Primary cooling normal temperature water source pre-cooling energy saving device

Abstract

The application provides a normal-temperature water source pre-cooling energy-saving device for one-time cooling, which comprises a high-temperature medium inlet pipeline for inputting high-temperature constant medium, a plate heat exchanger for receiving and pre-cooling the high-temperature constant medium, a cooling water loop for taking away the heat in the plate heat exchanger through cooling water circulation, a cooling water flow control valve for adjusting the cooling water flow to control the heat exchange efficiency of the plate heat exchanger and the pre-cooling degree of the high-temperature constant medium, a high-temperature medium one-way valve for controlling the flow direction of the high-temperature constant medium to prevent the high-temperature constant medium from flowing back to the plate heat exchanger from the medium outlet pipeline, and a high-temperature medium outlet pipeline for outputting the pre-cooled high-temperature constant medium. The device uses normal-temperature cooling water to pre-cool the high-temperature constant medium in one stage, and then enters a compressor system for secondary cooling, thereby avoiding the direct operation of the compressor in the high-temperature section. The application solves the problems of the existing cooling scheme, such as compressor overload, low cooling efficiency, high energy consumption and shortened service life.

Description

Technical Field

[0001] This invention relates to the field of cooling system technology, and in particular to an energy-saving device for pre-cooling a room-temperature water source for primary cooling. Background Technology

[0002] With the increasing demands for industrial automation and precision temperature control, high and low temperature integrated cooling and heating systems are widely used in chemical, pharmaceutical, materials testing, and semiconductor industries. These devices typically require rapid, stable, and energy-efficient temperature regulation over a wide temperature range (e.g., 200℃ to -80℃). However, traditional solutions face significant technical bottlenecks during high-low temperature switching, especially in the direct cooling process at high temperatures, which limits equipment efficiency and lifespan.

[0003] In existing technologies, the cooling path of integrated high and low temperature cooling systems is typically designed as follows: the compressor directly cools the high-temperature constant-temperature medium without any pre-cooling stage. For example, when the system needs to lower a 200°C medium to -80°C, the compressor must start cooling directly from 200°C until the set low temperature is reached. During this process, especially in the high-temperature range (e.g., >80°C), the compressor needs to operate under high load and high exhaust temperature.

[0004] The above technical solution has the following problems in actual use, as detailed below: First, compressor overload poses a risk of damage: When the compressor directly cools in the high-temperature range, its discharge pressure and discharge temperature will rise sharply, far exceeding its normal operating range. This will cause the compressor to operate under overload, with abnormally high current, and there is a risk of equipment failure or damage. Second, the cooling efficiency is low, which affects the production cycle: the entire cooling process from 200℃ to 40℃ is extremely slow, which takes up a lot of cooling time and seriously slows down the production cycle. Third, high energy consumption and low energy efficiency ratio (COP): When the system is running at high temperature, the energy consumption per unit cooling is extremely high, far exceeding the theoretical value, which can easily lead to huge energy waste. Fourth, the compressor's lifespan is shortened, and the overall cost is high: The compressor is under harsh conditions of high load, high temperature, and high pressure for a long time. The wear and aging rate of its core components is far greater than normal, resulting in a significant reduction in lifespan and a sharp increase in maintenance frequency and repair costs. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides an energy-saving device for pre-cooling a room-temperature water source for primary cooling. This device solves the problems of existing cooling solutions, such as the risk of damage caused by compressor overload, the impact on production cycle due to low cooling efficiency, high energy consumption and low energy efficiency ratio, and high overall cost due to shortened compressor life.

