A multi-layer reuse energy-saving and consumption-reducing system for a cooling tower water collector

Abstract

This invention belongs to the technical field of energy conservation and water resource recycling in industrial circulating water systems. It provides a multi-layered, multi-functional, energy-saving cooling tower water collector system, comprising a cooling tower body, a circulating water spray device, a packing layer, and a water collection system. The water collection system is a multi-layered composite structure, consisting of a primary heat recovery water collection layer, a secondary water pretreatment water collection layer, and a tertiary high-efficiency separation water collection layer, arranged sequentially from top to bottom. These three water collection layers are sealed to the inner wall of the cooling tower body, forming a stepped water vapor treatment channel. The side wall of the cooling tower body is equipped with corresponding functional interfaces for each water collection layer. An intelligent control system and a waste heat recovery heat exchanger are located at the bottom of the cooling tower body. This system is compact, highly adaptable, and can be used for the renovation of existing cooling towers and new construction projects in industries such as steel, chemical, and power. It operates stably, is easy to maintain, and has outstanding energy-saving and consumption-reducing effects, making it highly valuable for industrial promotion.

Description

Technical Field

[0001] This invention belongs to the field of energy conservation and consumption reduction and water resource recycling technology of industrial circulating water systems. It involves the optimization of cooling towers in high water and energy consumption scenarios such as steel and the transformation of cooling towers in water treatment and process cooling scenarios. Specifically, it is a multi-layer reuse energy conservation and consumption reduction system for cooling tower water collectors. Background Technology

[0002] As a core component of industrial circulating water systems, cooling towers primarily cool circulating water through water vapor evaporation. Their operating efficiency directly impacts the energy and water consumption of the entire production system. Water collectors are crucial components of cooling towers, their core function being to separate water vapor from the circulating water, reducing water loss. However, existing cooling tower water collectors suffer from the following technical deficiencies: 1. Single function: It only focuses on water vapor separation and does not recover and utilize the heat carried by the circulating water. A large amount of high-temperature waste heat is directly emitted into the atmosphere, resulting in energy waste. 2. Insufficient water resource recovery: The water collector only separates water and does not pre-treat suspended solids, scale and other impurities in the circulating water. The quality of the recovered water is poor, and additional chemicals are required for purification, which increases operating costs. In addition, impurities are easy to adhere to the surface of the water collector, reducing water collection efficiency. 3. High energy consumption: Traditional water collectors have high resistance, which causes the cooling tower fan to consume more electricity to maintain ventilation. In addition, the recovered water cannot be directly reused in the circulating water system, resulting in a large amount of water replenishment, which further increases the operating energy and water consumption. 4. Poor adaptability: Most existing water collectors are single-layer structures, which cannot be flexibly adjusted according to the operating conditions such as circulating water quality and water temperature, making it difficult to meet the energy-saving and consumption-reducing needs of different industrial scenarios.

[0003] To address the aforementioned issues, there is an urgent need to design a functionally integrated, multi-layered water collector structure that can ensure effective water vapor separation while simultaneously achieving heat recovery, water pretreatment, and water resource recycling, thereby reducing the energy and water consumption of cooling towers. Summary of the Invention

[0004] The purpose of this invention is to provide a multi-layer reuse energy-saving and consumption-reducing system for cooling tower water collectors. Through the functional integration of a three-layer composite water collection structure, it solves the problems of traditional water collectors having single functions, serious waste of energy and water resources, and high energy consumption.

[0005] The technical solution adopted by the present invention to achieve the above objectives is: A multi-layer reuse energy-saving and consumption-reducing system for cooling tower water collectors includes a cooling tower body, a circulating water spray device, a packing layer, and a water collection system. The water collection system is a multi-layer composite structure, consisting of a primary heat recovery water collection layer, a secondary water pretreatment water collection layer, and a tertiary high-efficiency separation water collection layer, arranged sequentially from top to bottom. The three water collection layers are sealed to the inner wall of the cooling tower body, forming a stepped water vapor treatment channel. The side wall of the cooling tower body is equipped with corresponding functional interfaces for each water collection layer, realizing heat export, impurity cleaning, and water reuse. The lower part of the cooling tower body is equipped with an intelligent controller for controlling the operation of the system and a waste heat recovery heat exchanger for collecting and utilizing waste heat.

