Low energy consumption circulating cooling water terminal throttling energy recovery device and method
Patent Information
- Application Number
- CN202611392757.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-09-09
- Publication Date
- 2026-10-16
Smart Images
Figure CN122920110A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of fluid pipeline pressure regulation technology, specifically relating to a low-energy-consumption circulating cooling water terminal throttling energy recovery device and method. Background Technology
[0002] Circulating cooling water systems are widely used infrastructure in industries such as chemical, power, metallurgy, and refrigeration. Booster pumps draw cooling water from the cooling water pool, pressurize it, and deliver it to heat exchange equipment. In the heat exchange equipment, the cooling water absorbs heat from the medium to be cooled and rises in temperature. Then it flows into the cooling tower to dissipate heat and cool down. The cooled water flows back to the pool, forming a closed loop.
[0003] Circulating cooling water systems typically require piping systems. Traditional valves in these pipes rely on valve stems passing through the valve body wall to drive the valve core via an external actuator. Packing seals or mechanical seals must be installed at the valve stem penetration point. However, over 60% of valve external leakage occurs at the packing seal. Aging, wear, and temperature changes in the packing all exacerbate leakage. Cooling media can easily seep along the valve stem gap, leading to a high risk of seal failure after long-term operation. Furthermore, the mechanical friction of the valve stem reduces the actuation accuracy. Traditional pipeline power generation devices adopt a shafted structure, with the impeller connected to an external generator via a central shaft, or the impeller having a central shaft supported by bearings. The central shaft and its supporting structure occupy the central flow channel of the pipeline, increasing head loss and making it unable to adapt to the inherent flow peak and valley fluctuations of the water supply network. At low flow velocities, the impeller is unable to overcome static friction and stops rotating, while at high flow velocities, it is easy to overload the generator, resulting in extremely low power generation efficiency and poor operational stability. Summary of the Invention
[0004] In view of the shortcomings of the existing technology, the purpose of this invention is to provide a low-energy-consumption circulating cooling water terminal throttling energy recovery device and method to solve the problems in the background technology.
[0005] To achieve the above objectives, the present invention provides the following technical solution: A low-energy-consumption circulating cooling water terminal throttling energy recovery device and method includes a guide pipe assembly module, a flow regulation and pressure regulation module, and a power generation module. The guide pipe assembly module includes a pipe assembly, and the pipe assembly includes an inlet pipe. The flow regulation and pressure regulation module is located at the front end of the inlet of the inlet pipe, the power generation module is located at the rear of the flow regulation and pressure regulation module, and the inlet pipe is connected to the end of the heat exchanger tube group. The flow and voltage regulation module includes a magnetic ring assembly and a regulating valve core assembly; The magnetic ring assembly includes an upper magnetic ring and a lower magnetic ring. Both the upper and lower magnetic rings are slidably arranged outside the inlet pipe along the axial direction of the inlet pipe, and a number of magnetic sheets are evenly distributed on the upper and lower magnetic rings. The regulating valve core assembly includes a valve core housing, a magnetic ring frame, and follower magnetic poles. The valve core housing is arranged axially in the inner cavity of the inlet pipe. The magnetic ring frame is coaxially arranged inside the valve core housing. Several follower magnetic poles are evenly distributed circumferentially on the magnetic ring frame, and the follower magnetic poles match the magnetic poles of the magnetic sheet.
[0006] As a further embodiment of the present invention, the pipe assembly further includes a central pipe, a rear connecting flange, a stepped groove, and a contraction section. The rear connecting flange is coaxially arranged with the inlet pipe and is interconnected with it. The inner diameter end of the rear connecting flange is provided with a stepped groove, the diameter of which is smaller than the inner diameter of the inlet pipe. The inner wall side of the central pipe is also provided with a contraction section.
[0007] As a further embodiment of the present invention, the pipe assembly further includes an upper cover and a lower cover, the upper cover and the lower cover being ring-fitted onto the outer wall end of the inlet pipe, and guide posts are evenly distributed in the inner cavities of the upper cover and the lower cover, and the upper magnetic ring and the lower magnetic ring are movably arranged in the cavities of the guide posts.
[0008] As a further embodiment of the present invention, the power generation module includes a power generation shell assembly, which includes a power generation end shell, a shunt pipe section, and a diffuser pipe. One end of the power generation end shell is connected to the central pipe, and the other end of the power generation end shell is connected to the diffuser pipe. A shunt pipe section matching the inner diameter of the central pipe is provided on the side of the power generation end shell near the central pipe.
[0009] As a further embodiment of the present invention, the regulating valve core assembly further includes an external cavity, an internal cavity, a column, a guide cone, a connecting shaft, and a sleeve. The valve core housing is provided with independent external and internal cavities. The column slides against one side of the inner wall of the external cavity, and a guide cone is fixedly connected to one end of the column, while a connecting shaft is fixedly connected to the other end of the column. The connecting shaft slides through the internal cavity, and a sleeve is fixedly connected to the end of the connecting shaft. The magnetic ring frame is fixedly installed at one end of the sleeve rod. The regulating valve core assembly also includes a limiting rod, which is fixedly installed in the inner cavity of the built-in cavity, and the magnetic ring frame slides through the limiting rod.
[0010] As a further embodiment of the present invention, the current and voltage regulation module further includes a drive assembly, which includes an outer housing, a drive shaft, a drive component, and a drive bracket. The outer housing is fixedly installed on the top of the upper cover, and the drive shaft is rotatably installed inside the outer housing. One end of the drive component is engaged with a lead screw on the surface of the drive shaft, and the other end of the drive component is fixedly connected to the drive bracket. The drive bracket passes through the upper cover and is fixedly connected to the upper magnetic ring.
[0011] As a further embodiment of the present invention, the flow regulation and pressure regulation module further includes a flow splitting component. The flow splitting component includes a main flow splitting pipe, a branch flow splitting pipe, a plug, a limiter, a movable valve core, a sliding sleeve, a pin, a drive shaft, a cam, a linkage shaft, and a driven gear. The main flow splitting pipe is arranged on one side of the branch flow splitting pipe section. The branch flow splitting pipe at one end is connected to the branch flow splitting pipe section. A plug and a limiter are fixedly arranged inside the branch flow splitting pipe. The movable valve core is slidably inserted into the plug, and a sliding sleeve is elastically fitted at the end of the movable valve core. A pin is also arranged at the end of the sliding sleeve. The drive shaft is rotatably installed in the main flow splitting pipe, and a cam coaxially fitted at one end of the drive shaft slides against the pin. A linkage shaft is slidably inserted at the other end of the drive shaft. A driven gear is coaxially arranged at the end of the linkage shaft, and the driven gear meshes with the drive gear.
