A cooling system for parallel independent water supply of double-plate heat exchanger of copper alloy furnace

Abstract

The utility model discloses a kind of parallel independent water supply cooling systems for copper alloy furnace double-plate heat exchanger, belong to non-ferrous smelting equipment cooling technical field.The system includes intelligent pump set redundancy switching unit, parallel equalization water supply unit and control system.Parallel equalization water supply unit is divided into two independent branches by water inlet mother pipe parallel connection, sequentially provided with stop valve, pressure gauge, double Y type filter unit, flow balance valve and temperature sensor on each branch, and temperature sensor is arranged at the inlet of cooling medium of plate heat exchanger.Intelligent pump set redundancy switching unit includes two parallel water pumps and the controlled valve of import and export thereof, realizes disturbanceless switching.The utility model solves the problem of temperature difference superposition, easy to block and poor reliability of series system, realizes the stable cooling of high cooling efficiency, online maintenance and intelligent redundancy, and guarantees the continuous and efficient production of copper alloy furnace.

Description

Technical Field

[0001] This utility model belongs to the technical field of copper alloy smelting cooling equipment, specifically relating to a cooling system for parallel independent water supply of a double-plate heat exchanger in a copper alloy furnace. Background Technology

[0002] In copper alloy smelting production, the furnace inductors and associated electrical cabinets of the industrial frequency induction furnace require stable circulating water cooling, typically ensured by a water pump station through plate heat exchangers. Currently, some workshops use series piping to provide external circulating cooling water for two plate heat exchangers. This series design has significant drawbacks: First, the water entering the second heat exchanger is actually the effluent from the first, with a significantly elevated water temperature, resulting in insufficient cooling capacity. Second, impurities in the piping flow sequentially through both heat exchangers, easily causing blockage and scaling in the plate channels, reducing heat exchange efficiency by more than 30%. Finally, the system lacks effective filtration and intelligent protection; when the furnace power increases, the inductor return water temperature can easily exceed the limit instantaneously, triggering a high-temperature alarm and forcibly shutting down the system. Statistics show that this causes 2-3 trips per shift, severely disrupting production and affecting ingot quality. To maintain production, companies are forced to adopt inefficient methods such as reducing power and frequent shutdowns for cleaning, resulting in high energy consumption and low production capacity.

[0003] While existing technologies have proposed improvements such as converting to parallel piping and adding filters, they generally suffer from the following problems: uneven flow distribution in parallel branches affects cooling performance; filter cleaning still requires interrupting the water supply to the corresponding branch, affecting production continuity; and there is a lack of rapid, automatic emergency response mechanisms in case of pump failure or extreme operating conditions, leaving room for improvement in system reliability. Therefore, there is an urgent need for a cooling system modification scheme that is structurally sound, easy to maintain, and highly reliable. Utility Model Content

[0004] The technical problem to be solved by this utility model is to overcome the defects of existing series cooling systems, such as temperature difference superposition, easy blockage, poor reliability, and uneven flow and inconvenient maintenance of existing parallel schemes, and to provide a parallel independent water supply cooling system for copper alloy furnace double plate heat exchangers with high cooling efficiency, online maintenance capability, and intelligent redundancy switching function.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is as follows:

[0006] A cooling system for parallel independent water supply of double-plate heat exchangers in a copper alloy furnace, comprising an inlet header, an outlet header, a first plate heat exchanger, and a second plate heat exchanger, further comprising:

[0007] Intelligent pump set redundancy switching unit: the inlet end is connected to the cooling water source, and the outlet end is connected to the inlet header;

[0008] Parallel balanced water supply unit: includes a first inlet branch pipe and a second inlet branch pipe that are branched off in parallel from the main inlet pipe. The first inlet branch pipe is connected to the inlet of the first plate heat exchanger, and the outlet of the first plate heat exchanger is connected in parallel to the main outlet pipe. The second inlet branch pipe is connected to the inlet of the second plate heat exchanger, and the outlet of the second plate heat exchanger is connected in parallel to the main outlet pipe.

[0009] On the first inlet branch pipe, a fifth shut-off valve, a first pressure gauge, a first double Y-type filter unit, a first flow balancing valve, and a second pressure gauge are sequentially arranged along the water flow direction. A first temperature sensor is provided at the inlet of the first plate heat exchanger.

