Water and energy saving type heat exchange device and control method for sauce liquor industry

Abstract

This invention relates to the field of condensation equipment for distillation of Maotai-flavor liquor, specifically a water-saving and energy-efficient heat exchange device and control method for the Maotai-flavor liquor industry. The device includes a condenser, an air guide column, and heat exchange tubes. Both the air guide column and heat exchange tubes are vertically arranged within the condenser. The heat exchange tubes are generally spiral-shaped, with their swirl radius varying periodically. The air guide column is located in the middle of the heat exchange tubes, and its lower end is equipped with air guide vanes located below the heat exchange tubes. The lower end of the condenser has an air inlet and a drain outlet, while the top has an exhaust outlet. A cooling water spray component is installed inside the condenser, located in the lower middle part of the heat exchange tubes. The upper end of the heat exchange tubes is connected to a liquor vapor input pipe, and the lower end is connected to a cooled liquor discharge pipe. This invention solves the problems of high energy and water consumption commonly found in traditional brewing industries.

Description

Technical Field

[0001] This invention relates to the field of distillation and condensation equipment for Maotai liquor, and in particular to a water-saving and energy-efficient heat exchange device and control method for the Maotai liquor industry. Background Technology

[0002] Maotai-flavor baijiu is a typical representative of Chinese baijiu, and its production heavily relies on a unique solid-state fermentation technology, commonly referred to in the industry as the "12987" process. This process involves a one-year production cycle, two rounds of feeding, nine distillations, eight fermentations with added yeast, and seven distillations. Due to the massive scale and extremely complex process, energy efficiency and water resource management have become major obstacles to the industry's green transformation, especially the resource-intensive consumption problem in the "seven distillations" stage. From a thermodynamic perspective, distillation is essentially the extraction of ethanol and flavor components from the mash. When the high-temperature alcohol vapor condenses into a liquid state, it releases a large amount of latent heat of vaporization. This high-intensity phase change heat transfer process demands a huge amount of cooling load and is the core of resource consumption.

[0003] Current baijiu production largely relies on traditional cooling methods, which are difficult to meet the high standards of energy conservation and emission reduction in modern industry. Existing water-cooling methods mostly depend on direct-flow or open-loop tube heat exchange systems, which have limitations: First, the water consumption is staggering. According to relevant national standards and industry water usage specifications (GB / T 18916.7-2014, DB52 / T 725-2011), combined with actual measurement data analysis, benchmark enterprises often have water consumption quotas as high as 56 m³ / kL, which translates to approximately 61 tons of water consumption per ton of baijiu. This not only increases operating costs but also places a heavy burden on the regional water ecosystem. Second, water quality deterioration makes reuse difficult. Affected by koji powder, microorganisms, and dust in the production environment, the cooling medium is prone to excessive turbidity, odor, and increased COD, often resulting in direct discharge due to lack of reusability, exacerbating the pressure on wastewater treatment. To address these challenges, some enterprises have explored air-cooling solutions, but these solutions still face bottlenecks. Among them, the "air conditioning refrigeration + tube heat exchange" solution can guarantee the cooling intensity, but it is maintained by consuming a lot of electricity, which is a high-energy-consuming alternative solution; while the simple tube air-cooling solution is limited by the physical properties of air (specific heat capacity, thermal conductivity) and is seriously affected by temperature fluctuations. In the high temperature environment of summer (ambient temperature exceeds 30°C), it often causes the risk of "alcohol leakage" due to insufficient heat exchange efficiency, which endangers production safety and material recovery.

[0004] Beyond hardware shortcomings, the coordinated control of the cooling process also exhibits significant limitations. The primary problem lies in insufficient sensing capabilities; mainstream control logic remains at the level of basic temperature regulation or relies solely on manual experience, lacking the ability to anticipate environmental disturbances and dynamic changes in steam load. Secondly, the system lacks multi-dimensional (multi-objective) optimization algorithms. The cooling process involves a non-linear dynamic balance between quality assurance and optimal energy efficiency, and traditional PID control schemes struggle to provide optimal solutions under complex operating conditions. This often leads to system fluctuations between "energy waste due to excessive condensation" and "wine loss due to insufficient cooling," making it difficult to achieve optimal operating efficiency.

[0005] In summary, developing a deep integration of new, high-efficiency, and energy-saving heat exchange devices with advanced intelligent control algorithms, so that they can simultaneously meet the high-efficiency heat transfer requirements of "energy-saving heat exchange" and the precise water use requirements of "industrial water-saving special equipment," is an urgent need for the Maotai-flavor liquor industry to achieve green and sustainable development. Summary of the Invention

[0006] In view of the shortcomings of the prior art described above, the purpose of this invention is to provide a water-saving and energy-saving heat exchange device and control method for the sauce-flavored liquor industry, which can solve the technical problems existing in the current sauce-flavored liquor production process, such as huge consumption of distillation cooling water, unstable temperature control, low heat exchange efficiency and high energy consumption of traditional air cooling technology under extreme climates.

[0007] To achieve the above objectives, this invention provides a water-saving and energy-efficient heat exchange device for the liquor industry, comprising a condenser, an air guide column, and heat exchange tubes. Both the air guide column and the heat exchange tubes are vertically arranged within the condenser. The heat exchange tubes are generally spiral-shaped, with their swirl radius varying periodically. The air guide column is located in the middle of the heat exchange tubes, and its lower end is equipped with air guide vanes located below the heat exchange tubes. The lower end of the condenser has an air inlet and a drain outlet, while the top has an exhaust outlet. A cooling water spray component is installed inside the condenser, located in the lower middle part of the heat exchange tubes. The upper end of the heat exchange tubes is connected to a liquor vapor input pipe, and the lower end is connected to a cooled liquor discharge pipe.

[0008] Optionally, it also includes a steam distributor; the heat exchange tubes are multiple, the swirl radius of the multiple heat exchange tubes is different, the multiple heat exchange tubes are arranged side by side, and there is a gap between adjacent heat exchange tubes; the number of wine steam input pipes is the same as the number of heat exchange tubes, and they correspond one-to-one, and the steam distributor is connected to the multiple wine steam input pipes respectively.

[0009] Optionally, the system also includes control equipment and temperature / humidity sensors. Each of the wine vapor input pipes is equipped with a wine vapor flow control valve, each heat exchange pipe is equipped with a multi-point temperature sensor, and the cooling wine discharge pipe is equipped with a single-point temperature sensor. The air inlet is connected to a variable frequency fan, and an air flow meter is installed on the pipe connecting the air inlet and the variable frequency fan. The inlet of the cooling water spray component is connected to a water pump, and a spray water control valve and a liquid flow meter are installed on the pipe connecting the cooling water spray component and the water pump. The control equipment is electrically connected to the wine vapor flow control valve, the multi-point temperature sensor, the single-point temperature sensor, the air flow meter, the variable frequency fan, the spray water control valve, the liquid flow meter, and the temperature / humidity sensor, respectively.

[0010] Optionally, the swirl radius of the heat exchange tube varies periodically.

[0011] Optionally, the cooling water spray component includes a water inlet pipe and an annular nozzle. The annular nozzle is provided with multiple high-pressure micro-mist nozzles, and the air guide column is vertically arranged in the middle of the inner ring of the annular nozzle.

[0012] Optionally, there are multiple air guide vanes, and the air guide vanes are turbine blades; the upper and lower ends of the air guide column are both conical structures.

[0013] Optionally, it also includes an exhaust chimney, which is connected to the exhaust port.

[0014] Optionally, the condenser tank is provided with a maintenance dust removal port, and the maintenance dust removal port is equipped with a removable sealing cover.

