperature is high, the output speed of the temperature regulating pump 91 is increased and the auxiliary regulating valve 82 is opened.

[0030] according to Figure 2 , Figure 4 As shown, a temperature equalization mixer 92 is provided at the junction of the cold medium outlet 34 and the outlet of the temperature regulating pump 91. The temperature equalization mixer 92 includes a mixing chamber 93, a circulating water inlet 94, a temperature regulating water inlet 95, and a mixed water outlet 96. The circulating water inlet 94 and the mixed water outlet 96 are located at both ends of the mixing chamber 93. The temperature regulating water inlet 95 is located on the side wall of the mixing chamber 93. The circulating water inlet 94 is connected to the cold medium outlet 34 of the heat exchanger 3, the temperature regulating water inlet 95 is connected to the outlet of the temperature regulating pump 91, and the mixed water outlet 96 is connected to... The inlet of the large particle spray device 14 and the circulating water auxiliary pipe 81; the density of hot water is less than that of cold water. When the two water flows merge, if there is no strong disturbance, the hot water will tend to float and the cold water will sink. Even if there is some turbulence, the speed at which heat is transferred from hot water molecules to cold water molecules is not fast enough to mix them fully. When the hot water flows into the distribution pipe of the large particle spray device 14 and the atomizing spray device 15, the upper hot water is distributed to the far end and the lower cold water is distributed to the near end, causing a local temperature difference in the packing layer 16 and affecting the heat exchange efficiency.

[0031] according to Figure 4 As shown, a diversion mechanism 97 is fixedly installed in both the circulating water inlet 94 and the temperature-regulating water inlet 95. The diversion mechanism 97 is a diversion plate 971 extending axially along the water inlet direction. The diversion plate 971 has multiple diversion blades 972 extending radially from the center of the circulating water inlet 94 and the temperature-regulating water inlet 95 to the pipe wall. A fluid channel 973 is formed between two adjacent diversion blades 972.

[0032] according to Figure 4 , Figure 5 As shown, a mixing mechanism 98 is fixedly installed in the mixing chamber 93 near the mixing water outlet 96. The mixing mechanism 98 consists of at least two mixing plates 981 perpendicular to the water flow direction. Each mixing plate 981 has several guide holes 982, and the positions of the guide holes 982 on adjacent mixing plates 981 are staggered.