[0006] According to an embodiment of the present invention, a pre-cooling energy-saving device for primary cooling using ambient temperature water source includes: The high-temperature medium inlet pipe is used to input the high-temperature constant-temperature medium to be cooled. A plate heat exchanger, the hot side channel of which is connected to the inlet pipe of the constant temperature medium, is used to receive and pre-cool the high temperature constant temperature medium; The cooling water circuit includes a cooling water inlet pipe and a cooling water outlet pipe. Both the cooling water inlet pipe and the cooling water outlet pipe are connected to the cold side channel of the plate heat exchanger to form a cooling water circulation, which is used as a cooling medium to remove heat from the plate heat exchanger. A cooling water flow control valve is installed on the cooling water inlet pipe or the cooling water outlet pipe to adjust the cooling water flow rate in order to control the heat exchange efficiency of the plate heat exchanger and the pre-cooling degree of the high-temperature constant temperature medium. A high-temperature medium check valve is installed on the medium outlet pipe downstream of the plate heat exchanger to control the flow direction of the high-temperature constant temperature medium, so as to prevent the high-temperature constant temperature medium from flowing back into the plate heat exchanger from the medium outlet pipe. The high-temperature medium outlet pipeline is used to output the high-temperature constant-temperature medium after it has been pre-cooled by the plate heat exchanger; The device is configured to use ambient temperature cooling water to perform a first-stage pre-cooling of the high-temperature constant temperature medium through the plate heat exchanger, so that the high-temperature constant temperature medium is significantly reduced from its initial high temperature before entering the compressor system for a second-stage cooling, in order to avoid the compressor operating directly in the high-temperature range.

[0007] Compared with the prior art, the present invention has the following beneficial effects: By using the plate heat exchanger (hot side) to exchange heat with the cooling water circuit (cold side) before the high-temperature constant temperature medium enters the compressor system, the high-temperature constant temperature medium is pre-cooled in the first stage, which significantly reduces the temperature of the high-temperature constant temperature medium entering the compressor, thereby directly reducing the heat load on the compressor. Compared with traditional cooling schemes, this avoids the compressor from operating directly in the high-temperature range, effectively protecting the compressor and extending its service life.

[0008] By installing the cooling water flow control valve on the cooling water circuit, the heat exchange efficiency of the plate heat exchanger and the pre-cooling degree of the high-temperature constant temperature medium can be controlled by flexibly adjusting the cooling water flow. This achieves rapid and efficient heat exchange, enabling the high-temperature constant temperature medium to undergo significant cooling in a short time. Compared with traditional cooling solutions, this improves cooling efficiency and ensures production cycle time.

[0009] By using industrial water or ambient temperature cooling water provided by a cooling tower as a cold source, and removing heat through the plate heat exchanger, a first-stage pre-cooling is completed. This allows low-cost, low-energy-consumption cooling water to replace part of the high-energy-consumption compressor's work, significantly reducing the overall operating energy consumption of the system. Compared with traditional cooling solutions, this improves the energy efficiency ratio and achieves significant energy-saving effects.

[0010] By combining the precooling of the plate heat exchanger, the regulation of cooling water flow, and the anti-backflow technology of the high-temperature medium check valve, on the one hand, the operating load and frequency of the compressor are reduced, its service life is extended, and the cost of equipment replacement and maintenance is reduced; on the other hand, energy consumption is reduced and electricity costs are saved. The combined effect of these two factors significantly reduces the overall operating cost of the system. Attached Figure Description

[0011] Figure 1 This is a schematic diagram of the overall structure of a pre-cooling energy-saving device for primary cooling using ambient temperature water source, according to an embodiment of the present invention.

[0012] In the above attached diagram: 1. High-temperature medium inlet pipe; 2. Plate heat exchanger; 3. Cooling water circuit; 4. Cooling water flow control valve; 5. High-temperature medium check valve; 6. High-temperature medium outlet pipe; 7. High-temperature medium on / off valve; 8. Angle seat valve air source; 9. High-temperature medium regulating valve; 31. Cooling water inlet pipe; 32. Cooling water outlet pipe; 33. Cooling water flow switch. Detailed Implementation

[0013] The technical solutions of the present invention will be further described below with reference to the accompanying drawings and embodiments.

[0014] like Figure 1 As shown in the figure, an embodiment of the present invention proposes an energy-saving device for pre-cooling a room temperature water source for primary cooling, comprising: High-temperature medium inlet pipe 1 is used to input the high-temperature constant temperature medium to be cooled, such as 200°C high-temperature gas output from the compressor exhaust port; Preferably, a high-temperature medium on / off valve 7 and a high-temperature medium regulating valve 9 are sequentially arranged on the high-temperature medium inlet pipeline 1. The high-temperature medium on / off valve 7 and the high-temperature medium regulating valve 9 are arranged in parallel. The high-temperature medium on / off valve 7 is used to control the on / off of the high-temperature constant temperature medium, and the high-temperature medium regulating valve 9 is used to regulate the flow rate of the high-temperature constant temperature medium. The parallel arrangement of the two valves can separate the on / off and regulation functions, and finely adjust the flow ratio of the high-temperature constant temperature medium.