[0015] This invention also provides a control method for a water-saving and energy-efficient heat exchange device used in the sauce-flavored liquor industry, characterized in that it is applied to the device described above, and the method includes:

[0016] S1: The control equipment acquires ambient temperature, ambient humidity, cool wine outlet temperature, cooling air flow rate, spray water flow rate, and average temperature inside the heat exchange tube;

[0017] S2: The ambient temperature Compared with a first preset temperature threshold, the ambient humidity Compared with a first preset humidity threshold, if and only if the ambient temperature Greater than the first preset temperature threshold And the ambient humidity Less than the first preset humidity threshold When necessary, the spray evaporative cooling mode is used; otherwise, the dry energy-saving cooling mode is used.

[0018] The spray evaporation cooling operation mode is as follows: the control equipment solves for the spray water flow rate setpoint and the cooling air flow rate setpoint; based on the cooling air flow rate setpoint, a first control command is generated to control the change in the air volume of the variable frequency fan; based on the spray water flow rate setpoint, a second control command is generated to control the opening of the spray water control valve; at the same time, the control equipment generates a third control command to control the opening of the vapor flow control valve based on the average temperature inside the heat exchange tube.

[0019] The dry energy-saving cooling operation mode is as follows: the control equipment solves the cooling air flow setpoint, and generates the first control command for controlling the fan based on the cooling air flow setpoint; at the same time, the control equipment generates the third control command for controlling the opening of the vapor flow control valve based on the average temperature inside the heat exchange tube.

[0020] S3: Repeat steps S1 and S2.

[0021] Optionally, the control device solves for the spray water flow rate setpoint and the cooling air flow rate setpoint based on the following relationship.

[0022]

[0023]

[0024] =

[0025] =

[0026]

[0027] In the formula, and As a weighting factor, Set to 1.5–5, Set it to 0.5–1.5; Indicates the first NP represents the number of predicted periods; biobjective function It is a calculated value; Indicates the first Predict the outlet temperature of chilled wine in one cycle. yes and The function; Indicates the first Predicted wind turbine power values ​​for each cycle; Indicates the first Predict spray water flow rate for each cycle; Indicates the first Predict spray water flow rate for each cycle; The price is per unit of electricity, expressed in yuan / kWh. The price is per unit of water, expressed in yuan per ton. Indicates the first Cooling airflow setpoint for each cycle Indicates the first The set value of the spray water flow rate for each cycle; Indicates the first The control input for a cycle-controlled variable frequency fan can be selected as frequency or speed. Indicates the first The control input for the spray water control valve in each cycle is specifically the opening degree;

[0028] Predicting the next Np periods under different control sequences Next, find the objective function. Minimum optimal sequence . It is the optimal result for the i-th cycle.

[0029] The beneficial effects of this invention are as follows: Cooling air is introduced through the air inlet pipe, and the air enters and passes through the air guide vanes and air guide columns, forcing the cooling air to form turbulence and enhancing convective heat transfer on the air side. Furthermore, this invention can be equipped with a cooling water spray unit that sprays cooling water from bottom to top. This method differs from the "high-flow-rate flushing" of traditional water spray cooling. Specifically, this invention utilizes a cooling water spray component to spray cooling water from bottom to top in the form of micron-sized droplets. After spraying, the droplets rapidly evaporate upon encountering the high-temperature heat exchange tube wall or hot air, absorbing the latent heat of vaporization. The latent heat of vaporization of water is approximately 2260 kJ / kg, while its specific heat capacity is only 4.18 kJ / kg. K means that the heat absorbed by evaporating 1 kg of water is equivalent to the heat required to raise the temperature of 1 kg of water to 540°C. Therefore, only a very small amount of water is needed to remove a huge amount of heat, that is, only about 1 / 50th of that required by traditional water cooling. The cooling water spray unit is only activated when necessary, and the spray volume is precisely controlled to ensure complete evaporation in the airflow. This utilizes the highly efficient heat absorption capacity of phase change and achieves "zero wastewater discharge" and "extremely low water consumption," fully meeting the definition of "dedicated industrial water-saving equipment."

[0030] Simultaneously, the air guide vanes and air guide columns of this invention create a swirling airflow within the device, extending the residence time of the water mist and further ensuring complete evaporation before exhaust. By precisely calculating the spray volume, "instant drying" is guaranteed, preventing droplets from accumulating into wastewater and further ensuring "zero wastewater discharge," thus completely solving the environmental problems of traditional water cooling. This invention addresses the high energy and water consumption problems prevalent in the traditional brewing industry, promoting the transformation and upgrading of traditional industries towards green manufacturing. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the structure of an embodiment of the present invention;

[0032] Figure 2 This is a schematic diagram of the heat exchange tube structure according to an embodiment of the present invention;

[0033] Figure 3 This is a schematic diagram illustrating the swirl radius of the heat exchange tube according to an embodiment of the present invention;

[0034] Figure 4 This is a diagram of the air guiding structure described in an embodiment of the present invention;

[0035] Figure 5 This is a structural diagram of the cooling water spray component according to an embodiment of the present invention;

[0036] Figure 6 This is a schematic diagram of the multivariable hierarchical control architecture described in an embodiment of the present invention.

[0037] Explanation of reference numerals in the attached figures:

[0038] 1. Steam distributor; 2. Control computer; 3. Centralized acquisition / drive; 4. First control circuit; 5. Air intake measurement signal circuit; 6. Multi-point temperature sensor; 7. Variable frequency fan control circuit; 8. Air temperature / humidity measurement signal circuit; 9. Temperature / humidity sensor; 10. Cooling wine discharge pipe; 11. Support; 12. Drain pipe; 13. Air flow meter; 14. Air flow control valve; 15. Variable frequency fan; 16. Air inlet pipe; 17. Air guide vane; 18. Inspection and dust removal port; 19. Water pump; 20. Spray water control valve; 21. Liquid flow meter; 22. Spray water flow measurement signal circuit; 23. Spray water flow control signal circuit; 24. Cooling water spray component; 25. Heat exchanger tube; 26. Air guide column; 27. Exhaust chimney; 28. Wine steam flow control signal circuit; 29. ​​Wine steam flow control valve. Detailed Implementation

[0039] The following specific examples illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention.

[0040] This invention belongs to the fields of energy conservation and environmental protection, and high-efficiency energy saving. Addressing the industry pain points in the current production of Maotai-flavor liquor, such as the huge consumption of distillation cooling water and the low heat exchange efficiency and high energy consumption of traditional air-cooling technology under extreme climates, this invention aims to achieve efficient heat exchange and water conservation. The following is a combination of... Figures 1 to 5 This embodiment provides a water-saving and energy-efficient heat exchange device for the sauce-flavored liquor industry, including a condenser, an air guide column 26, and a heat exchange tube 25. Both the air guide column 26 and the heat exchange tube 25 are vertically arranged inside the condenser. The heat exchange tube 25 has a generally spiral structure, and the swirl radius of the heat exchange tube 25 varies periodically. The air guide column 26 is located in the middle of the heat exchange tube 25, that is, at the axial center of the heat exchange tube 25. An air guide vane 17 is provided at the lower end of the air guide column 26. Air guide vanes 17 are located below the heat exchange tube 25, and air guide columns 26 are connected to the condenser tank through the air guide vanes 17. The lower end of the condenser tank is provided with an air inlet pipe 16 and a drain pipe 12, and the top is provided with an exhaust port. The condenser tank is provided with a cooling water spray component 24, which is located in the lower middle part of the heat exchange tube 25. The upper end of the heat exchange tube 25 is connected to a wine vapor input pipe, and the lower end of the heat exchange tube 25 is connected to a cooled wine discharge pipe 10, which extends out of the condenser tank.