[0012] As a further aspect of the present invention, an energy recovery method based on terminal throttling of low-energy-consumption circulating cooling water includes the following steps: S1. In the circulating cooling water circuit, remove the throttling valve on the pipeline between the outlet side of the booster pump and the inlet of the heat exchange equipment, so that the pipeline remains fully open. S2. A flow guide pipe module, a flow regulation and pressure regulation module, and a power generation module are connected in series on the outlet pipe of the heat exchange equipment. The flow regulation and pressure regulation module and the power generation module replace the eliminated throttle valve and undertake the main throttling function of the system. S3. The flow regulation and pressure regulation module controls the cooling water flow rate by adjusting the opening of the internal flow channel, and at the same time converts the pressure drop energy generated during the throttling process into electrical energy through the power generation module and outputs it to the outside. S4. The booster pump operates continuously at or near the rated speed to provide the basic head for the system; S5. The frequency converter is connected to the drive motor of the booster pump, and only makes minor adjustments to the speed of the booster pump within the range of 5% to 15% of the rated speed to maintain the stability of the inlet pressure of the heat exchange equipment. S6. Cooling water flows into the inlet pipe through the inlet flange and rotates through the spiral blades. The external drive component drives the upper and lower magnetic rings to slide along the pipe axis. The magnetic plates on them drive the internal magnetic ring frame and follower magnetic pole to move synchronously through non-contact magnetic coupling, thereby pushing the guide cone to move axially. The distance between the guide cone and the Venturi contraction section changes, causing the flow cross-sectional area to change, providing variable flow and head conditions for the power generation module. S7. The regulated water flow enters the generator housing and impacts the airfoil blades on the annular rim, driving the permanent magnet rotor to rotate. Through the wear-resistant coating, it couples with the external silicon steel stator to generate electrical energy. When the guide cone gets stuck, the magnetic coupling reaches saturation and slips out. At the same time, the axial buffering characteristic can suppress water hammer impact.
[0013] In summary, the embodiments of the present invention have the following beneficial effects compared with the prior art: This invention completely eliminates the hidden danger of leakage in the traditional valve stem hole through magnetic coupling non-contact transmission, and avoids the problem of airbag aging and deformation. It improves the long-term sealing performance and operation accuracy. When the guide cone is stuck, the magnetic saturation slippage can prevent damage from hard start. At the same time, the axial magnetic buffer can effectively suppress water hammer impact, greatly extend the service life of the equipment and reduce the frequency of maintenance. Furthermore, by sliding the external magnetic ring axially, the distance between the guide cone and the contraction section can be adjusted without contact, and the flow area can be dynamically changed to achieve flexible control of flow and pressure. This allows the power generation module to maintain a high-efficiency operating range under different peak and valley flow rates, avoiding stalling at low flow rates or damage from overload at high flow rates. It also features both pressure reduction and micro-power generation modes, adapting to day and night flow fluctuations and improving the overall efficiency of energy recovery. Furthermore, the integrated diversion component can automatically open the bypass pressure relief when the adjustment causes the pipeline pressure to exceed the standard, preventing pipe rupture, ensuring stable generator operation, and achieving safe and efficient long-term intelligent control. Attached Figure Description
[0014] Figure 1 This is a schematic diagram of one embodiment of the present invention.
[0015] Figure 2 This is a schematic diagram of the structure of the generator cylinder in one embodiment of the present invention.
[0016] Figure 3 This is a schematic diagram of the structure of the power generation shell assembly in one embodiment of the present invention.
[0017] Figure 4 This is a side view of one embodiment of the present invention.
[0018] Figure 5 This is a partial cross-sectional view of one embodiment of the present invention.
[0019] Figure 6 This is a partial cross-sectional view of the valve core housing in one embodiment of the present invention.
[0020] Figure 7 This is a schematic diagram of the exploded structure of one embodiment of the present invention.
[0021] Figure 8 This is a schematic diagram of the structure of a pipe assembly in one embodiment of the present invention.
[0022] Figure 9 This is a schematic diagram of the magnetic ring assembly in one embodiment of the present invention.
[0023] Figure 10 This is a schematic diagram of the structure of the upper cover and the lower cover in one embodiment of the present invention.
[0024] Figure 11This is a schematic diagram of the structure of the regulating valve core assembly in one embodiment of the present invention.
[0025] Figure 12 This is a schematic diagram of the structure of the driving component in one embodiment of the present invention.
[0026] Figure 13 This is a schematic diagram of the structure of a shunt component in one embodiment of the present invention.
[0027] Figure label: Pipe assembly, 101-Inlet pipe, 102-Inlet flange, 103-Front connection flange, 104-Middle pipe, 105-Rear connection flange, 106-Step groove, 107-Contraction section, 108-Connecting flange, 109-Generator cylinder, 110-Blade, 111-Upper cover, 112-Lower cover, 113-Guide groove, 114-Isolation cover, 115-Slide groove, 116-Guide column; Magnetic ring assembly, 201-upper magnetic ring, 202-lower magnetic ring, 203-guide hole, 204-magnetic sheet, 205-pin; Regulating valve core assembly, 301-valve core housing, 302-external cavity, 303-internal cavity, 304-cylinder, 305-guide cone, 306-connecting shaft, 307-sleeve rod, 308-magnetic ring frame, 309-follower magnetic pole, 310-limiting rod; Drive assembly, 401-external housing, 402-drive shaft, 403-lead screw, 404-drive gear, 405-drive component, 406-drive bracket, 407-driver; 501-Generator end shell, 502-Interface flange, 503-Diverter pipe section, 504-Tail flange, 505-Diffuser pipe, 506-Diffuser section flange, 507-Diffuser section, 508-Final section flange, 509-Generator cylinder; 6-Diverter assembly, 601-Diverter main pipe, 602-Diverter branch pipe, 603-Plug, 604-Limiter, 605-Modible valve core, 606-Sliding sleeve, 607-Pin rod, 608-Drive shaft, 609-Cam, 610-Linkage shaft, 611-Driven gear. Detailed Implementation
[0028] To more clearly illustrate the structural features and effects of the present invention, the present invention will be described in detail below with reference to the accompanying drawings and specific embodiments.