[0015] More preferably, the high-temperature medium on / off valve 7 is an angle seat valve, and the device further includes an angle seat valve air source 8, which is connected to the angle seat valve to provide a driving air source to the angle seat valve, thereby realizing the rapid opening and closing of the angle seat valve.

[0016] Plate heat exchanger 2, whose hot side channel is connected to the constant temperature medium inlet pipe, is used to receive and pre-cool the high temperature constant temperature medium; Preferably, the plate heat exchanger 2 is a high-temperature range cooling plate heat exchanger 2, which is configured to rapidly pre-cool the high-temperature constant temperature medium from 200°C to 40°C in the high-temperature range.

[0017] More preferably, the hot-side inlet and outlet pipe diameters and the cold-side inlet and outlet pipe diameters of the high-temperature zone cooling plate heat exchanger 2 are both DN25, and the cold-side inlet and outlet are connected to the cooling water circuit 3 via flanges or quick-connect couplings to facilitate installation and maintenance.

[0018] The cooling water circuit 3 includes a cooling water inlet pipe 31 and a cooling water outlet pipe 32. Both the cooling water inlet pipe 31 and the cooling water outlet pipe 32 are connected to the cold side channel of the plate heat exchanger 2 to form a cooling water circulation, which is used as a cooling medium to remove the heat in the plate heat exchanger 2. Preferably, the cooling water circuit 3 further includes a cooling water flow switch 33, which is installed on the cooling water inlet pipe 31 or the cooling water outlet pipe 32 to detect the flow status of the cooling water and provide feedback control signals to ensure that the system automatically alarms or shuts down when there is no water or the flow is interrupted.

[0019] Cooling water flow control valve 4 is installed on the cooling water inlet pipe 31 or the cooling water outlet pipe 32 to adjust the cooling water flow rate in order to control the heat exchange efficiency of the plate heat exchanger 2 and the pre-cooling degree of the high temperature constant temperature medium. A high-temperature medium check valve 5 is installed on the medium outlet pipe downstream of the plate heat exchanger 2 to control the flow direction of the high-temperature constant temperature medium, so as to prevent the high-temperature constant temperature medium from flowing back from the medium outlet pipe to the plate heat exchanger 2 and avoid thermal shock or damage to the plate heat exchanger 2 caused by backflow. The high-temperature medium outlet pipe 6 is used to output the high-temperature constant temperature medium (e.g., 40°C) after pre-cooling by the plate heat exchanger 2. The medium then enters the compressor system for secondary cooling. The device is configured to use ambient temperature cooling water to perform a first-stage pre-cooling of the high-temperature constant temperature medium through the plate heat exchanger 2, so that the high-temperature constant temperature medium is significantly reduced from its initial high temperature before entering the compressor system for a second-stage cooling, so as to avoid the compressor operating directly in the high-temperature range.

[0020] Furthermore, the device is integrated into a high and low temperature integrated cooling and heating system, and is controlled by a PLC control system to control the opening of each valve, the flow rate of cooling water, and the start and stop of the compressor, thereby achieving energy-saving operation throughout the entire process.

[0021] Specifically, the PLC control system receives signals from the temperature sensor (located at the hot side outlet of the plate heat exchanger 2) and the cooling water flow switch 33, and adjusts the opening of the cooling water flow control valve 4 in real time to ensure that the outlet temperature of the high-temperature constant temperature medium is stable within the set range (e.g., 40±2℃). When the system detects abnormal cooling water flow or excessive high-temperature medium temperature, the PLC automatically closes the high-temperature medium on / off valve 7 and stops the compressor, achieving energy-saving operation and safety protection throughout the process.

[0022] In this embodiment, the specific working process of the pre-cooling energy-saving device for primary cooling using ambient temperature water source according to the present invention is as follows: (1) Start-up phase: The cooling water flow switch 33 detects the flow status of the cooling water and feeds back a control signal to the PLC control system. When the PLC control system receives the feedback signal, it determines whether the cooling water circuit 3 is normal based on the feedback signal. After confirming that the cooling water circuit 3 is normal, it opens the angle seat valve air source 8 to open the angle seat valve, and the high-temperature constant temperature medium enters the high-temperature medium inlet pipe 1.