[0041] This invention introduces cooling air through the air inlet pipe 16. The cooling air enters and passes through the air guide vanes 17 and the air guide column 26, forcing the cooling air to form turbulence and enhancing convective heat transfer on the air side. Furthermore, this invention can be equipped with a cooling water spray unit to spray cooling water from bottom to top. This method differs from the "high-flow-rate flushing" of traditional water spray cooling. Specifically, this invention uses a cooling water spray component 24 to spray cooling water from bottom to top in the form of micron-sized droplets. After spraying, the droplets rapidly evaporate upon encountering the high-temperature heat exchange tube 25 wall or hot air, absorbing the latent heat of vaporization. The latent heat of vaporization of water is approximately 2260 kJ / kg, while its specific heat capacity is only 4.18 kJ / kg. K means that the heat absorbed by evaporating 1 kg of water is equivalent to the heat required to raise the temperature of 1 kg of water to 540°C. Therefore, only a very small amount of water is needed to remove a huge amount of heat, that is, only about 1 / 50th of that required by traditional water cooling. The cooling water spray unit is only activated when necessary, and the spray volume is precisely controlled to ensure complete evaporation in the airflow. This utilizes the highly efficient heat absorption capacity of phase change and achieves "zero wastewater discharge" and "extremely low water consumption," fully meeting the definition of "dedicated industrial water-saving equipment."

[0042] Simultaneously, the air guide vanes 17 and air guide columns 26, in conjunction with this invention, create a swirling airflow within the device, extending the residence time of the water mist and further ensuring complete evaporation of the water mist before exhaust. By precisely calculating the spray volume, "instant drying" is guaranteed, preventing droplets from accumulating into wastewater and further ensuring "zero wastewater discharge," thus completely solving the environmental problems of traditional water cooling. This invention addresses the high energy and water consumption problems prevalent in the traditional brewing industry, promoting the transformation and upgrading of traditional industries towards green manufacturing.

[0043] In this example, the heat exchange tubes 25 are made of rolled and welded stainless steel, ensuring the corrosion resistance and food safety of the device. There are multiple heat exchange tubes 25, each with a different swirl radius, arranged side-by-side with a gap between adjacent tubes. The number of alcohol vapor input pipes is the same as the number of heat exchange tubes 25, and they correspond one-to-one. Figure 1 As shown, the present invention also includes a steam distributor 1, which is connected to multiple wine steam input pipes.

[0044] like Figure 2 and 3 As shown, the swirl radius of each heat exchange tube 25 exhibits a periodic change; in other words, the heat exchange tube 25 has a periodic variable diameter structure, and multiple heat exchange tubes 25 constitute a periodic variable diameter swirling heat exchange tube assembly, such as... Figure 3 As shown, among the multiple heat exchange tubes 25, taking the outermost heat exchange tube 25 as an example, orange-red, sky blue, and blue-green represent different parts of the outermost heat exchange tube 25, respectively. The orange-red part of the heat exchange tube 25 is the large swirling section, and the swirling radius of the large swirling section is the large swirling radius R1; the blue-green part of the heat exchange tube 25 is the small swirling section, and the swirling radius of the small swirling section is the small swirling radius R2; the sky-blue part of the heat exchange tube 25 is the first transition section, and the swirling radius of the first transition section is the transition swirling radius R. tBelow the first transition section is the second transition section, which is not marked with color in the diagram. The transition vortex radius of the second transition section is the same as that of the first transition section, but the arrangement orientation of the second transition section is different from that of the first transition section. After rotating the second transition section longitudinally by 180°, its arrangement orientation is the same as that of the first transition section. The large vortex section and the small vortex section are smoothly connected by a transition section. This can be understood as follows: the large vortex section and the small vortex section are smoothly connected by the first transition section, and the small vortex section and the large vortex section are smoothly connected by the second transition section. In this embodiment, the large vortex radius R1 of the large vortex section is 370 mm and the length is 872 mm, the small vortex radius R2 of the small vortex section is 326 mm and the length is 815 mm, and the length of the transition section is set to 277 mm.

[0045] The large swirl radius R1 is greater than the small swirl radius R2; the large swirl section, the first transition section, the small swirl section and the second transition section form a periodic variable diameter swirl section structure; the heat exchange tube 25 is composed of multiple periodic variable diameter swirl section structures, and other periodic variable diameter swirl section structures of the heat exchange tube 25 are similar and will not be described in detail.

[0046] Furthermore, a support 11 is provided on the lower outer side of the condenser, and the support 11 is used to support the condenser.

[0047] This embodiment also includes control equipment, a temperature / humidity sensor 9, a vapor flow control valve 29 on each vapor inlet pipe, and a multi-point temperature sensor 6 on each heat exchange tube 25 to detect the average temperature inside the heat exchange tube 25. Furthermore, the multi-point temperature sensors 6 are non-uniformly distributed along the axial direction of the heat exchange tube 25, with a higher distribution density near the vapor inlet of the heat exchange tube 25 at higher temperatures, used to capture the specific location of the condensation phase change initiation point. A single-point temperature sensor is installed on the cooling vapor outlet pipe 10. The air inlet pipe 16 is connected to a variable frequency fan 1. 5. An air flow meter 13 and an air flow control valve 14 are installed on the pipe connecting the air inlet pipe 16 and the variable frequency fan 15; a water pump 19 is connected to the water inlet of the cooling water spray component 24, and a spray water control valve 20 and a liquid flow meter 21 are installed on the pipe connecting the cooling water spray component 24 and the water pump 19; the control equipment is electrically connected to the wine vapor flow control valve 29, the multi-point temperature sensor 6, the single-point temperature sensor, the air flow meter 13, the variable frequency fan 15, the spray water control valve 20, the liquid flow meter 21, and the temperature / humidity sensor 9. In addition, a steam flow meter can be installed on the wine vapor input pipe to observe the wine vapor inlet load and detect the wine vapor inlet flow rate. The temperature / humidity sensor 9 is also known as an air temperature and humidity composite sensor.

[0048] The temperature / humidity sensor 9 is used to detect the ambient temperature and humidity, and send the ambient temperature and humidity to the control device; the single-point temperature sensor is used to detect the cooling wine outlet temperature, and send the cooling wine outlet temperature to the control device; the air flow meter 13 is used to detect the cooling air flow rate, and send the cooling air flow rate to the control device; the liquid flow meter 21 is used to detect the spray water flow rate, and send the spray water flow rate to the control device; the multi-point temperature sensor 6 is used to detect the average temperature inside the heat exchange tube 25, and send the average temperature inside the heat exchange tube 25 to the control device; the control device is used to control the opening degree of the spray water control valve 20 and each of the wine vapor flow control valves 29, as well as the air volume of the variable frequency fan 15.

[0049] Each heat exchange tube 25 is equipped with a multi-point temperature sensor 6, which allows the control device to dynamically adjust the steam distribution of each heat exchange tube 25 based on the real-time heat exchange status (feedback from the multi-point temperature sensor 6). If the outlet temperature of a certain heat exchange tube 25 is too high, indicating that its heat load is too large, the control device will automatically close the steam flow control valve 29 of that heat exchange tube 25, forcing steam to flow to other heat exchange tubes 25 with lighter loads. This mechanism prevents the crude operation of having to increase the cooling intensity of the entire system due to the overload of a single heat exchange tube 25, ensuring a uniform distribution of heat load throughout the entire heat exchange array, and further reflecting the refined energy-saving design concept.