[0010] On the second inlet branch pipe, a sixth shut-off valve, a third pressure gauge, a second double Y-type filter unit, a second flow balancing valve, and a fourth pressure gauge are sequentially installed along the water flow direction; a second temperature sensor is installed at the inlet of the second plate heat exchanger.

[0011] A third temperature sensor is installed on the main water outlet pipe;

[0012] Control system: It is electrically connected to the first temperature sensor, the second temperature sensor, and the intelligent pump group redundancy switching unit respectively, and is used to control the intelligent pump group redundancy switching unit to perform switching operations according to the detection signal of the first temperature sensor or the second temperature sensor.

[0013] Furthermore, the intelligent pump group redundancy switching unit includes a first main pump and a second main pump arranged in parallel;

[0014] The first main pump is equipped with a first shut-off valve and a second shut-off valve on its inlet and outlet pipelines, respectively.

[0015] The inlet and outlet pipelines of the second main pump are respectively equipped with a third shut-off valve and a fourth shut-off valve;

[0016] The first, second, third, and fourth shut-off valves are all automatic valves controlled by the control system, and the first and second main pumps are electrically connected to the control system.

[0017] Furthermore, the first dual Y-type filter unit includes a first three-way switching valve, a first Y-type filter and a second Y-type filter arranged in parallel. The inlet of the first three-way switching valve is connected to the first inlet branch pipe, and the two outlets are respectively connected to the inlets of the first Y-type filter and the second Y-type filter. The outlets of the first Y-type filter and the second Y-type filter are connected in parallel to the first flow balancing valve.

[0018] The second dual Y-type filter unit includes a second three-way switching valve, a third Y-type filter and a fourth Y-type filter arranged in parallel. The inlet of the second three-way switching valve is connected to the second inlet branch pipe, and the two outlets are respectively connected to the inlets of the third Y-type filter and the fourth Y-type filter. The outlets of the third Y-type filter and the fourth Y-type filter are connected in parallel to the second flow balancing valve.

[0019] Furthermore, the first flow balancing valve and the second flow balancing valve are manually adjustable balancing valves or electrically adjustable valves with visible flow scales.

[0020] Furthermore, the control system is connected to the first temperature sensor and the second temperature sensor for signal transmission, and is also connected to the first main pump, the second main pump, the first shut-off valve, the second shut-off valve, the third shut-off valve, and the fourth shut-off valve for control.

[0021] When the detection value of the first or second temperature sensor reaches a preset threshold, the control system can start the second main pump and switch the corresponding valve to replace the operation of the first main pump, or vice versa.

[0022] The core concept of this invention lies in ensuring that both heat exchangers receive isothermal low-temperature water through "parallel independent water supply," thereby eliminating temperature difference superposition at the source. The combination of a "dual filtration unit" and a "flow regulating valve" enables online maintenance of the filters to ensure long-term unobstructed flow, while precisely controlling the flow distribution of each branch to ensure balanced cooling capacity. A "temperature sensor" installed at the inlet of the medium to be cooled in the heat exchanger directly monitors the heat load, providing the control system with the most direct and fastest early warning signal. Finally, the linkage between the "intelligent pump redundancy switching unit" and the aforementioned monitoring signals constructs a complete safety chain from early warning to seamless switching, completely eliminating system downtime caused by single-point failures.

[0023] The synergistic effect of various technical features produces results that are significantly better than simply piecing together existing technologies: parallel water supply and flow regulation solve the problem of uneven cooling capacity; the online maintenance feature of the dual filter ensures long-term efficient operation of the system without the need for production shutdown; and the intelligent linkage between the inlet temperature monitoring point and the redundant pump set transforms passive response to faults into proactive prevention and rapid recovery, greatly improving the overall reliability and availability of the system.

[0024] Compared with the prior art, the beneficial effects of this utility model are:

[0025] 1. This utility model adopts parallel water supply and is equipped with a flow regulating valve to ensure that both heat exchangers receive sufficient and balanced low-temperature cooling water, which can significantly improve the overall cooling efficiency of the system.