[0006] The primary heat recovery water collection layer has the core function of recovering waste heat from high-temperature water vapor. It uses a metal corrugated plate with excellent thermal conductivity (such as modified 304 stainless steel) and a surface coated with an anti-corrosion coating to prevent corrosion from circulating water. The metal corrugated plate has a micro heat conduction channel inside, which is connected to the external waste heat recovery heat exchanger. When high-temperature water vapor flows through, the heat is conducted to the heat exchanger through the heat conduction channel for preheating production water or heating, realizing the utilization of waste heat resources and reducing additional heating energy consumption.

[0007] The secondary water pretreatment water collection layer focuses on optimizing the quality of the recycled water. It uses a modified PVC corrugated plate with a composite nano-filtration membrane to intercept suspended solids, scale particles and other impurities in the circulating water, preventing impurities from entering the subsequent circulation system and causing scaling and blockage of the equipment. A removable impurity collection box is installed below, which can be cleaned regularly through the impurity collection drawer. Maintenance can be carried out without stopping the machine, ensuring the continuous and efficient operation of the water collection layer.

[0008] The three-stage high-efficiency separation and water collection layer: As the core water collection link, it adopts a honeycomb S-shaped guide channel water collection plate with a hydrophilic coating on the inner wall to improve the water vapor adsorption and separation efficiency and reduce water drift loss; the bottom arc-shaped guide channel guides the separated recycled water into the guide pipe, and the water quality detection sensor on the guide pipe monitors the water quality in real time. Qualified recycled water is directly reused in the circulating water spray device, and unqualified water is introduced into the pretreatment unit to reduce the amount of water replenishment and chemical consumption.

[0009] The intelligent controller collects data such as water temperature, water quality, and flow rate through sensors, and automatically adjusts the spacing between layers, fan speed, and flow control valve opening to avoid ineffective energy consumption, adapt to energy-saving requirements under different operating conditions, and improve the level of intelligent operation.

[0010] The beneficial effects of this invention are: 1. Significant energy-saving effect: The primary heat recovery water collection layer can recover high-temperature water vapor waste heat, reducing the preheating energy consumption of the production system. Actual tests have shown that it can reduce the energy consumption of the cooling tower-related system by 15%-25%; at the same time, the optimized water collection layer resistance design reduces the fan energy consumption by 8%-12%.

[0011] 2. Significant cost reduction: The three-stage water collection structure works synergistically to reduce the drift loss rate from the traditional 0.3%-0.5% to below 0.05%, increase the reuse rate of recycled water to over 90%, and significantly reduce the amount of make-up water; the secondary pretreatment reduces the amount of circulating water chemicals added by 30%-40%, thus reducing operating costs.

[0012] 3. Functional integration: The system integrates three major functions: heat recovery, water pretreatment, and water vapor separation, avoiding the structural complexity caused by the superposition of single equipment. It is highly compact and adaptable to the renovation of existing cooling towers (without major changes to the main structure) and new construction scenarios, with short renovation cycle and low cost.

[0013] 4. Easy maintenance: Each water collection layer component is detachable and easy to clean. The impurity collection box and the recycled water guide pipe are designed with convenient maintenance structure, reducing downtime for maintenance and improving the operational stability of the cooling tower. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the cross-sectional structure of the primary heat recovery water collection layer in this invention; Figure 3 This is a partial structural diagram of the secondary water pretreatment water collection layer in this invention; Figure 4 This is a schematic diagram of the three-stage high-efficiency separation water collection layer guide channel structure in this invention.

[0015] In the diagram: 1. Cooling tower body; 2. Circulating water spray device; 3. Packing layer; 4. Primary heat recovery water collection layer; 4-1. Corrugated metal plate; 4-2. Micro heat conduction channel; 4-3. Heat export interface; 5. Secondary water pretreatment water collection layer; 5-1. PVC corrugated plate; 5-2. Impurity collection box; 5-3. Impurity collection drawer; 6. Tertiary high-efficiency separation water collection layer; 6-1. Honeycomb PVC water collection plate; 6-2. S-shaped guide channel; 6-3. Arc-shaped guide groove; 6-4. Recovered water guide pipe; 7. Intelligent controller; 8. Waste heat recovery heat exchanger. Detailed Implementation

[0016] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings and actual industrial scenarios: A multi-layer reuse energy-saving and consumption-reducing system for cooling tower water collectors, such as Figure 1As shown, the system includes a cooling tower body 1, a circulating water spray device 2, a packing layer 3, and a water collection system. The water collection system is a multi-layer composite structure, consisting of a primary heat recovery water collection layer 4, a secondary water pretreatment water collection layer 5, and a tertiary high-efficiency separation water collection layer 6, arranged sequentially from top to bottom. The three layers of the water collection system are coaxial and sealed to the inner wall of the cooling tower body 1, forming a stepped water vapor treatment channel. The side wall of the cooling tower body 1 is equipped with corresponding functional interfaces for each water collection layer, realizing heat export, impurity cleaning, and water recycling.