[0050] like Figure 1As shown, the control device includes a control computer 2 and a data acquisition / drive 3. The control computer 2 is electrically connected to the data acquisition / drive 3. The data acquisition / drive 3 is electrically connected to the wine vapor flow control valve 29 via a wine vapor flow control signal line 28. The data acquisition / drive 3 is electrically connected to the multi-point temperature sensor 6. The data acquisition / drive 3 is electrically connected to the single-point temperature sensor via a first control line 4. The data acquisition / drive 3 is electrically connected to the air flow meter 13 via an air intake measurement signal line 5. The data acquisition / drive 3 is electrically connected to the variable frequency fan 15 via a variable frequency fan control line 7. The data acquisition / drive 3 is electrically connected to the spray water control valve 20 via a spray water flow control signal line 23. The data acquisition / drive 3 is electrically connected to the liquid flow meter 21 via a spray water flow measurement signal line 22. The data acquisition / drive 3 is electrically connected to the temperature / humidity sensor 9 via an air temperature / humidity measurement signal line 8. The control computer 2 includes a processor and a memory. The memory stores computer-executable instructions. When the processor executes the instructions, it runs the corresponding control method.

[0051] The control device, water pump 19, spray water control valve 20, liquid flow meter 21, spray water flow control signal line 23, and cooling water spray component 24 constitute a spray cooling system; the control device, variable frequency fan 15, air flow meter 13, air flow control valve 14, air intake volume measurement signal line 5, and variable frequency fan control line 7 constitute a dry cooling system; after collecting relevant data, the control device can activate the dry cooling system alone or activate both the spray cooling system and the dry cooling system simultaneously.

[0052] like Figure 4 As shown, there are multiple air guide vanes 17, which are turbine blades; the upper and lower ends of the air guide column 26 are both conical structures. The air guide vanes 17 and the air guide column 26 form an air guiding structure, which, in conjunction with the periodically variable diameter geometry of the heat exchange tube 25, allows the cooling air to tangentially scour the wall of the heat exchange tube 25 at a specific angle, enhancing the air-side convective heat transfer coefficient, thereby reducing the required fan speed and meeting the requirements of an energy-saving heat exchange device.

[0053] The swirl radius of each heat exchange tube 25 varies periodically in the circumferential direction. This periodic variable diameter structure of the heat exchange tube 25, combined with the air guiding structure, provides dual energy-saving benefits. Specifically, this includes optimized fluid dynamics inside the tube and enhanced aerodynamics outside the tube.

[0054] The optimization of fluid dynamics inside the tube (enhanced condensation): When high-temperature vapor flows through the heat exchange tube 25, the periodic decrease and increase of the vortex radius causes periodic changes in the radial velocity of the fluid. This violent fluctuation in the velocity field induces strong secondary flows and vortices, causing the fluid to generate "periodic oscillations" inside the tube, greatly increasing the turbulence (Reynolds number) of the fluid inside the heat exchange tube 25. In condensation heat transfer, the liquid film tightly adhering to the inner wall of the tube is the main source of thermal resistance. The periodic turbulent oscillations inside the heat exchange tube 25 of this invention can effectively thin and disrupt this condensate film, allowing the high-temperature vapor to contact the tube wall more directly for heat exchange. According to the principles of heat transfer, the condensate film is the main source of thermal resistance. Disrupting the condensate film can significantly improve the condensation heat transfer coefficient inside the tube. Specifically, based on the relationship between the Nusselt number (Nu) and the Reynolds number... The increase in turbulence directly improves the convective heat transfer coefficient.

[0055] Enhanced aerodynamics on the outside of the tube (enhanced convection): The periodic variable diameter structure of the heat exchange tube 25 increases its projected cross-sectional area in the vertical direction. When cooling air flows from bottom to top, the periodic variable diameter structure of the heat exchange tube 25 forces the airflow to constantly change direction. Combined with the air guiding structure, this forces the cooling air to form complex flow around and vortices, avoiding the formation of stagnant zones on the wall surface of the heat exchange tube 25, and enhancing the convective heat transfer coefficient h on the air side. air This means that the heat exchange effect required by traditional straight pipes can be achieved with a smaller fan power, which meets the characteristics of an energy-saving heat exchange device. From the perspective of control theory, this invention significantly shortens the process delay and time constant of the heat exchange process, improving the controllability of the heat exchange device from a hardware perspective.

[0056] According to the basic equation of heat transfer (in For total heat transfer, The overall heat transfer coefficient is... For heat exchange area, The logarithmic mean temperature difference indicates that, with the total heat load Q and heat transfer area A remaining constant, a significant increase in the heat transfer coefficient U means that the system can operate at a smaller mean temperature difference. It can operate at lower temperatures, or require less cooling medium flow under the same temperature difference. The significant increase in the value means a faster gain and response speed of the controlled object (the heat exchange tube 25), which directly reduces the airflow required by the variable frequency fan, thereby significantly reducing power consumption and achieving energy saving. In short, it significantly improves the overall heat transfer coefficient without increasing external energy consumption, reducing the airflow required to achieve the same cooling effect (Fi). air (and fan energy consumption).

[0057] like Figure 5 As shown, the cooling water spray component 24 includes a water inlet pipe and an annular nozzle. The annular nozzle is equipped with multiple high-pressure micro-mist nozzles, capable of atomizing water into tiny droplets with a diameter of micrometers. The air guide column 26 is vertically arranged in the center of the inner ring of the annular nozzle. The position of the cooling water spray component 24 can be adjusted within the lower middle range of the heat exchange tube 25. In this example, the cooling water spray component 24 is located at the lower part of the heat exchange tube 25. Figure 1 As shown.

[0058] like Figure 1 As shown, it also includes an exhaust chimney 27, which is connected to the exhaust port. The hot air after heat exchange has a significantly higher temperature than the ambient temperature and a lower density. Based on the principle of natural convection, the exhaust chimney 27 utilizes the "chimney effect" generated by the density difference of the hot air, i.e., it generates an upward chimney draft, providing a "free" baseline airflow, thereby providing passive exhaust power. This effectively reduces the operating load of the active variable frequency fan, making the exhaust chimney 27 not only a waste gas emission channel but also an important passive energy-saving component. The structural characteristics of the exhaust chimney 27 reduce the operating load of the variable frequency fan at the same airflow (… The baseline energy consumption under the present invention is reduced, and its effective adjustment range is increased, thereby directly improving the overall energy consumption of the present invention and reducing operating costs.

[0059] According to Archimedes' principle, hot air inside a chimney experiences an upward buoyant force, creating a natural draft. It can be approximated as:

[0060]

[0061] Where g is the acceleration due to gravity, and H is the height of the chimney. The density of the external cold air. This represents the density of the hot air inside the chimney.

[0062] The energy-saving contribution of the exhaust chimney 27: This natural draft acts as a "free" power source, helping to overcome system flow resistance (such as tube bundle resistance and guide vane resistance). When calculating the control command to control the air volume of the variable frequency fan, the control equipment will consider the natural lift force of the exhaust chimney 27 as a natural convection compensation term. The natural convection compensation term is generally relatively fixed and can be preset as a constant in the control equipment system and participate in the calculation of the variable frequency fan power, that is... The variable frequency fan energy consumption model includes a negative work offset for the chimney effect, thereby reducing the output power of the variable frequency fan. Under low load or winter conditions, it can even operate entirely by natural draft, achieving "zero power consumption" for the fan. This design, which utilizes natural forces to assist industrial processes, is also an important manifestation of the energy-saving characteristics of this invention.

