CN113587714A - Energy-saving optimization method of cooling tower - Google Patents

Energy-saving optimization method of cooling tower Download PDF

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Publication number
CN113587714A
CN113587714A CN202110752398.4A CN202110752398A CN113587714A CN 113587714 A CN113587714 A CN 113587714A CN 202110752398 A CN202110752398 A CN 202110752398A CN 113587714 A CN113587714 A CN 113587714A
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China
Prior art keywords
cooling tower
energy
motor
permanent magnet
reduced
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CN202110752398.4A
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Chinese (zh)
Inventor
高敬璞
魏军
周颖
任超
于同山
刘媛媛
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Dalian Spindle Environmental Facilities Co ltd
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Dalian Spindle Environmental Facilities Co ltd
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Priority to CN202110752398.4A priority Critical patent/CN113587714A/en
Publication of CN113587714A publication Critical patent/CN113587714A/en
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28HEAT EXCHANGE IN GENERAL
    • F28FDETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F27/00Control arrangements or safety devices specially adapted for heat-exchange or heat-transfer apparatus
    • F28F27/003Control arrangements or safety devices specially adapted for heat-exchange or heat-transfer apparatus specially adapted for cooling towers
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28HEAT EXCHANGE IN GENERAL
    • F28CHEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA COME INTO DIRECT CONTACT WITHOUT CHEMICAL INTERACTION
    • F28C1/00Direct-contact trickle coolers, e.g. cooling towers
    • F28C1/10Arrangements for suppressing noise

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Motor Or Generator Cooling System (AREA)

Abstract

The invention discloses an energy-saving optimization method for a cooling tower, and belongs to the technical field of energy. The method comprises the following four measures which are jointly implemented: the energy consumption of a driving fan is reduced, the mechanical transmission loss is reduced, the flow resistance of an air duct is reduced, the environment detection capability is improved, and the compatibility of software and hardware on a client level is perfect. The invention has the beneficial effects that: the operation energy consumption of the cooling tower can be reduced; the structural complexity of the cooling tower can be reduced; the use comfort of the cooling tower can be improved.