[0026] 2. The design of this utility model, which combines a double Y-type filter with a three-way switching valve, enables online cleaning and switching of the filter. Maintenance does not affect the normal operation of the corresponding branch, achieving "zero downtime" maintenance.

[0027] 3. This utility model sets the key temperature monitoring point at the inlet of the medium to be cooled in the heat exchanger, which can more directly and quickly reflect the real heat load of the sensor or electrical cabinet, providing the system with an earlier warning and intervention time window;

[0028] 4. This utility model links the intelligent pump set redundancy switching unit with the inlet temperature signal, enabling seamless switching within seconds when the temperature exceeds the limit or the pump fails. It provides dual backup of power and mechanical components, greatly enhancing the robustness and continuous production capacity of the system.

[0029] 5. The system structure of this utility model is clear, the flow rate is easy to adjust, the filter clogging status can be easily judged by differential pressure, and the full flange connection is easy to disassemble, making the system debugging, maintenance and heat exchanger cleaning and maintenance more convenient, which helps to significantly extend the stable operation cycle of the equipment. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0031] In the diagram: 1-First shut-off valve; 2-First main pump; 3-Second shut-off valve; 4-Third shut-off valve; 5-Second main pump; 6-Fourth shut-off valve; 7-Inlet main pipe; 8-First inlet branch pipe; 9-Fifth shut-off valve; 10-First pressure gauge; 11-First three-way switching valve; 12-First Y-type filter; 13-Second Y-type filter; 14-First flow balancing valve; 15-Second pressure gauge; 16-First temperature sensor; 17-First plate heat exchanger; 18-Second inlet branch pipe; 19-Sixth shut-off valve; 20-Third pressure gauge; 21-Second three-way switching valve; 22-Third Y-type filter; 23-Fourth Y-type filter; 24-Second flow balancing valve; 25-Fourth pressure gauge; 26-Second temperature sensor; 27-Second plate heat exchanger; 28-Outlet main pipe; 29-Third temperature sensor. Detailed Implementation

[0032] The present invention will be further described below with reference to the embodiments and accompanying drawings.

[0033] like Figure 1 As shown in the figure, the parallel independent water supply cooling system for a double-plate heat exchanger of a copper alloy furnace provided in this embodiment mainly includes an intelligent pump group redundancy switching unit, a parallel balanced water supply unit and a control system.

[0034] Intelligent pump set redundancy switching unit: The first main pump 2 and the second main pump 5 are connected in parallel, with their front ends connected to a cooling water source (such as a cold water tank or pipe network), forming a one-in-one standby relationship. The inlet and outlet pipes of the first main pump 2 are equipped with a first shut-off valve 1 and a second shut-off valve 3, respectively; the inlet and outlet pipes of the second main pump 5 are equipped with a third shut-off valve 4 and a fourth shut-off valve 6, respectively. These four shut-off valves are electrically operated and controlled by the control system. During normal operation, if the first main pump 2 is working, the first shut-off valve 1 and the second shut-off valve 3 are open, the second main pump 5 is on standby, and the third shut-off valve 4 and the fourth shut-off valve 6 are closed.

[0035] Parallel balanced water supply unit: The inlet main pipe 7 receives cooling water from the pump set and is divided into a first inlet branch pipe 8 and a second inlet branch pipe 18. The first inlet branch pipe 8 serves the first plate heat exchanger 17, and the second inlet branch pipe 18 serves the second plate heat exchanger 27.

[0036] On the first inlet branch pipe 8, a fifth shut-off valve 9, a first pressure gauge 10, a first double Y-type filter unit, a first flow balancing valve 14, and a second pressure gauge 15 are installed sequentially along the water flow direction. The first double Y-type filter unit consists of a first three-way switching valve 11 and a first Y-type filter 12 and a second Y-type filter 13 connected in parallel. By operating the first three-way switching valve 11, water can flow through either filter while the other remains standby, thus achieving online cleaning. The first flow balancing valve 14 is used to set and lock the flow rate of this branch. A first temperature sensor 16 is installed on the inlet pipe of the medium to be cooled (high-temperature internal circulating water from the sensor) of the first plate heat exchanger 17.