[0017] Primary heat recovery water collection layer 4, such as Figure 2 As shown, its core function is to recover waste heat from high-temperature water vapor. It uses a metal corrugated plate 4-1 with excellent thermal conductivity (such as modified 304 stainless steel) with an anti-corrosion coating to prevent corrosion from circulating water. The two layers of metal corrugated plates are embedded with micro heat conduction channels 4-2. The two ends of the micro heat conduction channels 4-2 are sealed and connected to the heat outlet interface 4-3. The distance between the two layers of metal corrugated plates is 8-12mm, and the corrugation angle of the corrugated plates is 30-45°. The heat outlet interface 4-3 is connected to the external waste heat recovery heat exchanger. When high-temperature water vapor flows through, the heat is conducted to the heat exchanger through the micro heat conduction channels 4-2 and the heat outlet interface 4-3 for preheating production water or heating, realizing the utilization of waste heat resources and reducing additional heating energy consumption.

[0018] Secondary water pretreatment water collection layer 5 focuses on optimizing the quality of recycled water, such as... Figure 3 As shown, the modified PVC corrugated plate 5-1 uses a composite nanofiltration membrane. The surface of the composite nanofiltration membrane has a pore size of 5-10μm, which is used to intercept suspended solids, scale particles and other impurities in the circulating water, preventing impurities from entering the subsequent circulation system and causing scaling and blockage of the equipment. A detachable impurity collection box 5-2 is provided below. The impurity collection box 5-2 is snapped into the impurity collection drawer 5-3 on the side wall of the cooling tower, which can realize quick cleaning and maintenance without stopping the machine, ensuring the continuous and efficient operation of the water collection layer.

[0019] The three-stage high-efficiency separation and water collection layer 6 serves as the core water collection link, such as... Figure 4 As shown, a honeycomb PVC water collection plate 6-1 is used, with an S-shaped guide channel 6-2 inside. The inner wall of the S-shaped guide channel 6-2 is coated with a polyethylene glycol modified acrylate hydrophilic coating to improve the water vapor adsorption and separation efficiency and reduce water drift loss. The bottom arc-shaped guide groove 6-3 guides the separated recycled water into the recycled water guide pipe 6-4. The water quality detection sensor on the recycled water guide pipe 6-4 monitors the water quality in real time. Qualified recycled water flows into the main recycled guide pipe and is directly reused in the circulating water spray device 2. Unqualified water is introduced into the pretreatment unit to reduce the amount of makeup water and the consumption of chemicals.

[0020] A spacing adjustment mechanism is installed between the three water collection layers, with an adjustment range of 15-30cm. It can be flexibly adjusted according to the circulating water volume and water vapor temperature to adapt to different working conditions.

[0021] The system also includes an intelligent controller 7, which is electrically connected to a water quality sensor, a temperature sensor, a flow sensor, a flow control valve, a waste heat recovery heat exchanger, and a cooling tower fan. The intelligent controller 7 collects data such as water temperature, water quality, and flow rate through the sensors, and automatically adjusts the spacing between the layers, the fan speed, and the opening of the flow control valve to avoid ineffective energy consumption, adapt to the energy-saving requirements under different operating conditions, and improve the level of intelligent operation.

[0022] The intelligent controller 7 also has parameter adjustment, alarm, and flow path switching functions. When the water quality exceeds the standard, it will automatically alarm and switch the recovery water path, which is an important guarantee for the safe operation of the cooling tower water collector.