[0063] The condenser is provided with inspection and dust removal ports 18 on both sides, and each inspection and dust removal port 18 is equipped with a removable sealing cover. Dust accumulation on the surface of the heat exchange tubes 25 creates additional thermal resistance, severely reducing the heat transfer coefficient. The inspection and dust removal ports 18 are used to periodically remove dust and distiller's grains particles deposited on the surface of the heat exchange tubes 25 to maintain the cleanliness of the surface, prevent increased thermal resistance and decreased heat exchange efficiency due to dust accumulation, thereby ensuring the long-term energy saving and operational stability of this invention. Additionally, it facilitates personnel maintenance of internal components.

[0064] This embodiment also provides a control method for a water-saving and energy-efficient heat exchange device used in the sauce-flavored liquor industry. The method is applied to the aforementioned water-saving and energy-efficient heat exchange device and includes:

[0065] Step S101: First, initialization and self-test. The system starts up and loads thermodynamic model parameters (such as air density corresponding to the local altitude, latent heat of vaporization of water, and the reference heat transfer coefficient U0 of the heat exchanger). The system self-tests the health status of all sensors and actuators to ensure there are no faults.

[0066] Step S102: Full-dimensional data acquisition, the control computer 2 in the control device acquires the ambient temperature. Ambient humidity Cooling wine outlet temperature Cooling airflow Spray water flow rate Average temperature inside heat exchange tube 25 and inlet flow rate of alcohol vapor The outlet temperature of the cooled liquor can be understood as the temperature of the cooled liquor at the outlet pipe 10, which is detected using the single-point temperature sensor. Additionally, the inlet load of the liquor vapor can also be collected. In order to observe the inlet load of the alcohol vapor;

[0067] In this step, computer 2 is controlled to periodically (e.g., once per second) collect ambient temperature data. Ambient humidity and process parameters ( , , , ).

[0068] The key point of this step: Introducing ambient humidity. This is the key difference between this invention and traditional temperature control. Ambient humidity determines the wet-bulb temperature of the air, and the wet-bulb temperature determines the theoretical limit temperature of evaporative cooling. This is the physical basis for determining whether to activate the spray evaporative cooling operation mode.

[0069] Step S103: Feedforward disturbance suppression, the system monitors the inlet flow rate of the alcohol vapor. The steam flow rate fluctuates greatly due to the significant intermittent nature of the baijiu distillation process (upper still, distillation, lower still). This fluctuation occurs at the outlet temperature. Before any change occurs, the feedforward module follows the energy conservation formula. It estimates the required changes in cooling load and adjusts the opening of fans or water valves in advance. This avoids the lag of traditional feedback control and prevents "runaway cooling" (when the flow rate suddenly increases) or overcooling waste (when the flow rate suddenly decreases) caused by untimely adjustment.

[0070] Step S2: Multi-parameter state recognition and mode switching, which is the core logic for achieving "industrial water conservation". The algorithm determines the current operating condition.

[0071] The ambient temperature Compared with a first preset temperature threshold, the ambient humidity Compared with a first preset humidity threshold, if and only if the ambient temperature Greater than the first preset temperature threshold And the ambient humidity Less than the first preset humidity threshold When the ambient temperature is high, a spray evaporative cooling mode is used; otherwise, a dry energy-saving cooling mode is used. This step involves intelligent status determination; in other words, the control computer 2 runs a built-in "multi-parameter status recognition algorithm" to determine the collected ambient temperature. and ambient humidity The system compares and judges the "preset environmental energy-saving threshold (first preset temperature threshold and first preset humidity threshold)" to generate a "processing stage switching instruction". The switching instruction is used to select the current optimal operating mode between "dry energy-saving cooling operation mode" and "spray evaporation cooling operation mode".

[0072] Switching logic of multi-parameter state recognition algorithm It can be summarized as follows:

[0073]

[0074] In low temperature or high humidity environments ( If the ambient cold source is sufficient, or the air humidity is too high for evaporation, the algorithm automatically determines that it is in "dry energy-saving cooling operation mode," forcibly shutting down the spray cooling system, completely closing water pump 19 and spray valve, and using only the variable frequency fan for air cooling, achieving 100% water saving and absolute zero water consumption; this only applies to extreme conditions of high temperature and low humidity (…). At this point, simple air cooling consumes too much power and is ineffective, so the system switches to "spray water-saving evaporative cooling mode" to compensate for temperature loss through water mist evaporation. This intelligent switching based on environmental perception eliminates indiscriminate water use and achieves intelligent water conservation. For example, a first preset temperature threshold can be set. The temperature is 30°C, and the first preset humidity threshold is... It is 70%.

[0075] The spray evaporation cooling operation mode is as follows: the control computer 2 in the control equipment solves for the spray water flow rate setpoint. and cooling airflow setpoint The control device's data acquisition / driver 3 generates a first control command based on the cooling airflow setpoint to control the variable frequency fan's airflow variation; the control device's data acquisition / driver 3 generates a second control command based on the spray water flow setpoint to control the opening of the spray water control valve 20; simultaneously, the control device's data acquisition / driver 3 acquires the average temperature inside the heat exchange tube 25, and based on the average temperature inside the heat exchange tube 25, generates a third control command to control the opening of the alcohol vapor flow control valve 29, ensuring that the heat load is evenly distributed among all the heat exchange tubes 25, preventing a decrease in cooling efficiency and waste of water resources due to local overheating; the variable frequency fan acquires the first control command and adjusts the airflow according to the first control command; the spray water control valve 20 acquires the second control command and adjusts the opening of the spray water control valve 20 according to the second control command; the alcohol vapor flow control valve 29 acquires the third control command and adjusts the opening of the alcohol vapor flow control valve 29 according to the third control command; in the spray evaporation cooling operation mode, efficient heat exchange is achieved by utilizing the latent heat of phase change of water;

[0076] When the "spray evaporation cooling operation mode" is selected, a multi-objective control strategy is adopted. The multi-objective control strategy adopts a multi-input multi-output (MIMO) control algorithm. This algorithm accurately calculates the minimum amount of water required for evaporation based on the real-time heat load, that is, using the minimum amount of spray cooling water to avoid water waste and wastewater generation caused by excessive spraying, and ensure that the water resource utilization rate reaches the theoretical limit.

[0077] The spray evaporative cooling operation mode means that the spray cooling system and the dry cooling system are used simultaneously.

[0078] The dry-type energy-saving cooling operation mode is as follows: the control computer 2 in the control equipment solves for the cooling air flow setpoint. The control device's data acquisition / drive 3 generates a first control command for controlling the fan based on the cooling airflow setpoint. Simultaneously, the data acquisition / drive 3 acquires the average temperature inside the heat exchange tube 25 and generates a third control command to control the opening of the alcohol vapor flow control valve 29 based on this average temperature. The variable frequency fan acquires the first control command and adjusts its airflow accordingly. The alcohol vapor flow control valve 29 acquires the third control command and adjusts its opening accordingly; this is a multi-objective control strategy. In dry-type energy-saving cooling operation mode, the control device closes the spray water control valve 20, utilizing only the sensible heat of the air for heat exchange, achieving zero water consumption in the production process.

[0079] Dry energy-saving cooling operation mode means that the dry cooling system is used alone.

[0080] To address the issues of "local overheating (alcohol runoff)" or "local undercooling (energy waste)" caused by uneven flow distribution in a parallel structure of multiple heat exchange tubes 25, this invention introduces distributed control. By adjusting the alcohol vapor flow valve of each tube, the load on all heat exchange tubes 25 is ensured to be balanced, avoiding energy waste caused by overloading the entire system to accommodate the hottest tube. Specifically, the third control command is multiple, each corresponding to a different alcohol vapor flow control valve 29, independently adjusting the opening of each valve to ensure that the heat load is evenly distributed among all the parallel heat exchange tubes 25, preventing a decrease in cooling efficiency and water waste due to local overheating.