[0037] The configuration of the second inlet branch pipe 18 is completely symmetrical with that of the first inlet branch pipe 8, including a second shut-off valve 19, a third pressure gauge 20, a second double Y-type filter unit (including a second three-way switching valve 21, a third Y-type filter 22, and a fourth Y-type filter 23), a second flow balancing valve 24, a fourth pressure gauge 25, and a second temperature sensor 26.

[0038] The cooling medium outlets of the first and second plate heat exchangers (17, 27) converge into the main water outlet pipe 28, which is equipped with a third temperature sensor 29.

[0039] The control system (PLC or DCS) receives signals from all temperature sensors (16, 26, 29) and pressure gauges (10, 15, 20, 25), and controls the start and stop of each electric valve and water pump. Its control logic includes: monitoring the values ​​of the first and second temperature sensors (16, 26); issuing an audible and visual warning if the value exceeds the set warning value of 58℃; immediately starting the standby pump if the temperature reaches the high limit of 60℃ or a main pump fault signal is received, and controlling the relevant valves to operate in a preset sequence, completing the switching within seconds to ensure uninterrupted water supply. Simultaneously, by comparing the pressure gauge readings before and after the filter (e.g., 10 vs. 15, 20 vs. 25), the filter clogging status can be determined, prompting for cleaning.

[0040] The working process of this utility model:

[0041] The operation of this cooling system is a collaborative process in which the intelligent pump set redundant switching unit provides power, the parallel balanced water supply unit performs cooling, and the entire process is monitored and intelligently adjusted by the control system.

[0042] Its working process is as follows:

[0043] 1. Normal cooling operation process:

[0044] Power supply: The control system is set by default to use the first main pump 2 as the main pump and the second main pump 5 as the standby pump. When starting the system, the control system opens the first shut-off valve 1 and the second shut-off valve 3, and starts the first main pump 2. The external circulating cooling water is drawn from the water source, pressurized by the first main pump 2, and then sent to the inlet header 7.

[0045] Parallel independent water supply: The pressurized low-temperature cooling water is divided into two paths in the inlet header 7: one path enters the first inlet branch pipe 8, and the other path enters the second inlet branch pipe 18. The water flow in the two branches is independent of each other, and the temperature of both is the initial low temperature.

[0046] Filtration and Flow Distribution: The water flowing into the first inlet branch pipe 8 passes sequentially through the fifth shut-off valve 9 (in the open state), the first three-way switching valve 11 of the first double Y-type filter unit (switching to the first Y-type filter 12, with the second Y-type filter 13 as a backup), and the first flow balancing valve 14. The first flow balancing valve 14 has been pre-set to a specific opening degree manually or by the control system to ensure that the cooling water flow allocated to the first plate heat exchanger 17 accurately meets its design requirements. The operation of the second inlet branch pipe 18 is completely symmetrical, with the second flow balancing valve 24 ensuring the flow supply to the second plate heat exchanger 27.

[0047] Heat exchange process: Cooling water, after precise flow distribution and filtration, enters the cooling medium side (plate side) of the first plate heat exchanger 17 and the second plate heat exchanger 27, respectively. Simultaneously, high-temperature hot water (internal circulating water) from the furnace inductor enters the cooling medium side (shell side) of the first plate heat exchanger 17, while hot water from the electrical cabinet enters the second plate heat exchanger 27. Inside the plate heat exchangers, the high-temperature internal circulating water and the low-temperature external circulating water undergo efficient counter-current heat exchange through the plates. The internal circulating water, after being cooled, returns to the inductor and electrical cabinet for reuse, while the external circulating water, after absorbing heat, flows from the heat exchanger outlet into the main outlet pipe 28, ultimately returning to the cooling tower or external pipe network.

[0048] Real-time monitoring: Throughout the process, the control system continuously collects key data.

[0049] First temperature sensor 16 and second temperature sensor 26: directly monitor the temperature of the internal circulating hot water entering the heat exchanger, and truly reflect the cooling requirements and heat load of the sensor and electrical cabinet.

[0050] First, second, third, and fourth pressure gauges (10, 15, 20, 25): monitor the inlet pressure of each branch and the pressure difference before and after the filter. An increase in pressure difference is a direct signal that the filter is clogged.