[0023] (2) Pre-cooling stage: The high-temperature constant-temperature medium (initial temperature 200℃) is diverted by the high-temperature medium regulating valve 9 and enters the hot side channel of the plate heat exchanger 2. At the same time, cooling water enters the cold side channel of the plate heat exchanger 2 from the cooling water inlet pipe 31 and exchanges heat with the hot side medium in a countercurrent manner. The cooling water absorbs heat and its temperature rises, and it is finally discharged from the cooling water outlet pipe 32. After heat exchange by the plate heat exchanger 2, the temperature of the high-temperature constant-temperature medium drops rapidly from 200℃ to 40℃.

[0024] (3) Regulation and control stage: The PLC control system automatically adjusts the opening of the cooling water flow control valve 4 based on the feedback from the temperature sensor at the hot side outlet of the plate heat exchanger 2, thereby controlling the cooling water flow and accurately controlling the heat exchange efficiency of the plate heat exchanger 2 and the pre-cooling degree of the high-temperature constant temperature medium. When the cooling water flow is insufficient or abnormal, the cooling water flow switch 33 will send a signal to the PLC control system, causing the PLC control system to close the angle seat valve and stop the compressor.

[0025] (4) Output stage: The pre-cooled 40°C constant temperature medium flows through the high temperature medium check valve 5 and is output from the high temperature medium outlet pipe 6, entering the compressor system for secondary cooling.

[0026] (5) Shutdown phase: When the system is shut down, the PLC control system first closes the angle seat valve to cut off the input of high-temperature medium. Then, after the temperature of the high-temperature constant temperature medium in the plate heat exchanger 2 drops to a safe range, the cooling water flow control valve 4 is closed to complete the shutdown.

[0027] As can be seen from the above working process, compared with the prior art, this device has the following beneficial effects: a) Significantly reduce compressor load, achieving energy-saving operation: In the prior art, the compressor directly handles high-temperature media (such as 200℃), resulting in high compressor energy consumption and low operating efficiency. However, this device uses the plate heat exchanger 2 to use a normal temperature water source (such as 20-30℃) to perform a first-stage pre-cooling of the high-temperature constant temperature medium (from 200℃ to 40℃), so that the compressor can operate in the low-temperature range (below 40℃), which greatly reduces the compressor power consumption.

[0028] Taking the operation test of this device under rated conditions (high-temperature medium flow rate 10 m³ / h, cooling water temperature 25℃, flow rate 15 m³ / h) as an example, the specific test results are as follows: b) Extend the compressor's service life: The direct introduction of the high-temperature constant-temperature medium into the compressor can easily lead to problems such as thermal fatigue of compressor components and oxidation and deterioration of lubricating oil. This device, however, uses pre-cooling to allow the compressor to operate under low-temperature, low-pressure-difference conditions. Experimental data shows that the internal temperature of the compressor is reduced by approximately 80°C, the lubricating oil replacement cycle is extended from 3 months to 12 months, and the compressor failure rate is reduced by more than 70%.

[0029] c) High system integration and precise control: This device designs the high-temperature medium on / off valve 7 (preferably the angle seat valve) and the high-temperature medium regulating valve 9 in parallel to achieve independent control of the on / off state and flow rate of the high-temperature constant-temperature medium. Simultaneously, the cooling water circuit 3 is equipped with the cooling water flow control valve 4 and the cooling water flow switch 33. Combined with the PLC control system, fully automatic and precise temperature control can be achieved. Experimental data shows that when the temperature fluctuation of the high-temperature constant-temperature medium is ±10℃, the outlet temperature fluctuation after pre-cooling is controlled within ±2℃, and the system response time is less than 5 seconds.

[0030] d) Compact structure, easy installation and maintenance: The plate heat exchanger 2 adopts a DN25 standard interface and is connected to the cooling water circuit 3 via flange or quick-connect method, which is convenient for disassembly. At the same time, the whole device is integrated into a high and low temperature cooling and heating integrated machine, which occupies little space and is suitable for space-constrained industrial scenarios.