[0029] Please see Figures 1-13An embodiment of the present invention discloses a low-energy-consumption circulating cooling water terminal throttling energy recovery device and method, comprising a guide pipe assembly module, a flow regulation and pressure regulation module, and a power generation module. The guide pipe assembly module includes a pipe assembly 1, which includes an inlet pipe 101. The flow regulation and pressure regulation module is disposed at the front end of the inlet of the inlet pipe 101, and the power generation module is disposed at the rear side of the flow regulation and pressure regulation module. The inlet pipe 101 is connected to the end side of the heat exchanger tube assembly. The flow regulation and pressure regulation module includes a magnetic ring assembly 2 and a regulating valve core assembly 3. The magnetic ring assembly 2 includes an upper magnetic ring 201 and a lower magnetic ring 202. The upper magnetic ring 201 and the lower magnetic ring 202 are both slidably arranged outside the inlet pipe 101 along the axial direction of the inlet pipe 101. A plurality of magnetic plates 204 are evenly distributed on the upper magnetic ring 201 and the lower magnetic ring 202. The regulating valve core assembly 3 includes a valve core housing 301, a magnetic ring frame 308 and a follower magnetic pole 309. The valve core housing 301 is arranged axially in the inner cavity of the inlet pipe 101. The magnetic ring frame 308 is coaxially arranged inside the valve core housing 301. A plurality of follower magnetic poles 309 are evenly distributed circumferentially on the magnetic ring frame 308, and the follower magnetic poles 309 match the magnetic poles of the magnetic plates 204.
[0030] In practical application, the low-energy-consumption circulating cooling water terminal throttling energy recovery device of this embodiment consists of a guide pipe assembly module, a flow regulation and pressure regulation module, and a power generation module. The guide pipe assembly module includes a pipe assembly 1, which includes an inlet pipe 101. The inlet pipe 101 is provided with an inlet flange 102 and a front connecting flange 103 at its front and rear ends, respectively. The front connecting flange 103 and the rear connecting flange 105 on one side of the middle pipe 104 are connected by a flange structure. The connecting flange 108 at the other end of the middle pipe 104 and the interface flange 502 on one side of the power generation housing 501 are connected by a flange structure. The inner wall of the inlet pipe 101 is also fixedly assembled with a power generation cylinder 109. The inner diameter end of the power generation cylinder 109 is provided with several spiral blades 110, and the blades 110 and the valve core housing 301 are fixedly connected so that after the external water flows in through the inlet flange 102, it rotates under the guidance of the blades 110. Since a magnetic ring frame 308 is slidably arranged inside the valve core housing 301, and a guide cone 305 is fixedly connected to one end of the magnetic ring frame 308, and an upper magnetic ring 201 and a lower magnetic ring 202 are slidably arranged outside the inlet pipe 101, and several magnetic plates 204 are evenly distributed on the upper magnetic ring 201 and the lower magnetic ring 202, the magnetic poles of the magnetic plates 204 match the magnetic poles of the follower magnetic poles 309, thereby forming magnetic coupling in the axial direction. When the upper magnetic ring 201 and the lower magnetic ring 202 slide axially, the magnetic ring frame 308 and the follower magnetic poles 309 slide synchronously with them. When the guide cone 305 moves closer to the contraction section 107, the distance between the guide cone 305 and the contraction section 107 shortens, further reducing the flowable cross-sectional area between them. When the pressure on the side of the cooling water input pump remains constant, Bernoulli's equation shows that the pressure at that point increases synchronously, and the flow velocity further accelerates, thereby changing the power generation efficiency of the power generation module. In this embodiment, since the guide cone 305 and the upper magnetic ring 201 and lower magnetic ring 202 adopt a non-contact magnetic coupling transmission method, compared with the existing valve stem transmission connection or airbag drive structure, this structure does not conduct cooling medium through sliding holes, effectively preventing cooling medium from seeping out through holes and ensuring that the structure can be used for a long time without leakage. On the other hand, compared with using airbags to drive the guide cone 305, the airbags have problems such as aging and deformation after long-term use, which not only affects the pushing accuracy, but also poses a risk of wear and leakage, further reducing the service life.
[0031] Furthermore, the magnetic coupling non-contact drive method adopted in this structure reduces the risk of wear and leakage caused by mechanical friction, while possessing an inherent overload protection function. When the guide cone 305 is obstructed or completely jammed due to abnormal working conditions such as foreign object jamming, corrosion scaling, or mechanical damage, the magnetic ring frame 308 fixedly connected to the guide cone 305 still tends to continue rotating under the continuous action of the driving magnetic field. In this state, the torque transmitted by the magnetic coupling will increase rapidly with the increase of slip until it reaches the saturation magnetic torque limit of the magnetic circuit system. At this time, the coupling magnetic field will collapse, that is, a magnetic saturation slippage phenomenon will occur. This slippage process can effectively cut off the rigid torque transmission path between the driving end and the driven end, thereby preventing the drive motor or transmission mechanism from generating a hard start impact due to overload, avoiding the impact from being directly transmitted to the end actuator or the inner wall of the pipeline, and protecting the valve core assembly and pipeline system from sudden damage.
[0032] Furthermore, the magnetic coupling structure has a defined elastic buffer stroke and damping characteristics in the axial direction, which can effectively suppress water hammer pressure waves caused by rapid valve action or pump start-up and shutdown in the pipeline system. When the water hammer shock wave is transmitted to the valve core assembly in the axial direction, the axial magnetic interaction between the magnetic ring frame 308 and the corresponding drive magnetic ring will generate a reversible relative displacement. This displacement process converts the impact kinetic energy into magnetic potential energy and gradually dissipates it, thereby making the valve core 305 action process more stable and continuous, avoiding oscillations or instantaneous overshoot caused by rigid impact. Since the upper magnetic ring 201 and the lower magnetic ring 202 are respectively located on the inner and outer sides of the non-ferromagnetic isolation sleeve, the change in their relative axial position directly reflects the real-time axial displacement of the internal guide cone 305. Therefore, operation and maintenance personnel only need to visually observe the relative spacing and alignment of the upper magnetic ring 201 and the lower magnetic ring 202 through the transparent window or external markings on the casing. Without disassembling the equipment, they can quickly and accurately determine the actual opening position and movement status of the guide cone 305, providing intuitive and reliable external indicators for daily inspection, fault prediction and maintenance work, and improving the maintainability and operational safety of the equipment.