[0051] Third temperature sensor 29: Monitors the total return water temperature of the system and evaluates the overall cooling effect.

[0052] 2. Filter online cleaning and maintenance process:

[0053] When the control system detects that the pressure difference between the first pressure gauge 10 and the second pressure gauge 15 of the first branch continues to increase to the set threshold, or when performing preventive maintenance as planned, the first dual Y-type filter unit can be cleaned online. The specific process is as follows:

[0054] Flow path switching: The operator or control system drives the first three-way switching valve 11 to switch the inlet water from the currently operating first Y-type filter 12 to the standby second Y-type filter 13. The switching action is rapid, the water supply of the first inlet branch pipe 8 is uninterrupted, and the cooling of the first plate heat exchanger 17 is not affected in any way.

[0055] Isolation and Cleaning: At this point, the first Y-type filter 12 is isolated. The operator can safely remove and clean the filter screen to remove trapped impurities by closing its drain valve or opening its end cap.

[0056] Restoring to standby: After cleaning, reset the first Y-type filter 12. At this time, the second Y-type filter 13 is in operation, and the first Y-type filter 12 is switched to standby. This process achieves "zero downtime" maintenance. The maintenance process for the filters in the second branch is exactly the same.

[0057] 3. Intelligent pump set redundancy switching process:

[0058] When the first temperature sensor 16 or the second temperature sensor 26 detects that the temperature exceeds the upper limit setting value, such as 60°C, or when the control system receives an electrical fault signal from the first main pump 2, the system automatically triggers the emergency switching procedure, completing a seamless switch from the main pump to the standby pump within 3-5 seconds.

[0059] Step 1: Start the standby pump: The control system immediately starts the second main pump 5 as a standby pump. At this time, its inlet and outlet third shut-off valve 4 and fourth shut-off valve 6 are still in the closed state, and the pump starts under low load.

[0060] Step Two: Establishing a Backup Path: The control system rapidly opens the third shut-off valve 4 and the fourth shut-off valve 6 simultaneously or sequentially. Cooling water begins to be pumped into the inlet header 7 via the second main pump 5. At this time, the system is supplied with water by the first main pump 2 and the second main pump 5 operating in parallel for a short period, and the system pressure is stable.

[0061] Step 3: Disconnect the original main pump circuit: After the control system confirms that the second main pump 5 is operating normally and the pressure is stable, it immediately closes the first shut-off valve 1 and the second shut-off valve 3 simultaneously or sequentially. At this point, the cooling water supply is entirely provided by the second main pump 5.

[0062] Step 4: Stop the original main pump: The control system stops the first main pump 2, and the switching process is complete. During the entire switching period, the cooling water supply flow and pressure to the inlet header 7 remained basically stable, effectively preventing the furnace body from tripping due to instantaneous overheating caused by power interruption.

[0063] Alarms and indications: During and after the switching process, the control system will trigger an audible and visual alarm and clearly indicate on the human-machine interface that the currently operating pump is the second main pump 5, and the first main pump 2 has switched to a standby state awaiting maintenance.

[0064] 4. Early warning and adjustment process:

[0065] Early warning: When the value detected by the first temperature sensor 16 or the second temperature sensor 26 continuously exceeds the warning value, such as 58°C, but does not reach the high limit, the control system will issue an audible and visual warning in advance to prompt the operator to pay attention to the production load or check the system, but will not trigger a trip or pump switching, leaving a time window for manual intervention.

[0066] Flow rebalancing: If the flow rate of the two branches deviates due to changes in pipeline characteristics after long-term operation, the flow rate of the two branches can be precisely adjusted back to the set value by adjusting the opening of the first flow balancing valve 14 or the second flow balancing valve 24, combined with their own flow display, to ensure that the cooling effect is always in the optimal state.

[0067] Through the above-mentioned working process, this utility model realizes the transformation from "passive response to faults" to "proactive early warning and intelligent protection", and constructs a copper alloy furnace cooling system that is efficient, stable, reliable and easy to maintain, ensuring the continuity and economy of smelting production.