[0033] Working principle: According to Figures 1-5As shown in the figure, circulating water enters from the inlets of the large particle spray device 14 and the atomizing spray device 15, flows downwards, and finally flows into the collection tank 13. Ambient cold air enters from the air inlet 17 of the cooling tower 1, flows upwards, and finally exits from the air outlet 12. The water flow and airflow come into contact in opposite directions and are cooled through heat exchange. The cooled circulating water is sent from the outlet of the collection tank 13 to the circulating water main pipeline 8 by the circulating pump 2 and flows into the cold medium inlet 33 of the heat exchanger 3. The hot medium from the spheroidizing furnace enters the heat exchanger 3 from the hot medium inlet 31. The two exchange heat through the partition wall in the heat exchanger 3. The hot medium is cooled and flows back to the spheroidizing furnace from the hot medium outlet 32, while the cold medium (i.e., circulating water) is heated and cooled. The medium outlet 34 flows back to the main circulating water pipeline 8 and enters the cooling tower 1 for cooling. The temperature regulating pipeline 9, connected in parallel with the main circulating water pipeline 8, allows a portion of the cooled circulating water to bypass the main circulation and directly return to the inlet of the large particle spray device 14, reducing the inlet water temperature of the cooling tower 1. The flow acquisition module 5 collects the actual circulating water flow rate Q1 in real time, and the temperature acquisition module 6 collects the medium temperatures T1 to T4 at each port of the heat exchanger 3 in real time. The DCS controller 4 receives the real-time data from the flow acquisition module 5 and the temperature acquisition module 6, calculates the target circulating water flow rate Q2 according to the formula, and outputs a control signal to the circulating pump 2 to adjust its output speed, thus ensuring the actual circulating water flow rate... Q1 quickly approaches the target flow rate of circulating water Q2; when the target flow rate of circulating water Q2 calculated by DCS controller 4 continuously exceeds the preset threshold (e.g., 70%) of the rated flow rate of circulating pump 2 or the temperature T4 of cold medium outlet 34 continuously exceeds the set target value, the temperature regulating pump 91 controlling the flow rate of circulating water in temperature regulating pipeline 9 is first started and its output speed is adjusted to mix the cooled circulating water with the high-temperature circulating water after heat exchange with the heat medium in the spheroidizing furnace, thereby reducing the inlet water temperature of cooling tower 1 and thus reducing the outlet water temperature of cooling tower 1. After the temperature regulating pump 91 is running, if the temperature T4 of cold medium outlet 34 still continues to be higher than the set target value, the auxiliary regulating valve 82 is opened to start atomization. The spray device 15 significantly reduces the outlet water temperature of the cooling tower 1. When the heat load decreases or the environment improves, the target flow rate Q2 of the circulating water calculated by the DCS controller 4 continues to decrease. First, the auxiliary regulating valve 82 is closed to stop the atomizing spray. Then, the output speed of the temperature regulating pump 91 is reduced until it is closed, and only the large particle spray device 14 is used as a cooling means. The feedback calibration module 7 receives the adjusted actual flow rate Q1' of the circulating water and the medium temperature T1' to T4' of each port, calculates the actual heat exchange efficiency and compares it with the preset value. When the performance does not meet the standard, it determines whether the PID and front-end calculation model parameters are inappropriate and dynamically adjusts them, updating the new parameters to the DCS controller 4.

[0034] This specific embodiment is merely an explanation of the present invention and is not intended to limit the invention. After reading this specification, those skilled in the art can make modifications to this embodiment without contributing any inventive step, but such modifications are protected by patent law as long as they are within the scope of the claims of the present invention.

Claims

1. A spheroidizing furnace circulating cooling water system based on heat exchange demand dynamic regulation, comprising a cooling tower (1), a circulating pump (2), a heat exchanger (3), a DCS controller (4), a flow acquisition module (5), a temperature acquisition module (6), a feedback calibration module (7) and a circulating water main pipeline (8), the outlet of the cooling tower (1) is communicated with the cold medium inlet (33) of the heat exchanger (3) through the circulating water main pipeline (8), the cold medium outlet (34) of the heat exchanger (3) is communicated with the inlet of the cooling tower (1) through the circulating water main pipeline (8), the circulating pump (2) and the flow acquisition module (5) are arranged on the circulating water main pipeline (8), the cold and hot medium inlets and outlets of the heat exchanger (3) are provided with the temperature acquisition module (6), the DCS controller (4) is internally provided with a heat exchange efficiency calculation module and a PID adjustment algorithm, receives real-time data of the flow acquisition module (5) and the temperature acquisition module (6), calculates a target flow value and outputs a control signal to the circulating pump (2), and the feedback calibration module (7) receives the adjusted flow and temperature data, compares them with target values and dynamically corrects PID parameters.

2. The dynamic regulation based on heat exchange requirement spheroidizing furnace circulating cooling water system according to claim 1, characterized in that, The flow acquisition module (5) acquires the actual flow of circulating water in real time, the temperature acquisition module (6) acquires the medium temperature of each port of the heat exchanger (3) in real time, and the DCS controller (4) calculates the target flow of circulating water according to the temperature difference and outputs a control signal to the circulating pump (2).

3. The dynamic regulation based on heat exchange requirement spheroidizing furnace circulating cooling water system according to claim 2, characterized in that, The calculation formula of the DCS controller (4) for calculating the target flow of circulating water is Q2=(C1×m1×|T1-T2|) / (C2×|T4-T3|), wherein Q2 is the target flow of circulating water, C1 is the specific heat capacity of the hot medium, m1 is the mass flow of the hot medium, T1 is the temperature of the hot medium inlet (31), T2 is the temperature of the hot medium outlet (32), C2 is the specific heat capacity of the cold medium, T3 is the temperature of the cold medium inlet (33), and T4 is the temperature of the cold medium outlet (34).