[0033] Furthermore, the inlet pipe 101, the generator cylinder 109, and the valve core housing 301 are all made of non-ferromagnetic materials. These non-ferromagnetic materials include, but are not limited to, austenitic stainless steel, copper alloys, or high-performance engineering plastics. These materials have a relative permeability close to 1, and will not be magnetized in a magnetic field or form a magnetic flux shortcut. This ensures that the magnetic lines of force in the drive magnetic circuit can strictly follow the designed path to pass through the isolation sleeve and act on the internal magnetic ring frame 308, avoiding the weakening of coupling efficiency due to eddy current losses, hysteresis losses, or magnetic flux shunting generated by the housing or pipe itself. At the same time, the selection of non-ferromagnetic materials can also prevent external stray magnetic fields from interfering with the internal magnetic coupling system, ensuring the stability and control accuracy of torque transmission, while taking into account the corrosion resistance and structural strength requirements of the pipeline system.
[0034] Please see Figure 8 and Figure 9 In a preferred embodiment of the present invention, the pipe assembly 1 further includes a central pipe 104, a rear connecting flange 105, a stepped groove 106, and a contraction section 107. The rear connecting flange 105 is coaxially arranged with the inlet pipe 101 and communicates with it. The inner diameter end of the rear connecting flange 105 is provided with a stepped groove 106, the diameter of which is smaller than the inner diameter of the inlet pipe 101. The inner wall side of the central pipe 104 is also provided with a contraction section 107.
[0035] In practical application, the contraction section 107 on one side of the centrally located pipe 104 is a Venturi contraction section, which is used to increase the incoming water flow rate. Since the water flow in the water supply pipe has a strong peak-valley characteristic, the flow rate during peak water usage can be several times that during trough water usage. The optimal operating point of the generator with a fixed structure is: when the actual flow rate deviates from the design value, not only will the efficiency drop sharply, but the impeller will also be unable to overcome the starting resistance when the flow rate is too low, causing the generator to stall and stop. When the flow rate is too high, the generator will be overloaded, which may damage the windings or magnetic circuit.
[0036] Therefore, by adjusting the distance between the guide cone 305 and the contraction section 107, the flow guiding area can be adjusted. When the pressure is constant, the outlet flow area can be changed by axial displacement, thereby changing the back pressure and effective head of the generator section and realizing the regulation of flow rate and pressure. The bottom of the upper magnetic ring 201 is provided with a pin 205, and the top of the lower magnetic ring 202 is provided with a slot 206 that matches the pin 205. After the upper cover 111 and the lower cover 112 are fixed and locked, the pin 205 is inserted into the slot 206, so that the pin 205 and the slot 206 are moved synchronously in the axial direction.
[0037] Please see Figure 10 In a preferred embodiment of the present invention, the pipe assembly 1 further includes an upper cover 111 and a lower cover 112, the upper cover 111 and the lower cover 112 being circumferentially attached to the outer wall end of the inlet pipe 101, and guide posts 116 being evenly distributed in the inner cavities of the upper cover 111 and the lower cover 112, and the upper magnetic ring 201 and the lower magnetic ring 202 being movably arranged in the cavity of the guide posts 116.
[0038] In practical application, the upper cover 111 and the lower cover 112 are circumferentially fastened and locked to the surface of the inlet pipe 101 by bolts. Guide grooves 113 are provided on both sides of the pipe opening of the upper cover 111 and the lower cover 112. Elastic sealing strips are pre-installed inside the guide grooves 113. Isolation covers 114 are evenly distributed inside the upper cover 111 and the lower cover 112. The isolation covers 114 are used to shield magnetic interference and prevent disturbance of the magnetic field on the power generation module side. A sliding groove 115 is also provided on one side of the upper cover 111. The drive bracket 406 in the outer shell 401 slides through the sliding groove 115 and is fixedly connected to the upper magnetic ring 201. Guide posts 116 are also provided in the upper cover 111. The upper magnetic ring 201 is limited and slidably assembled on the guide post 116 to restrict the rotation of the upper magnetic ring 201 and the lower magnetic ring 202 in the axial direction.
[0039] Please see Figure 3In a preferred embodiment of this embodiment, the power generation module includes a power generation shell assembly 5, which includes a power generation end shell 501, a diversion pipe section 503, and a diffuser pipe 505. One end of the power generation end shell 501 is connected to the central pipe 104, and the other end of the power generation end shell 501 is connected to the diffuser pipe 505. A diversion pipe section 503 matching the inner diameter of the central pipe 104 is provided on the side of the power generation end shell 501 near the central pipe 104.
[0040] In practical application, the generator housing 501 has an interface flange 502 and a tail flange 504 at both ends. The generator housing 501 has a generator cylinder 509 inside. The two ends of the generator cylinder 509 are rotatably mounted in the generator housing 501 through bearings. An impeller is arranged on the inner wall of the generator cylinder 509. When water flows through the inner cavity of the generator cylinder 509, it drives the cylinder to rotate and generate electricity. One end of the diffuser pipe 505 is connected to the tail flange 504 through the diffuser section flange 506. The diffuser pipe 505 also has a conical Venturi diffuser section to slow down the water flow rate and reduce the formation of cavitation.