[0023] The working process of this system is as follows: After the circulating water is atomized by the spray device 2, it flows through the circulating water spray packing layer 3 for initial cooling, and the high-temperature water vapor enters the water collection system downwards. Water vapor first enters the primary heat recovery water collection layer 4, where the metal corrugated plate 4-1 absorbs the heat of the water vapor and conducts it through the internal heat conduction channel 4-2 to the heat outlet interface 4-3. The external waste heat recovery heat exchanger 8 is then connected to preheat the water supply for steel rolling production, increasing the water supply temperature by 15-20℃ and reducing boiler heating energy consumption. After cooling, the water vapor enters the secondary water pretreatment water collection layer 5. The corrugated filter plate 5-1 traps impurities such as iron oxide scale and water scale particles in the water vapor. The impurities fall into the impurity collection box 5-2 below. The impurity collection drawer 5-3 is cleaned once a month to prevent impurities from clogging the subsequent channels. The pretreated water vapor enters the three-stage high-efficiency separation water collection layer 6. The S-shaped guide channel 6-2 extends the water vapor residence time. The hydrophilic coating adsorbs water to form water droplets, which flow into the recovery water guide pipe 6-4 through the arc-shaped guide channel 6-3. After the water quality detection sensor detects that it is qualified, it is directly transported to the circulating water spray device 2 for reuse. If it is unqualified, it is introduced into the emergency pretreatment tank. The intelligent controller 7 collects data from various sensors in real time. When the temperature of the circulating water rises, it automatically increases the opening of the heat export interface valve and increases the fan speed to ensure cooling and waste heat recovery efficiency. When the water quality exceeds the standard, it issues an alarm signal and switches the recovery water diversion path to ensure that the circulating water quality meets the standard.

[0024] After application testing in a steel rolling mill water treatment cooling tower, the structure reduced cooling tower fan energy consumption by 10%, water replenishment by 85%, circulating water agent cost by 35%, and waste heat recovery to meet 60% of the workshop's daily heating needs. The energy-saving and consumption-reducing effects are significant and it is fully adapted to the needs of industrial high water and energy consumption scenarios.

[0025] The above embodiments are merely preferred embodiments of the present invention. Those skilled in the art can adjust the water collection layer spacing, corrugated plate parameters, etc., according to the operating conditions of cooling towers in different industries, all of which fall within the protection scope of the claims of the present invention.

Claims

1. A multi-layer reuse energy-saving and consumption-reducing system for cooling tower water collectors, characterized in that: The system includes a cooling tower body, a circulating water spray device, a packing layer, and a water collection system. The water collection system is a multi-layered composite structure, consisting of a primary heat recovery water collection layer, a secondary water pretreatment water collection layer, and a tertiary high-efficiency separation water collection layer, arranged from top to bottom. The three water collection layers are sealed to the inner wall of the cooling tower body, forming a stepped water vapor treatment channel. The side wall of the cooling tower body is equipped with corresponding functional interfaces for each water collection layer, and an intelligent controller and a waste heat recovery heat exchanger are installed at the bottom of the cooling tower body.

2. The multi-layer reuse energy-saving and consumption-reducing system for cooling tower water collectors according to claim 1, characterized in that: The primary heat recovery water collection layer uses a metal corrugated plate with excellent thermal conductivity. The metal corrugated plate has a micro heat conduction channel inside, which is connected to the external waste heat recovery heat exchanger. When high-temperature water vapor flows through it, the heat is conducted to the heat exchanger through the heat conduction channel.

3. The multi-layer reuse energy-saving and consumption-reducing system for cooling tower water collectors according to claim 2, characterized in that: The surface of the corrugated metal plate is coated with an anti-corrosion coating.

4. The multi-layer reuse energy-saving and consumption-reducing system for cooling tower water collectors according to claim 1, characterized in that: The secondary water pretreatment water collection layer uses a modified PVC corrugated plate with a composite nanofiltration membrane to trap impurities in the circulating water, and a detachable impurity collection box is provided below.

5. A multi-layer reuse energy-saving and consumption-reducing system for cooling tower water collectors according to claim 1, characterized in that: The three-stage high-efficiency separation and water collection layer adopts a honeycomb PVC water collection plate with an S-shaped flow channel inside. The bottom arc-shaped flow channel guides the separated recycled water into the flow pipe. The water quality detection sensor on the flow pipe monitors the water quality in real time. Qualified recycled water is directly reused in the circulating water spray device, while unqualified water is introduced into the pretreatment unit to reduce the amount of water replenishment and chemical consumption.

6. A multi-layer reuse energy-saving and consumption-reducing system for cooling tower water collectors according to claim 5, characterized in that: The inner wall of the S-shaped flow channel is coated with a polyethylene glycol-modified acrylate hydrophilic coating.

7. A multi-layer reuse energy-saving and consumption-reducing system for cooling tower water collectors according to claim 1, characterized in that: The intelligent controller collects water temperature, water quality, and flow data through sensors, and automatically adjusts the spacing between layers, fan speed, and flow control valve opening to adapt to energy-saving requirements under different operating conditions.

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