Claims

1. A cooling system for parallel independent water supply of double-plate heat exchangers in a copper alloy furnace, comprising an inlet header (7), an outlet header (28), a first plate heat exchanger (17), and a second plate heat exchanger (27), characterized in that: Also includes: Intelligent pump set redundancy switching unit: the inlet end is connected to the cooling water source, and the outlet end is connected to the inlet header (7). Parallel balanced water supply unit: includes a first inlet branch pipe (8) and a second inlet branch pipe (18) branched out in parallel from the inlet main pipe (7). The first inlet branch pipe (8) is connected to the inlet of the first plate heat exchanger (17), and the outlet of the first plate heat exchanger (17) is connected in parallel to the outlet main pipe (28). The second inlet branch pipe (18) is connected to the inlet of the second plate heat exchanger (27), and the outlet of the second plate heat exchanger (27) is connected in parallel to the outlet main pipe (28). On the first inlet branch pipe (8), a fifth shut-off valve (9), a first pressure gauge (10), a first double Y-type filter unit, a first flow balance valve (14), and a second pressure gauge (15) are arranged in sequence along the water flow direction. A first temperature sensor (16) is provided at the inlet of the first plate heat exchanger (17). On the second inlet branch pipe (18), a sixth shut-off valve (19), a third pressure gauge (20), a second double Y-type filter unit, a second flow balancing valve (24), and a fourth pressure gauge (25) are arranged sequentially along the water flow direction; a second temperature sensor (26) is arranged at the inlet of the second plate heat exchanger (27). A third temperature sensor (29) is installed on the main outlet pipe (28); Control system: It is electrically connected to the first temperature sensor (16), the second temperature sensor (26) and the intelligent pump group redundancy switching unit respectively, and is used to control the intelligent pump group redundancy switching unit to perform switching operation according to the detection signal of the first temperature sensor (16) or the second temperature sensor (26).

2. The cooling system according to claim 1, characterized in that, The intelligent pump set redundancy switching unit includes a first main pump (2) and a second main pump (5) connected in parallel. The first main pump (2) is equipped with a first shut-off valve (1) and a second shut-off valve (3) on its inlet and outlet pipes, respectively. The inlet and outlet pipelines of the second main pump (5) are respectively equipped with a third shut-off valve (4) and a fourth shut-off valve (6); The first shut-off valve (1), the second shut-off valve (3), the third shut-off valve (4) and the fourth shut-off valve (6) are all automatic valves controlled by the control system. The first main pump (2) and the second main pump (5) are electrically connected to the control system.

3. The cooling system according to claim 1, characterized in that, The first dual Y-type filter unit includes a first three-way switching valve (11), a first Y-type filter (12) and a second Y-type filter (13) arranged in parallel. The inlet of the first three-way switching valve (11) is connected to the first inlet branch pipe (8), and the two outlets are respectively connected to the inlets of the first Y-type filter (12) and the second Y-type filter (13). The outlets of the first Y-type filter (12) and the second Y-type filter (13) are connected in parallel to the first flow balancing valve (14). The second dual Y-type filter unit includes a second three-way switching valve (21), a third Y-type filter (22) and a fourth Y-type filter (23) connected in parallel. The inlet of the second three-way switching valve (21) is connected to the second inlet branch pipe (18), and the two outlets are respectively connected to the inlets of the third Y-type filter (22) and the fourth Y-type filter (23). The outlets of the third Y-type filter (22) and the fourth Y-type filter (23) are connected in parallel to the second flow balancing valve (24).

4. The cooling system according to claim 1, characterized in that, The first flow balancing valve (14) and the second flow balancing valve (24) are manually adjustable balancing valves or electrically adjustable valves with visible flow scales.

5. The cooling system according to claim 1, characterized in that, The control system is connected to the first temperature sensor (16) and the second temperature sensor (26) for signal connection, and is also connected to the first main pump (2), the second main pump (5), the first shut-off valve (1), the second shut-off valve (3), the third shut-off valve (4), and the fourth shut-off valve (6) for control connection. When the detection value of the first temperature sensor (16) or the second temperature sensor (26) reaches the preset threshold, the control system can start the second main pump (5) and switch the corresponding valve to replace the first main pump (2) in operation, or vice versa.

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