[0041] Furthermore, the motor section pipe wall on one side of the generator end housing 501 is formed by casting and curing silicon steel sheets laminated with an iron core and stator coils. The silicon steel sheets are laminated along the circumference of the pipe to form a magnetically conductive skeleton, and the three-phase stator coils are embedded in the slots of the silicon steel sheet iron core. The whole is vacuum cast and cured with epoxy resin to form a composite pipe wall with magnetic conductivity, pressure bearing and insulation functions. The coils play a role in strengthening the structure, and the inner surface of the pipe wall is covered with an ultra-thin wear-resistant insulating coating, such as plasma-sprayed alumina ceramic. Alternatively, a micro-arc oxidation layer with a thickness of 0.1 to 0.3 mm is used. Only the surface of this coating is in contact with the water flow. The generator cylinder 509 is coupled to the silicon steel core through the wear-resistant coating on the inner surface of the pipe wall. The outer surface of the pipe wall is exposed to the air and can dissipate heat naturally. The generator cylinder 509 is an annular rim body, including a neodymium iron boron permanent magnet fixed to the outside of the inner cylinder and 5 to 7 airfoil blades fixed to the inside of the inner cylinder. The rotor has no central drive shaft, and the permanent magnet is coupled to the silicon steel core through the inner wall coating.
[0042] Furthermore, the generator cylinder 509 is provided with an annular water-lubricated bearing at the end of the venturi contraction section on the inlet side, which is embedded in the inner wall of the venturi to provide basic radial centering for the generator cylinder 509. The outlet end is provided with a fan-shaped water-lubricated bearing, which undertakes the main radial positioning and axial thrust functions. The bearing material is silicon carbide ceramic or water-lubricated special composite material, and the pipeline water flow is used as the lubrication medium, so no additional lubrication system is required.
[0043] Please see Figure 1In a preferred embodiment of the present invention, the regulating valve core assembly 3 further includes an external cavity 302, an internal cavity 303, a column 304, a guide cone 305, a connecting shaft 306, and a sleeve 307. The valve core housing 301 is provided with independent external cavities 302 and internal cavities 303. The column 304 is slidably attached to one side of the inner cavity wall of the external cavity 302, and one end of the column 304 is fixedly connected to the guide cone 305, and the other end of the column 304 is fixedly connected to the connecting shaft 306. The connecting shaft 306 is slidably inserted into the internal cavity 303, and the end of the connecting shaft 306 is fixedly connected to the sleeve 307. The magnetic ring frame 308 is fixedly installed at one end of the sleeve 307. The regulating valve core assembly 3 further includes a limiting rod 310, which is fixedly installed in the inner cavity of the internal cavity 303, and the magnetic ring frame 308 is slidably inserted into the limiting rod 310.
[0044] In practical application, the column 304 slides against one side of the inner wall of the external cavity 302, and a guide cone 305 is fixedly connected to one end of the column 304, while a connecting shaft 306 is fixedly connected to the other end. The connecting shaft 306 slides through the internal cavity 303, and a sleeve 307 is fixedly connected to the end of the connecting shaft 306. The magnetic ring frame 308 is fixedly installed at one end of the sleeve 307. The regulating valve core assembly 3 also includes a limiting rod 310. 310 is fixedly installed in the inner cavity of the built-in cavity 303, and the magnetic ring frame 308 slides through the limiting rod 310. The guide cone 305 is a conical sealing body with a cone angle of 25 to 35 degrees. The cone surface is hardened and made of Stellite alloy overlay or ceramic coating with a hardness of not less than HRC45. The bottom of the valve core housing 301 is provided with an circumferential through groove. The through groove mating surface is provided with a PTFE or nylon soft sealing ring. When the guide cone 305 is pushed to the limit position, the contraction section 107 cooperates with the soft sealing ring to achieve shut-off.
[0045] Please see Figure 12 In a preferred embodiment of the present invention, the current and voltage regulating module further includes a drive assembly 4. The drive assembly 4 includes an outer housing 401, a drive shaft 402, a drive member 405, and a drive bracket 406. The outer housing 401 is fixedly installed on the top of the upper cover 111. The drive shaft 402 is rotatably installed inside the outer housing 401. One end of the drive member 405 is engaged with a lead screw 403 on the surface of the drive shaft 402. The other end of the drive member 405 is fixedly connected to the drive bracket 406. The drive bracket 406 passes through the upper cover 111 and is fixedly connected to the upper magnetic ring 201.
[0046] In practical application, the outer housing 401 is fixedly installed on the top outer wall of the upper cover 111. The drive shaft 402 is rotatably installed in the internal cavity of the outer housing 401 via a bearing. One end of the drive member 405 is engaged with the lead screw 403 on the surface of the drive shaft 402 through its internal threaded hole. The other end of the drive member 405 is fixedly connected to a drive bracket 406. The drive bracket 406 passes through the slide groove 115 opened on the upper cover 111 and is fixedly connected to the upper surface of the upper magnetic ring 201. The driver 407 installed inside the outer housing 401 drives the drive shaft 402 to rotate around its own axis when powered on. The rotational motion of the drive shaft 402 is converted into the linear motion of the drive member 405 along the axial direction through the threaded engagement between the lead screw 403 and the drive member 405, and then drives the upper magnetic ring 201 through the drive bracket 406. Ring 201 and lower magnetic ring 202 move synchronously along the axial direction on the outer wall of the inlet pipe 101. At the same time, a drive gear 404 is fixedly installed on the coaxial side of the drive shaft 402. When the drive shaft 402 rotates, the drive gear 404 rotates synchronously, so that the rotation of the drive gear 404 drives the corresponding component in the diversion assembly 6 to move through the meshing transmission. This embodiment has two relative working conditions: pressure reduction condition and micro-power generation condition. In the micro-power generation condition, the generator set only needs to extract a small amount of electrical energy from the pipeline to supply low-power monitoring and control equipment such as sensors, transmitters and controllers. The medium pressure drop consumed by the generator is extremely small. When the water consumption at night drops to a very low or even zero flow state, the annular rim body generator cylinder 509 will naturally stop due to the lack of sufficient driving torque, without producing any additional side effects or safety hazards. Under pressure reduction conditions, the core function of this equipment is to replace the traditional pressure reducing valve and use the generator set to consume the excess pressure difference in the pipeline to achieve the purpose of pressure reduction. During the daytime period when the water flow is large, the generator operates normally and continuously consumes the excess pressure difference upstream, thereby controlling the downstream pressure within the target range. However, when the water flow drops to near zero at night, the generator set stops due to insufficient flow and cannot continue to consume the excess pressure difference upstream. At this time, by controlling the drive 407 to drive the guide cone 305 to adjust the axial distance between it and the contraction section 107, the throttling area can be changed and additional local resistance loss can be generated. Thus, the downstream pressure can still be effectively controlled under zero flow or micro flow conditions, realizing the pressure regulation function in the entire operating range.