[0081] S3: Repeat steps S1 and S2, that is, select the operating mode in stages and continuously optimize the control.

[0082] In step S2, the dual objective function The paradigm is:

[0083]

[0084] In the formula, and As a weighting factor, It can be set to 1.5–5. It can be set to 0.5–1.5 during the optimization process. For larger areas, prioritize maintaining temperature. Prioritize energy conservation when the target size is large; dual objective function It is not a physical quantity, but only a calculated value; This refers to the outlet temperature of the cooled wine. This is the preset target temperature for the wine outlet. The unit price is yuan / kWh, and it represents external input. The unit price is the water price per ton, and it is an external input. The control input for the variable frequency fan can be either frequency or speed, with the frequency range being 0–50 Hz and the speed range being 0–50 rpm. This is the control input for the spray water control valve 20, specifically the opening degree of the spray water control valve 20. For a given control input The instantaneous power consumed by the variable frequency fan depends on the model of the variable frequency fan, typically 5–50kW; For a given control input The spray water flow rate is expressed in m³ / h and ranges from 0 to 100%.

[0085] The objective of this biobjective function is: 1) to minimize the outlet temperature of the cooled liquor. With respect to the preset target temperature of the wine outlet The outlet temperature deviation between ( ); 2) Minimize a "system comprehensive consumption index", which is the weighted sum of the energy consumption of the variable frequency fan and the energy consumption of the water pump 19. A model predictive control (MPC) strategy is adopted to solve a bi-objective function that includes "outlet temperature deviation temperature" and "comprehensive energy consumption".

[0086] Optimize the solution process of the dual objective function: Employ numerical optimization algorithms (such as quadratic programming) to predict, under the constraint conditions, the conditions under different control sequences in the next Np periods. (i.e., repeatedly adjusting the control hypothesis sequence) ), find the objective function Minimum optimal sequence , This is the optimal result for the i-th cycle, representing the control quantity at the next moment that will minimize long-term costs under predicted future operating conditions. For example, the algorithm might calculate that to offset an increase in steam load, it is more economical to slightly increase the spray volume (with a small increase in water consumption) than to drastically increase the variable frequency fan speed (which would lead to a dramatic increase in power consumption).

[0087] The control equipment calculates the spray water flow rate setpoint and the cooling air flow rate setpoint based on the following relationship:

[0088]

[0089] =

[0090]

[0091] In the formula, Indicates the first NP represents the number of predicted periods (meaning how many periods to predict). and As a weighting factor, It can be set to 1.5–5. It can be set to 0.5–1.5; a biobjective function. It is a calculated value; Indicates the first Predict the outlet temperature of chilled wine in one cycle. yes and The function; Indicates the first Predicted wind turbine power values ​​for each cycle; Indicates the first Predict spray water flow rate for each cycle; Indicates the first Predict spray water flow rate for each cycle; The price is per unit of electricity, expressed in yuan / kWh. The price is per unit of water, expressed in yuan per ton. Indicates the first Cooling airflow setpoint for each cycle Indicates the first The set value of the spray water flow rate for each cycle; Indicates the first The control input for a cycle-controlled variable frequency fan can be selected as frequency or speed. Indicates the first The control input of the spray water control valve for each cycle is the opening degree; the constraints of this formula include: equipment limits (such as the maximum air volume of the variable frequency fan), process safety (temperature upper and lower limits), dynamic change rate limits, etc.

[0092] Under the "spray evaporation cooling operation mode," the system faces a complex optimization problem involving multiple variables, strong coupling, and multiple objectives: the dual objective function must simultaneously determine the combination of "how much air" and "how much water" to just meet the cooling target. At the same time, reduce the total operating cost ( The lowest possible value is achieved. To address this issue, a "rolling optimization" approach is applied to the "bi-objective function".

[0093] The power of the variable frequency fan 15 corresponds to a corresponding airflow rate, and the cooling airflow rate is also related to... Correspondingly, the cooling airflow setting value is the same as... The transformation relationship is denoted as = The corresponding spray water flow rate setpoint corresponds to the corresponding spray water control valve opening, and the conversion relationship is as follows: The specific determination depends on the spray water control valve 20 and the variable frequency fan 15 used; the corresponding relationship is preset in the control computer 2, and after solving using a dual objective function, the control computer 2 automatically solves for... In short, the control computer 2 calculates the optimal cooling airflow setpoint in real time. and spray water flow rate setting value The control computer 2 sends the calculation result to the centralized acquisition / drive 3, which generates a "distributed control command" to drive the spray water control valve and the variable frequency fan to execute. The "distributed control command" includes the first control command, the second control command, and the third control command.

[0094] Under the "spray evaporation cooling operation mode", the optimization process is as follows: the algorithm predicts the temperature trajectory over a future period of time, and meets the following conditions... Under the constraints, find a set of optimal control sequences. This minimizes the total operating cost. In other words, the algorithm searches for the optimal ratio of airflow to water flow in each control cycle. For example, when natural wind (chimney effect) is strong, the algorithm automatically reduces the variable frequency fan speed; when a small amount of mist can significantly reduce the huge power consumption caused by the high speed of the variable frequency fan, the algorithm will choose to activate a micro-mist. This global optimization ensures that the system always operates at the point of highest coefficient of performance (COP).

[0095] Energy and water conservation are reflected in the algorithm's automatic utilization of physical characteristics. For example, when it detects high chimney draft, it reduces the inverter fan's commands; when it calculates that a small amount of water mist evaporation can replace a significant increase in air volume (the inverter fan's power is proportional to the cube of its rotational speed), it reduces the inverter fan's commands. When the device is in use, it will activate a micro-spray function to save a significant amount of energy. This ensures that every drop of water and every unit of electricity is used effectively.

[0096] In this example, when the "dry energy-saving cooling operation mode" is selected, the spray water control valve 20 is closed, i.e., the spray water flow rate is set to the specified value. =0, the spray cooling system is not working, resulting in zero water consumption; all parameters related to the spray cooling system in the dual objective function are zero. This invention employs a "cascade control" strategy, one of which uses the outlet temperature deviation ( The "external loop" controller, acting as the input, calculates the set value of the cooling airflow. ; and an "internal loop" controller that adjusts the variable frequency fan to track the cooling airflow setpoint.

[0097] Based on the outlet temperature deviation, the required cooling airflow setpoint Fair_sp(k+1) is calculated using the PID formula, specifically:

[0098]

[0099] In the formula, The outlet temperature deviation at time k is obtained through preprocessing, and the PID parameters are pre-tuned control parameters. This will be directly used as the setpoint for the central processing unit / drive 3 (Level 1). The PID loop of the central processing unit / drive 3 (Level 1) will be responsible for setting the actual cooling airflow. Track this setting.

[0100] The "inner loop" controller can employ a discrete PID (proportional-integral-derivative) algorithm, and its control increment... The calculation is as follows:

[0101]

[0102] In the formula, for The deviation of the outlet temperature at any given time, for The outlet temperature deviation at time -1 for The outlet temperature deviation at time -2 These are proportional, integral, and differential gains, respectively.

[0103] Compared to traditional fixed-speed fans, variable frequency control outputs linearly according to the actual heat load, avoiding the power loss caused by "overpowering a small load".

[0104] This invention achieves dual optimization of "water saving" and "energy saving" in the cooling process through innovative hardware structure design and deep coupling of control methods.