Description

Energy-saving optimization method of cooling tower
Technical Field
The invention relates to an energy-saving optimization method for a cooling tower, and belongs to the technical field of energy.
Background
Many industrial processes, business centers and data centers generate a large amount of heat, if the heat is not timely removed and the temperature is reduced, the comfort problem is generated slightly, the product and the service quality are influenced seriously, and even safety accidents can be caused more seriously. Generally, medium and large-sized air conditioning systems can be adopted to realize temperature and humidity reduction. In use, large air conditioning systems are often accompanied by the use of cooling towers on the condensing side. The cooling tower is electrically driven, and utilizes the contact and evaporation heat absorption of circulating water and air to realize the cooling and heat extraction of the condensation pipeline of the air conditioning system.
With the rapid development of refrigeration technology in recent years, such as the development and application of magnetic suspension centrifugal compressors, the proportion of the main machine power consumption of the air conditioning system in the total energy consumption is gradually reduced. But the condensing and heat dissipating part has little efficiency improvement amplitude of the fan and the water pump, so that the proportion of the condensing and heat dissipating part in the total energy consumption is gradually improved. Taking the centralized air conditioning system as an example, the energy consumed by the cooling water system accounts for about 1/4 of the total power consumption (2021, 21(4): 66). The heat exchange efficiency of the cooling tower and the natural cold air and the fluency of the heat dissipation path are one of the most critical factors for determining the operation efficiency of the whole system of the central air conditioner (Guangzhou communication technology 2020,40(7): 71). For data centers, air conditioning systems consume approximately 40% to 50% of the total energy (building energy savings 2020,18(11): 28). The data center of a communication company only has one cooling tower with electricity charge of more than 60 ten thousand yuan per year (intelligent building 2020(5): 35). The electric energy used for the cooling tower in China is about 400 hundred million kWh (journal of scientific and technological economy 2019,27(9):81) every year, the energy consumption of the cooling tower is reduced, and the cooling tower has obvious economic benefit and environmental protection benefit.
Main products of the current cooling tower sold in the market are mostly constant rotating speed and maintenance type products needing to be on duty, and the adaptability to variable operation conditions is not strong, so that the energy-saving potential is very large. In recent years, the energy-saving upgrading transformation and research and development ideas of cooling towers in the field are developed in the directions of replacing or additionally installing energy-saving parts, reducing the structural complexity, improving the system reliability, remotely diagnosing and the like. From the viewpoint of overall energy saving effect, further development is still required.
Disclosure of Invention
In order to overcome the defects in the prior art, the invention aims to provide an energy-saving optimization method for a cooling tower, which is used for detecting the waterproof performance before use, can be used when the detection is qualified and ensures the normal operation of the cooling tower.
The technical scheme of the invention is as follows: an energy-saving optimization method for a cooling tower comprises the following four measures which are jointly implemented: the energy consumption of a driving fan is reduced, the mechanical transmission loss is reduced, the flow resistance of an air duct is reduced, the environment detection capability is improved, and the compatibility of software and hardware on a client level is perfect.
The reduction of the energy consumption of the driving fan is specifically as follows: the permanent magnet synchronous motor with the rotating speed of 50-500 rpm capable of being dynamically adjusted is used for replacing a common three-phase asynchronous motor in a cooling tower to drive a fan, a permanent magnet of the permanent magnet synchronous motor is embedded in a rotor core formed by stacking silicon steel alloys, so that the eddy current loss prevention capability is realized, and the fatal hall sweeping short circuit problem can be solved; the heat loss of the motor is reduced, a newly designed concentrated winding and end non-phase lap joint structure is adopted, and the heat productivity of the end is reduced by at least 30%; and the secondary treatment technology of epoxy encapsulation and paint dipping is adopted, so that the winding is effectively wrapped, and the heat conduction is enhanced by at least 8%; the method for reducing the mechanical transmission loss specifically comprises the following steps: a special frequency converter is additionally arranged, the rotating speed of a motor can be dynamically adjusted within the range of 10 hz-200 hz of output frequency, and the rotating speed of the motor is 50 rpm-500 rpm, so that the power consumption of a cooling tower is well matched with the load of a unit and the ambient temperature; the reduction of the flow resistance of the air channel specifically comprises the following steps: the motor double-layer sealing structure is designed, and the waterproof and anticorrosive coating of the motor is additionally coated, so that the performance is not lower than the IP56 grade, and the performance attenuation caused by environmental factors such as high temperature, humidity, water quality and the like of the external environment is prevented.
The permanent magnet synchronous motor is directly connected with the cooling tower fan.
The permanent magnet synchronous motor is built in, the maximum sinking distance from outlet air is 50cm, and a transmission shaft between the permanent magnet synchronous motor and the fan is shortened.
The method for improving the environment detection capability specifically comprises the following steps: implementing a multi-point and mutual-checking detection technology, wherein the multi-point comprises 6-10 temperature monitoring points, 2 humidity monitoring points, 2-4 pressure monitoring points, 3-6 flow monitoring points, 2-4 current monitoring points, 2 liquid level monitoring points, 2 vibration monitoring points and 2 noise monitoring points, the detection points feed dynamic monitoring data back to a lower computer of a central control system in real time, and if the errors of the detection data of the same type are between 5% and 10% or the data are contradictory, namely the relative errors are more than 10%, the sensor is reported to be in error immediately; if the detection data of the same type can be verified together with the evidence, namely the relative error is less than or equal to 5 percent, the data can be used as a data basis for implementing automatic regulation and control, and the dynamic matching operation between the unit output and the load requirement is realized.