[0047] Please see Figure 13In a preferred embodiment of the present invention, the flow regulation and pressure regulation module further includes a flow splitting component 6. The flow splitting component 6 includes a main flow splitting pipe 601, a branch flow splitting pipe 602, a plug 603, a limiter 604, a movable valve core 605, a sliding sleeve 606, a pin 607, a transmission shaft 608, a cam 609, a linkage shaft 610, and a driven gear 611. The main flow splitting pipe 601 is located on one side of the branch flow splitting pipe section 503. The branch flow splitting pipe 602 at one end of the main flow splitting pipe 601 is connected to the branch flow splitting pipe section 503. A plug 603 and a... are fixedly arranged inside the branch flow splitting pipe 602. The limiter 604 has a movable valve core 605 that is slidably inserted into the plug 603, and a sliding sleeve 606 is elastically fitted at the end of the movable valve core 605. A pin 607 is also provided at the end of the sliding sleeve 606. The drive shaft 608 is rotatably installed in the diversion manifold 601, and a cam 609 coaxially fitted at one end of the drive shaft 608 slides against the pin 607. A linkage shaft 610 is slidably inserted at the other end of the drive shaft 608. A driven gear 611 is coaxially provided at the end of the linkage shaft 610, and the driven gear 611 meshes with the drive gear 404.
[0048] In practical application, the drive gear 404, during its rotation, can drive the driven gear 611 meshing with it to rotate synchronously in the opposite direction. Since the driven gear 611 is slidably inserted into one side of the shaft end of the linkage rod 610 through its central hole and torque is transmitted through a keyed or splined connection, the driven gear 611 can synchronously drive the linkage rod 610 to rotate around its own axis. The rotational motion of the linkage rod 610 further drives the cam 609 fixedly mounted at its end to rotate synchronously. During rotation, the cam 609 pushes the sliding sleeve 606 through its cam profile surface, causing it to slide axially on the limiter 604. Since the sliding sleeve 606 and the movable valve core 605 are in sliding elastic contact through an elastic element, the sliding sleeve 606 can adjust the magnitude of the elastic preload pressure on one side of the movable valve core 605 during axial movement. Furthermore, during the axial sliding of the upper magnetic ring 201, when the flow velocity of the medium in the pipeline increases due to changes in the upstream operating conditions, resulting in a corresponding increase in pipeline pressure, the aforementioned linkage mechanism automatically weakens the elastic clamping force on one side of the movable valve core 605. This allows the movable valve core 605 to overcome the elastic force and open under the action of the medium pressure when the pressure in the pipeline exceeds the predetermined safety threshold. This enables some high-pressure medium to bypass and release pressure through the branch pipeline of the branch pipe 602, effectively preventing pipeline rupture accidents due to excessive pressure and improving the safety and reliability of the entire equipment under abnormal operating conditions.
[0049] The specific workflow of this embodiment is as follows: S1. In the circulating cooling water circuit, remove the throttling valve on the pipeline between the outlet side of the booster pump and the inlet of the heat exchange equipment, so that the pipeline remains fully open. S2. A flow guide pipe module, a flow regulation and pressure regulation module, and a power generation module are connected in series on the outlet pipe of the heat exchange equipment. The flow regulation and pressure regulation module and the power generation module replace the eliminated throttle valve and undertake the main throttling function of the system. S3. The flow regulation and pressure regulation module controls the cooling water flow rate by adjusting the opening of the internal flow channel, and at the same time converts the pressure drop energy generated during the throttling process into electrical energy through the power generation module and outputs it to the outside. S4. The booster pump operates continuously at or near the rated speed to provide the basic head for the system; S5. The frequency converter is connected to the drive motor of the booster pump, and only makes minor adjustments to the speed of the booster pump within the range of 5% to 15% of the rated speed to maintain the stability of the inlet pressure of the heat exchange equipment. S6. Cooling water flows into the inlet pipe 101 through the inlet flange 102. It is guided by the spiral blades 110 on the inner wall of the generator cylinder 109 to rotate. The driver 407 in the outer shell 401 drives the drive shaft 402 to rotate, so that the lead screw 403 engages with the drive component 405. Through the drive bracket 406, the upper magnetic ring 201 slides axially along the guide column 116. The upper magnetic ring 201 and the lower magnetic ring 202 are locked and move synchronously through the pin 205 and the slot 206. The evenly distributed magnetic sheets 204 on them drive the internal magnetic ring frame 308 and the follower magnetic pole 309 to move synchronously through non-contact magnetic coupling. This pushes the sleeve rod 307, the connecting shaft 306 and the column 304, causing the guide cone 305 to move axially. The distance between the guide cone 305 and the Venturi contraction section 107 in the central pipe 104 changes, and the flow cross-sectional area changes. According to the Bernoulli effect, the water pressure and flow rate are adjusted to provide variable flow and head conditions for the generator module. S7. The regulated water flows into the generator housing 501 through the diversion pipe section 503, impacting the airfoil blades on the annular rim generator cylinder 509, driving the permanent magnet rotor to rotate. Through the wear-resistant coating on the inner surface of the generator housing 501, it couples with the external silicon steel stator to generate electrical energy. The electrical energy flows out through the diffuser 505. When the guide cone 305 is stuck, the magnetic coupling between the magnetic sheet 204 and the follower magnetic pole 309 reaches saturation and produces slippage, preventing hard start from damaging components such as the limit rod 310 in the inner cavity of the valve core housing 301. S8, the drive gear 404 on the coaxial side of the drive shaft 402 rotates, meshes with the driven gear 611, drives the linkage shaft 610 and the transmission shaft 608, pushes the pin 607 through the cam 609, so that the sliding sleeve 606 slides on the limiter 604, adjusts the elastic pressure of the movable valve core 605 in the plug 603, and realizes diversion and pressure relief through the diversion branch pipe 602 and the diversion main pipe 601 to prevent pipe burst. The equipment can switch between micro-generation mode and pressure reduction mode. When the flow rate is zero at night, the generator will stop naturally, realizing low energy consumption operation at all times.