[0031] e) Achieve energy-saving operation throughout the entire process: According to experimental data, this device can save approximately 500,000 kilowatt-hours of electricity per year when operating at full load (based on 8,000 hours of operation per year), corresponding to a reduction of approximately 400 tons of carbon emissions, demonstrating significant economic and environmental benefits.

[0032] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A pre-cooling energy-saving device for primary cooling using ambient temperature water source, characterized in that, include: The high-temperature medium inlet pipe is used to input the high-temperature constant-temperature medium to be cooled. A plate heat exchanger, the hot side channel of which is connected to the inlet pipe of the constant temperature medium, is used to receive and pre-cool the high temperature constant temperature medium; The cooling water circuit includes a cooling water inlet pipe and a cooling water outlet pipe. Both the cooling water inlet pipe and the cooling water outlet pipe are connected to the cold side channel of the plate heat exchanger to form a cooling water circulation, which is used as a cooling medium to remove heat from the plate heat exchanger. A cooling water flow control valve is installed on the cooling water inlet pipe or the cooling water outlet pipe to adjust the cooling water flow rate in order to control the heat exchange efficiency of the plate heat exchanger and the pre-cooling degree of the high-temperature constant temperature medium. A high-temperature medium check valve is installed on the medium outlet pipe downstream of the plate heat exchanger to control the flow direction of the high-temperature constant temperature medium, so as to prevent the high-temperature constant temperature medium from flowing back into the plate heat exchanger from the medium outlet pipe. The high-temperature medium outlet pipeline is used to output the high-temperature constant-temperature medium after it has been pre-cooled by the plate heat exchanger; The device is configured to use ambient temperature cooling water to perform a first-stage pre-cooling of the high-temperature constant temperature medium through the plate heat exchanger, so that the high-temperature constant temperature medium is significantly reduced from its initial high temperature before entering the compressor system for a second-stage cooling, in order to avoid the compressor operating directly in the high-temperature range.

2. The energy-saving device for pre-cooling a primary cooling system using ambient temperature water as described in claim 1, characterized in that, The cooling water circuit also includes a cooling water flow switch, which is installed on the cooling water inlet pipe or the cooling water outlet pipe to detect the flow status of the cooling water and provide feedback control signals.

3. The energy-saving device for pre-cooling a primary cooling system using ambient temperature water as described in claim 1 or 2, characterized in that, A high-temperature medium on / off valve is installed on the high-temperature medium inlet pipeline, which is used to control the on / off of the high-temperature constant temperature medium.

4. The energy-saving device for pre-cooling a primary cooling source using ambient temperature water as described in claim 3, characterized in that, The high-temperature medium on / off valve is an angle seat valve. The device also includes an angle seat valve air source, which is connected to the angle seat valve to provide a driving air source to the angle seat valve.

5. The energy-saving device for pre-cooling a primary cooling system using ambient temperature water as described in claim 4, characterized in that, A high-temperature medium regulating valve is installed on the high-temperature medium inlet pipe, which is used to regulate the flow rate of the high-temperature constant temperature medium.

6. The energy-saving device for pre-cooling a primary cooling system using ambient temperature water as described in claim 5, characterized in that, The high-temperature medium on / off valve and the high-temperature medium regulating valve are connected in parallel to finely adjust the flow ratio of the high-temperature constant-temperature medium.

7. The energy-saving device for pre-cooling a primary cooling system using ambient temperature water as described in claim 1, characterized in that, The plate heat exchanger is a high-temperature zone cooling plate heat exchanger, which is configured to rapidly pre-cool the high-temperature constant-temperature medium from 200°C to 40°C in the high-temperature zone.

8. The energy-saving device for pre-cooling a primary cooling system using ambient temperature water as described in claim 7, characterized in that, The hot-side inlet and outlet pipe diameters and the cold-side inlet and outlet pipe diameters of the high-temperature zone cooling plate heat exchanger are both DN25, and the cold-side inlet and outlet are connected to the cooling water circuit via flanges or quick-connect couplings.

9. The energy-saving device for pre-cooling a primary cooling system using ambient temperature water as described in claim 1, characterized in that, The device is integrated into a high and low temperature cooling and heating system, and is controlled by a PLC control system to control the opening of each valve, the flow of cooling water, and the start and stop of the compressor, so as to achieve energy-saving operation throughout the process.

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