[0105] like Figure 6 As shown, in order to fully utilize the energy-saving and water-saving potential of the aforementioned hardware, this invention constructs a multivariable hierarchical control architecture system based on the aforementioned device and control method. This architecture draws on the standard Pudu model of industrial control, decoupling the control task into three logical layers to ensure the system's real-time performance, reliability, and optimization capabilities. Specifically, the architecture system is decoupled into three logical layers as follows:

[0106] Level 0 of the field device layer contains the hardware that constitutes the physical process. This includes all sensors (such as multi-point temperature sensor 6, single-point temperature sensor, air flow meter 13, liquid flow meter 21, and temperature / humidity sensor 9) and all final actuators (such as variable frequency fan 15, spray water control valve 20, and alcohol vapor flow control valve 29). In short, the field device layer is for sensing and execution. This layer is the direct interface to the physical process, responsible for the raw data acquisition and physical execution of actions. Sensors are the data foundation for achieving water and energy conservation; all actuators have continuous adjustment capabilities, rather than simple on / off control.

[0107] Level 1 (Integrated Acquisition / Driver 3): This layer includes I / O modules for programmable logic controllers (PLCs) or distributed control systems (DCS), variable frequency drive (VFD) drivers, valve positioners, etc. This layer is responsible for performing "fast" and "simple" tasks, as well as "fast and accurate" closed-loop control. Level 1 receives setpoints from Level 2 and adjusts the actuators of Level 0 through a high-speed PID loop to eliminate local nonlinear errors. For example, when Level 2 issues an airflow rate of 5000 m³ / h... 3When the command " / h" is executed, the Level 1 controller reads the data from the air flow meter 13 in real time and adjusts the frequency of the variable frequency fan in milliseconds. If the variable frequency fan speed decreases due to voltage fluctuations, Level 1 will compensate immediately without the need for Level 2 intervention. This layer ensures the full execution of energy-saving commands.

[0108] Taking airflow control as an example: Level 1 reads the current actual airflow F air (From air flow meter 13, now updated to a value close to time k+1), and the cooling air flow setpoint F. air_sp In comparison, by using high-speed PID calculations, the operating frequency of the variable frequency fan 15 is adjusted in real time, driving the actual air volume to approach the set value.

[0109] Execution effect: In the next control cycle, the actuator's actions will cause F air F water As the actual parameters gradually reach their set values, they will then affect... At the next data collection time (k+1), the new... It will be measured, thus initiating a new round of optimization.

[0110] Level 2 (Brain and Decision-Making): Corresponding to the control computer 2 described in this invention, this is the runtime environment for the core intelligent algorithms of this invention. It does not directly operate the hardware but performs complex calculations and decisions based on global data. It communicates with Level 1 via an industrial bus (such as Profinet or Modbus TCP) to issue "setpoints" for supervision and control. This layer is responsible for executing "slow" but "intelligent" computationally intensive tasks. Internally, it runs a "multi-parameter state recognition algorithm," a "multi-objective optimization MPC algorithm," and a "distributed heat load balancing algorithm." These algorithms calculate the optimal operating parameters of the system based on real-time electricity prices, water prices, weather conditions, and production load. The core algorithms of this invention run at this layer, including:

[0111] Status recognition module: used to select the current optimal operating mode between "dry energy-saving cooling operation mode" and "spray evaporation cooling operation mode" in step S2 of the above-mentioned control method for a water-saving and energy-saving heat exchange device for the sauce-flavor liquor industry, that is, to complete the execution mode switching logic;

[0112] Phased prediction and optimization module: Used to perform multi-objective optimization calculations for the "dry energy-saving cooling operation mode" or "spray evaporation cooling operation mode" in step S2 of the above-mentioned control method for a water-saving and energy-saving heat exchange device for the sauce-flavor liquor industry.

[0113] Distributed load balancing module: Includes a heat load balancing algorithm, which is used to calculate the energy consumption model of variable frequency fans in a bi-objective function. It includes a natural convection compensation term, which calculates the natural lift force based on the density difference of hot air in the chimney. The control system then reduces the output frequency of the variable frequency fan accordingly to achieve passive energy saving.

[0114] The present invention has the following beneficial effects:

[0115] ① Significant water saving: Compared with traditional water cooling, this system adopts a strategy of "dry air cooling as the main method and spray evaporation as a supplement," which can reduce the cooling water quota for Maotai liquor production by more than 90%, and there is no cooling wastewater discharge, solving the industry's environmental pain point; ② Deep energy saving: Combining the enhanced heat transfer of the periodic variable diameter pipe, the natural draft of the chimney, and the energy consumption optimization of the MPC algorithm, the system's power consumption is significantly reduced compared with traditional forced air cooling, achieving high efficiency and low carbon emissions in the heat exchange process; ③ Precise control and quality improvement: Eliminating the impact of environmental interference and load fluctuations, the temperature control accuracy of the liquor outlet is high, eliminating "gas leakage and liquor runoff," and improving the yield of premium liquor; ④ Strong applicability: The device has a compact structure and flexible control, meeting the energy-saving standards of newly built factories and facilitating the green transformation of old workshops.

[0116] The hierarchical architecture system constructed in this invention utilizes a multi-parameter state recognition algorithm to monitor ambient temperature and humidity and liquor vapor load in real time, enabling intelligent switching between two operating modes: "dry energy-saving cooling" (zero water consumption) and "spray water-saving evaporative cooling" (minimum water consumption). In spray mode, the system employs a model predictive control (MPC) strategy, performing rolling optimization based on a dual objective function to dynamically adjust the ratio of variable frequency fan speed to spray flow rate. This ensures that the liquor outlet temperature accurately meets the standard while minimizing the system's overall energy consumption (electricity and water consumption). Furthermore, the system introduces distributed heat load balancing control, eliminating local hot spots and uneven cooling by independently adjusting the steam flow rate of each heat exchanger tube 25. This invention achieves inherent safety, deep water conservation, and extreme energy saving in the cooling process of sauce-flavored liquor production.

[0117] The entire system forms a closed loop of "measurement → evaluation → prediction → optimization → execution → remeasurement":

[0118] 1. Measurement (time k): Obtain the current real state of the system and environment.

[0119] 2. Assessment and Forecasting: Assess current costs and forecast future dynamics based on the model.

[0120] 3. Optimization (k+0.3s~0.8s): Based on the prediction, the optimal control action is solved with the objective of minimizing the total future cost. The optimization is based on the current and predicted environmental parameters (k+0.3s~0.8s). ), process status ( ) and economic parameters ( ).

[0121] 4. Execution (starting from time k+1): Implement the optimized "optimal settings".

[0122] 5. Feedback: The effect of the execution is reflected in the measurement value at the next sampling time, thereby correcting the prediction error of the model and starting a new round of optimization.

[0123] This rolling optimization mechanism enables the system to continuously adapt to environmental changes and process fluctuations, always dynamically maintaining itself at the Pareto optimal frontier of "precise temperature control" and "lowest operating cost," thereby achieving the "deep water saving" and "ultimate energy saving" claimed in the patent.