4. The dynamic regulation based on heat exchange requirement spheroidizing furnace circulating cooling water system according to claim 2, characterized in that, When the actual heat exchange efficiency is lower than 90% of the design value, the DCS controller (4) sends an alarm signal and records fault data.

5. The dynamic regulation based on heat exchange requirement spheroidizing furnace circulating cooling water system according to claim 1, characterized in that, The cooling tower (1) comprises a tower body (11), the top of the tower body (11) is provided with an air outlet (12), the bottom of the tower body (11) is provided with a water collecting pool (13), and the tower body (11) is sequentially provided with a large-particle spraying device (14), an atomizing spraying device (15), a filler layer (16) and an air inlet (17) from top to bottom at a position between the air outlet (12) and the water collecting pool (13), the outlet of the water collecting pool (13) is connected to the cold medium inlet (33) of the heat exchanger (3), the cold medium outlet (34) is connected to the inlet of the large-particle spraying device (14), the cold medium outlet (34) is connected to the inlet of the atomizing spraying device (15) to form a circulating water auxiliary pipeline (81), and an auxiliary adjusting valve (82) is arranged on the circulating water auxiliary pipeline (81).

6. The heat exchange demand based dynamically regulated spheroidizing furnace circulating cooling water system according to claim 5, characterized in that, The outlet of the circulating pump (2) and the cold medium outlet (34) are further provided with a temperature adjusting pipeline (9), and the temperature adjusting pipeline (9) is provided with a temperature adjusting pump (91).

7. The heat exchange demand based dynamically regulated spheroidizing furnace circulating cooling water system according to claim 6, characterized in that, The auxiliary adjusting valve (82) and the temperature adjusting pump (91) are controlled to start or stop or to open or close by the DCS controller (4).

8. The dynamic regulation based on heat exchange requirement spheroidizing furnace circulating cooling water system according to claim 6, characterized in that, The cold medium outlet (34) and the outlet of the temperature adjusting pump (91) are provided with a uniform temperature mixer (92), and the uniform temperature mixer (92) comprises a mixing cavity (93), a circulating water inlet (94), a temperature adjusting water inlet (95) and a mixed water outlet (96), the circulating water inlet (94) and the mixed water outlet (96) are arranged at two ends of the mixing cavity (93), the temperature adjusting water inlet (95) is arranged on the side wall of the mixing cavity (93), the circulating water inlet (94) is connected to the cold medium outlet (34) of the heat exchanger (3), the temperature adjusting water inlet (95) is connected to the outlet of the temperature adjusting pump (91), and the mixed water outlet (96) is connected to the large particle spraying device (14) and the inlet of the circulating water auxiliary pipeline (81).

9. The dynamic regulation based on heat exchange requirement spheroidizing furnace circulating cooling water system according to claim 8, characterized in that, The circulating water inlet (94) and the temperature adjusting water inlet (95) are both fixedly provided with a flow dividing mechanism (97), the flow dividing mechanism (97) is a flow dividing plate (971) extending axially along the water inlet direction, the flow dividing plate (971) has a plurality of flow dividing blades (972) extending radially from the center of the circulating water inlet (94) and the temperature adjusting water inlet (95) to the pipe wall, and a fluid passage (973) is formed between two adjacent flow dividing blades (972).

10. The heat exchange demand based dynamically regulated spheroidizing furnace circulating cooling water system according to claim 9, characterized in that, The mixing cavity (93) is fixedly provided with a flow mixing mechanism (98) near the mixed water outlet (96), the flow mixing mechanism (98) is at least two flow mixing plates (981) perpendicular to the water flow direction, and a plurality of flow guide holes (982) are formed in the flow mixing plates (981), and the positions of the flow guide holes (982) on two adjacent flow mixing plates (981) are staggered.

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