[0050] In the above workflow, the current regulation and voltage regulation module and the power generation module account for 85% to 95% of the total voltage drop required by the system, and the voltage regulation range of the frequency converter accounts for 5% to 15% of the total voltage drop required by the system. The voltage regulation module and the power generation module convert the voltage drop energy during the throttling process into electrical energy. The generated electrical energy is used to directly feed back to the drive motor of the booster pump to reduce the effective power of the booster pump from the grid, supply power to external loads, connect to the grid, or store in an energy storage device. The flow regulation and pressure regulation module and the power generation module include a shaftless flange generator embedded in the pipeline and a back pressure regulation section with an adjustable outlet area. The back pressure regulation section controls the effective head of the generator by changing the outlet flow area, thereby changing the power generation while regulating the cooling water flow, thus achieving the following triple linkage control: Changes in cooling water flow rate alter the flow velocity within the heat exchange equipment, thereby changing the heat transfer coefficient K and adjusting the amount of heat exchanged. The change in flow rate simultaneously alters the distribution relationship between the outlet flow area of the back pressure regulating section and the effective head of the generator, thereby changing the power generation capacity. The outlet flow area of the back pressure regulating section is the only main regulating variable of the system, and the heat exchange and power generation are linked through this regulating variable.
[0051] Furthermore, the flow regulation and pressure regulation module and the power generation module adopt a continuously rotating impeller mechanism for throttling and energy conversion, replacing the traditional shut-off throttling method of the throttling valve, so that the pressure change on the outlet side of the heat exchange equipment is smooth and continuous, eliminating the water hammer effect and pressure change caused by the opening and closing of traditional valves and the impact on the heat exchange equipment.
[0052] Furthermore, a check valve is installed on the inlet side of the heat exchange equipment to prevent cooling water from backflowing into the heat exchange equipment when the system stops or the flow rate changes suddenly; a check valve is installed on the outlet side of the booster pump to prevent high-pressure water in the pipeline from flowing back and causing the pump to reverse and be damaged when the booster pump stops. Furthermore, the pipeline between the booster pump outlet and the heat exchange equipment inlet adopts an enlarged pipe diameter design to reduce friction loss along the pipeline; the heat exchange equipment adopts a relaxed design with increased parallel channels and fewer bends to reduce equipment pressure drop. Furthermore, each heat exchanger is equipped with its own flow regulation and pressure regulation module and power generation module on its outlet pipeline. When the throttling capacity of a single power generation unit is insufficient to consume all available pressure drop, multiple power generation units are connected in series. When multiple heat exchangers are connected in parallel and operating independently, the power generation units at their respective outlets are controlled independently.
[0053] In practical use, this workflow converts the ineffective pressure drop energy dissipated by traditional throttling valves into electrical energy for external output, achieving effective recovery of energy that was originally irreversibly lost. The throttling pressure drop can account for more than 40% of the total required pressure drop of the system. Calculated with a power generation efficiency of no less than 30%, the throttling energy recovery rate is no less than 12%. The recovered electrical energy can be directly fed back to the drive motor of the booster pump, reducing the effective power of the pump from the grid. It can also supply power to external loads or be connected to the grid, reducing the net power consumption of the system. The booster pump operates at or near the rated speed, always working near the optimal efficiency range, avoiding the problem of a sharp drop in pump efficiency at low loads in the variable frequency speed control scheme. The pump's high-efficiency operation itself has a significant energy-saving effect. Since the throttling point is moved from the pump outlet to the heat exchange equipment outlet, the working pressure of the heat exchange equipment is maintained by the stable output of the booster pump and is no longer affected by changes in the opening of the throttling valve or the speed regulation of the frequency converter. This constant pressure environment can eliminate the risk of flashing caused by pressure fluctuations inside the heat exchange equipment, extend the service life of seals and pipelines, and stabilize heat exchange efficiency. By adjusting the opening of a single flow channel, the cooling water flow rate, the heat exchange capacity of the heat exchange equipment, and the power output of the generator can be controlled simultaneously. This coupled control simplifies the system control logic and further improves the response speed and control accuracy. The flow regulation and pressure regulation module and the power generation module use a continuously rotating impeller mechanism for throttling, replacing the shut-off opening and closing action of the traditional throttling valve, so that the pressure change on the outlet side of the heat exchange equipment is smooth and continuous, and the water hammer impact caused by rapid valve opening and closing is eliminated. When multiple heat exchange devices are running in parallel, each device outlet is equipped with a flow regulation and voltage regulation module and a power generation module, which can independently control the flow of each branch to meet the different heat load requirements of different heat exchange devices. This is something that a single variable frequency speed control scheme cannot achieve. Since the throttling function is transferred to the end and converted into electrical energy recovery, measures such as increasing the pipe diameter and optimizing the heat exchange equipment channels can be taken during the design to reduce the total system resistance, further reducing the power of the booster pump and reducing the overall system energy consumption by 30% to 45%. Unlike distributed power generation technologies such as photovoltaics and waste heat, which require complex grid connection equipment, the power generation device and booster pump of this invention are located in the same circulating water system. The recovered electrical energy can be directly fed back to the pump's drive motor, completing a closed-loop transfer from electrical energy to water potential energy and back to electrical energy within the system. This eliminates the grid connection conversion link, and the reduction in the system's net power consumption is the actual economic benefit, without affecting the operation of the factory's original power distribution system.
[0054] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.
Claims
1. A low-energy-consumption circulating cooling water terminal throttling energy recovery device, characterized in that, include: The system includes a flow guide pipe module, a flow regulation and pressure regulation module, and a power generation module. The flow guide pipe module includes a pipe assembly, and the pipe assembly includes an inlet pipe. The flow regulation and pressure regulation module is located at the front end of the inlet of the inlet pipe, the power generation module is located at the rear of the flow regulation and pressure regulation module, and the inlet pipe is connected to the end of the heat exchanger tube group. The flow and voltage regulation module includes a magnetic ring assembly and a regulating valve core assembly; The magnetic ring assembly includes an upper magnetic ring and a lower magnetic ring. Both the upper and lower magnetic rings are slidably arranged outside the inlet pipe along the axial direction of the inlet pipe, and a number of magnetic sheets are evenly distributed on the upper and lower magnetic rings. The regulating valve core assembly includes a valve core housing, a magnetic ring frame, and follower magnetic poles. The valve core housing is arranged axially in the inner cavity of the inlet pipe. The magnetic ring frame is coaxially arranged inside the valve core housing. Several follower magnetic poles are evenly distributed circumferentially on the magnetic ring frame, and the follower magnetic poles match the magnetic poles of the magnetic sheet.