[0124] To visually demonstrate the technical advantages of this invention, the following table compares the key performance indicators of this invention with those of existing technologies:

[0125] Table 1: Comparison of Key Performance Indicators of the Invention and Existing Technologies in the Baijiu Industry

[0126] Main cooling medium water Air Air + a small amount of water mist It combines the convenience of air cooling with the high efficiency of water cooling. Water consumption (m³ / ton of wine) 50～60 0 <5 (Summer use only) Water saving rate >90%, meets water saving requirements Wastewater discharge Large quantities (high COD) none None (total evaporation) Completely solve environmental pollution problems Power consumption level Medium (water pump constant) High (forced variable frequency fan) Low (inverter + natural wind + phase change) Energy saving rate >25%, meets energy saving requirements Temperature control accuracy Low (manually adjusted) Extremely low (highly affected by environmental factors) High (±1°C, MPC control) Eliminate wine evaporation and increase the rate of premium wine. Summer Operational Stability Stablize Poor quality (easily leaks out) Extremely high (spray compensation) Solving the industry pain point of air-cooled systems struggling to survive the summer Heat exchanger structure Ordinary tube Standard tube / finned tube Periodic variable diameter cyclone tube Enhance heat transfer coefficient and reduce equipment size

[0127] In summary, this invention constructs a hardware foundation that meets the standards of an "energy-saving heat exchange device" through the physical integration of a "periodic variable diameter swirl heat exchange tube" and the "chimney effect"; and achieves an operational logic that meets the standards of an "industrial water-saving special equipment" through the algorithm integration of "multi-parameter state recognition" and "multi-objective optimization MPC". This system not only significantly reduces resource consumption in the production of Maotai-flavor liquor, achieving water and energy conservation, but also improves the level of intelligent production, possessing extremely high promotional value.

[0128] The above embodiments are merely illustrative of the principles and effects of the present invention and are not intended to limit the invention. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in the present invention should still be covered by the claims of the present invention.

[0129] It should be noted that the illustrations provided in this embodiment are only schematic representations of the basic concept of the present invention. Therefore, the drawings only show units relevant to the present invention and are not drawn according to the actual number, shape, and size of units in implementation. In actual implementation, the form, quantity, and proportion of each unit can be arbitrarily changed, and the unit layout may be more complex. The structures, proportions, and sizes shown in the accompanying drawings are only for illustrative purposes to aid those skilled in the art and are not intended to limit the implementation conditions of the present invention. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in proportions, or adjustments to the size, without affecting the effects and objectives of the present invention, should still fall within the scope of the technical content disclosed in the present invention. Furthermore, the terms such as "upper," "lower," "left," "right," "middle," and "one" used in this specification are only for clarity of description and are not intended to limit the scope of the present invention. Changes or adjustments to their relative relationships, without substantially altering the technical content, should also be considered within the scope of the present invention.

Claims

1. A control method for a water-saving and energy-efficient heat exchange device used in the sauce-flavored liquor industry, characterized in that, A water-saving and energy-efficient heat exchange device is adopted, which includes: The system comprises a condenser, an air guide column, and heat exchange tubes. Both the air guide column and the heat exchange tubes are vertically arranged within the condenser. The heat exchange tubes are generally spiral-shaped, with their swirl radius varying periodically. The air guide column is located in the middle of the heat exchange tubes, and its lower end is equipped with air guide vanes positioned below the heat exchange tubes. The condenser has an air inlet and a drain outlet at its lower end, and an exhaust outlet at its top. A cooling water spray component is installed inside the condenser, located in the lower middle part of the heat exchange tubes. The upper end of the heat exchange tubes is connected to a wine vapor input pipe, and the lower end is connected to a cooled wine discharge pipe. The method includes: S1: The control equipment acquires ambient temperature, ambient humidity, cool wine outlet temperature, cooling air flow rate, spray water flow rate, and average temperature inside the heat exchange tube; S2: The ambient temperature Compared with a first preset temperature threshold, the ambient humidity Compared with a first preset humidity threshold, if and only if the ambient temperature Greater than the first preset temperature threshold And the ambient humidity Less than the first preset humidity threshold When necessary, the spray evaporative cooling mode is used; otherwise, the dry energy-saving cooling mode is used. The spray evaporation cooling operation mode is as follows: the control equipment solves for the spray water flow rate setpoint and the cooling air flow rate setpoint; based on the cooling air flow rate setpoint, a first control command is generated to control the change in the air volume of the variable frequency fan; based on the spray water flow rate setpoint, a second control command is generated to control the opening of the spray water control valve; at the same time, the control equipment generates a third control command to control the opening of the vapor flow control valve based on the average temperature inside the heat exchange tube. The dry energy-saving cooling operation mode is as follows: the control equipment solves the cooling air flow setpoint, and generates the first control command for controlling the fan based on the cooling air flow setpoint; at the same time, the control equipment generates the third control command for controlling the opening of the vapor flow control valve based on the average temperature inside the heat exchange tube. The control equipment calculates the spray water flow rate setpoint and the cooling air flow rate setpoint based on the following relationship: In the formula, and As a weighting factor, Set to 1.5–5, Set it to 0.5–1.5; Indicates the first NP represents the number of predicted periods; biobjective function It is a calculated value; Indicates the first Predict the outlet temperature of chilled wine for each cycle. yes and The function; Indicates the first Predicted wind turbine power values ​​for each cycle; Indicates the first Predict spray water flow rate for each cycle; The price is per unit of electricity, expressed in yuan / kWh. The price is per unit of water, expressed in yuan per ton. Indicates the first Cooling airflow setpoint for each cycle Indicates the first The set value of the spray water flow rate for each cycle; Indicates the first The control input for a cycle-controlled variable frequency fan is either frequency or speed. Indicates the first The control input for the spray water control valve in each cycle is specifically the opening degree; Predicting the next Np periods under different control sequences Next, find the objective function. Minimum optimal sequence , It is the first The optimal result for each cycle; S3: Repeat steps S1 and S2.

2. The control method for a water-saving and energy-efficient heat exchange device used in the sauce-flavored liquor industry according to claim 1, characterized in that, It also includes a steam distributor; there are multiple heat exchange tubes with different swirl radii, and the multiple heat exchange tubes are arranged side by side with a gap between adjacent heat exchange tubes; the number of wine steam input pipes is the same as the number of heat exchange tubes and they correspond one-to-one, and the steam distributor is connected to each of the multiple wine steam input pipes.

3. The control method for a water-saving and energy-efficient heat exchange device used in the sauce-flavored liquor industry according to claim 2, characterized in that, It also includes control equipment and temperature / humidity sensors. Each wine vapor input pipe is equipped with a wine vapor flow control valve, each heat exchange pipe is equipped with a multi-point temperature sensor, and the cooling wine discharge pipe is equipped with a single-point temperature sensor. The air inlet is connected to a variable frequency fan, and an air flow meter is installed on the pipe connecting the air inlet and the variable frequency fan. The inlet of the cooling water spray component is connected to a water pump, and a spray water control valve and a liquid flow meter are installed on the pipe connecting the cooling water spray component and the water pump. The control equipment is electrically connected to the wine vapor flow control valve, the multi-point temperature sensor, the single-point temperature sensor, the air flow meter, the variable frequency fan, the spray water control valve, the liquid flow meter, and the temperature / humidity sensor, respectively.

4. The control method for a water-saving and energy-efficient heat exchange device used in the sauce-flavored liquor industry according to claim 1, characterized in that, The cooling water spray component includes a water inlet pipe and an annular nozzle. The annular nozzle is equipped with multiple high-pressure micro-mist nozzles, and the air guide column is vertically arranged in the middle of the inner ring of the annular nozzle.

5. The control method for a water-saving and energy-efficient heat exchange device used in the sauce-flavored liquor industry according to claim 1, characterized in that, There are multiple air guide vanes, and each air guide vane is a turbine blade.

6. The control method for a water-saving and energy-efficient heat exchange device used in the sauce-flavored liquor industry according to claim 5, characterized in that, The upper and lower ends of the air guide column are both conical structures.

7. The control method for a water-saving and energy-efficient heat exchange device used in the sauce-flavored liquor industry according to claim 1, characterized in that, It also includes an exhaust chimney, which is connected to the exhaust port.

8. The control method for a water-saving and energy-efficient heat exchange device used in the sauce-flavored liquor industry according to claim 1, characterized in that, The condenser tank is equipped with a maintenance and dust removal port, which is fitted with a removable sealing cover.

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