2. The low-energy-consumption circulating cooling water terminal throttling energy recovery device according to claim 1, characterized in that, The piping assembly also includes a central pipe, a rear connecting flange, a stepped groove, and a contraction section. The rear connecting flange is coaxially arranged with the inlet pipe and is interconnected with it. The inner diameter end of the rear connecting flange is provided with a stepped groove, the diameter of which is smaller than the inner diameter of the inlet pipe. The inner wall side of the central pipe is also provided with a contraction section.
3. The low-energy-consumption circulating cooling water terminal throttling energy recovery device according to claim 2, characterized in that, The pipe assembly also includes an upper cover and a lower cover, which are fastened to the outer wall of the inlet pipe. Guide posts are evenly distributed in the inner cavities of the upper cover and the lower cover, and the upper magnetic ring and the lower magnetic ring are movably arranged in the cavities of the guide posts.
4. The low-energy-consumption circulating cooling water terminal throttling energy recovery device according to claim 2, characterized in that, The power generation module includes a power generation shell assembly, which includes a power generation end shell, a shunt pipe section, and a diffuser pipe. One end of the power generation end shell is connected to the central pipe, and the other end of the power generation end shell is connected to the diffuser pipe. A shunt pipe section matching the inner diameter of the central pipe is provided on the side of the power generation end shell near the central pipe.
5. The low-energy-consumption circulating cooling water terminal throttling energy recovery device according to claim 1, characterized in that, The regulating valve core assembly also includes an external cavity, an internal cavity, a column, a guide cone, a connecting shaft, and a sleeve. The valve core housing has independent external and internal cavities. The column slides against one side of the inner wall of the external cavity, and a guide cone is fixedly connected to one end of the column. A connecting shaft is fixedly connected to the other end of the column. The connecting shaft slides through the internal cavity, and a sleeve is fixedly connected to the end of the connecting shaft. The magnetic ring frame is fixedly installed at one end of the sleeve rod. The regulating valve core assembly also includes a limiting rod, which is fixedly installed in the inner cavity of the built-in cavity, and the magnetic ring frame slides through the limiting rod.
6. The low-energy-consumption circulating cooling water terminal throttling energy recovery device according to claim 3, characterized in that, The current and voltage regulation module also includes a drive assembly, which includes an outer housing, a drive shaft, a drive component, and a drive bracket. The outer housing is fixedly installed on the top of the upper cover, and the drive shaft is rotatably installed inside the outer housing. One end of the drive component is engaged with a lead screw on the surface of the drive shaft, and the other end of the drive component is fixedly connected to the drive bracket. The drive bracket passes through the upper cover and is fixedly connected to the upper magnetic ring.
7. The low-energy-consumption circulating cooling water terminal throttling energy recovery device according to claim 1, characterized in that, The flow regulation and pressure regulation module also includes a flow splitting assembly, which includes a main flow splitting pipe, branch flow splitting pipes, plugs, limiters, movable valve cores, sliding sleeves, pins, drive shafts, cams, linkage shafts, and driven gears. The main flow splitting pipe is located on one side of the branch flow splitting pipe section. One end of the main flow splitting pipe is connected to the branch flow splitting pipe section. Plugs and limiters are fixedly installed inside the branch flow splitting pipes. The movable valve core is slidably inserted into the plug, and a sliding sleeve is elastically fitted at the end of the movable valve core. A pin is also provided at the end of the sliding sleeve. The drive shaft is rotatably installed in the main flow splitting pipe, and a cam coaxially mounted at one end of the drive shaft slides against the pin. A linkage shaft is slidably inserted at the other end of the drive shaft. A driven gear is coaxially arranged at the end of the linkage shaft, and the driven gear meshes with the drive gear.
8. An energy recovery method based on low-energy-consumption circulating cooling water terminal throttling, employing the low-energy-consumption circulating cooling water terminal throttling energy recovery device according to any one of claims 1-7, comprising the following steps: S1. In the circulating cooling water circuit, remove the throttling valve on the pipeline between the outlet side of the booster pump and the inlet of the heat exchange equipment, so that the pipeline remains fully open. S2. A flow guide pipe module, a flow regulation and pressure regulation module, and a power generation module are connected in series on the outlet pipe of the heat exchange equipment. The flow regulation and pressure regulation module and the power generation module replace the eliminated throttle valve and undertake the main throttling function of the system. S3. The flow regulation and pressure regulation module controls the cooling water flow rate by adjusting the opening of the internal flow channel, and at the same time converts the pressure drop energy generated during the throttling process into electrical energy through the power generation module and outputs it to the outside. S4. The booster pump operates continuously at or near the rated speed to provide the basic head for the system; S5. The frequency converter is connected to the drive motor of the booster pump, and only makes minor adjustments to the speed of the booster pump within the range of 5% to 15% of the rated speed to maintain the stability of the inlet pressure of the heat exchange equipment. S6. Cooling water flows into the inlet pipe through the inlet flange and rotates through the spiral blades. The external drive component drives the upper and lower magnetic rings to slide along the pipe axis. The magnetic plates on them drive the internal magnetic ring frame and follower magnetic pole to move synchronously through non-contact magnetic coupling, thereby pushing the guide cone to move axially. The distance between the guide cone and the Venturi contraction section changes, causing the flow cross-sectional area to change, providing variable flow and head conditions for the power generation module. S7. The regulated water flow enters the generator housing and impacts the airfoil blades on the annular rim, driving the permanent magnet rotor to rotate. Through the wear-resistant coating, it couples with the external silicon steel stator to generate electrical energy. When the guide cone gets stuck, the magnetic coupling reaches saturation and produces slippage. At the same time, the axial buffering characteristic suppresses water hammer impact.