The software and hardware compatibility of the client layer is perfect, and the client layer comprises a parameter monitoring instrument and meter which are arranged in a quality and quantity guaranteed manner, an upper computer man-machine interaction interface which is provided with a computer and a mobile phone dual platform and is designed based on an objectification-oriented idea, and a lower computer control logic and control program execution device which is matched in a coordinated manner; the method comprises the steps of establishing a cloud data platform, linking real-time detection data-a client-a customer service end by utilizing a cloud message channel through a wireless transmission technology, and sending early warning in time once the cooling tower is found to be in a high energy consumption mode during operation, even potential safety hazards are generated, so that manual intervention and adjustment are required in time.
The invention has the beneficial effects that: the operation energy consumption of the cooling tower can be reduced; the structural complexity of the cooling tower can be reduced; the use comfort of the cooling tower can be improved.
Drawings
FIG. 1 is a top view of a cooling tower using a built-in permanent magnet synchronous motor to drive a fan;
FIG. 2 is a top view of a cooling tower using an external three-phase asynchronous motor to drive a fan;
fig. 3 is a schematic diagram of a corresponding relationship between a permanent magnet, a silicon steel sheet, an air slot and a rotating shaft in a permanent magnet synchronous motor.
In the figure: 1. the cooling tower comprises a cooling tower body, 2, a cooling tower upper end cover, 3, an air outlet fairing, 4, a permanent magnet synchronous motor, 5, an upper bracket, 6, fan blades, 7, a direct connection structure, 8, a cable, 9, a three-phase asynchronous motor, 10, a motor upper cover, 11, a belt sleeve, 12, a connecting shaft, 13, a permanent magnet, 14, a silicon steel alloy sheet, 15, a wedge-shaped heat insulation air groove, 16 and a rotating shaft.
Detailed Description
The invention is further described below with reference to the accompanying drawings:
example 1
Fig. 1 shows a three-dimensional structure of a cooling tower using a built-in permanent magnet synchronous motor to drive a fan.
The following four core measures are implemented in combination: the energy-saving system comprises a driving fan, a.
The measures for reducing the energy consumption of the driving fan are as follows: the fan is driven by using the permanent magnet synchronous motor 1 with the rotating speed capable of being dynamically adjusted between 50rpm and 500rpm, and the adjusting precision is 2.5 rpm. The rotor of the permanent magnet synchronous motor is composed of a rotor iron core, a permanent magnet 13, a rotating shaft 16, a heat insulation air slot 15 and the like. The rotor core is formed by stacking hundred groups of silicon steel alloy sheets 14, and the permanent magnet 13 is embedded in the rotor core 14. The structure of which is shown in figure 3. The structure is characterized in that: firstly, the eddy current loss can be prevented; secondly, the magnetic steel can be ensured not to be in direct contact with the alternating magnetic field of the stator, and the risk of demagnetization is reduced; thirdly, can effectively protect the magnet steel, avoid outside collision impact to cause the damage to the magnet steel, and even the magnet steel appears bursting apart the scheduling problem, can not cause fatal chamber of sweeping short circuit problem yet to ensure that the motor can be effective in longer life cycle and do not attenuate significantly. The permanent magnet synchronous motor 4 is also provided with a double-layer sealing structure, and a waterproof and anticorrosive coating of the motor is additionally coated. In a humid environment at 40 ℃, tap water is sprayed to the motor, the motor does not have a water inlet phenomenon, and the rotating speed and the energy efficiency of the motor do not have a decay phenomenon. The technology for reducing the heat loss of the motor is implemented, and comprises the steps of adopting a newly designed concentrated winding and a non-interphase lap joint structure at the end part, and reducing the heat productivity of the end part by more than 45%; and the secondary treatment technology of epoxy potting and paint dipping is adopted, so that the winding is effectively wrapped, and the heat conduction is enhanced by 10 percent. The permanent magnet synchronous motor is additionally provided with a special frequency converter, and the output frequency adjustment can be implemented at the highest resolution of 1hz within the frequency range of 10hz to 200hz, so that the rotating speed of the motor responds at the highest adjustment precision of 2.5rpm within the range of 50rpm to 500rpm correspondingly. The frequency converter is arranged in a floor type control cabinet of the cooling tower unit, an input circuit of the frequency converter is connected with a lower computer of the control system through a shielding cable, and an output circuit of the frequency converter is connected with a corresponding binding post in a power box of the permanent magnet synchronous motor. Through the cooperation of permanent magnet synchronous motor and converter, can demonstrate characteristics such as fan speed governing precision height, speed ratio are big, operate steadily. In addition, the permanent magnet synchronous motor can implement soft start under the cooperation of a frequency converter, and the starting noise is reduced by 10 decibels. When the measures are implemented simultaneously, taking a 30kW permanent magnet synchronous motor selected in the implementation case as an example, under the condition that the environmental wet bulb temperature is 28 ℃, the energy-saving effect of the full-load operation of the permanent magnet synchronous motor is about 15 percent compared with that of the traditional three-phase asynchronous motor with the same power.
The measures for reducing the mechanical transmission loss are as follows: the preferred rotating speed range of the permanent magnet synchronous motor 4 used in the invention is 300 rpm-500 rpm, which is just matched with the requirement of the cooling tower on the rotating speed of the fan, so that the permanent magnet synchronous motor 4 can be directly connected with the cooling tower fan through a direct structure 7. Thus, the reduction belt drive can be eliminated. And correspondingly, the belt sleeve 12, the belt pulley, the speed reducing bearing, the bearing seat and the connecting shaft 12 are also eliminated. The direct connection method can effectively avoid the loss of mechanical transmission efficiency, the transmission efficiency can be improved by 8 percent, and the running noise is reduced by 2 decibels. And also reduces the energy consumption associated with the manufacturing and maintenance process by reducing the use of parts.
The measure for reducing the air duct flow resistance is as follows: the motor mounting position in this embodiment is on the upper bracket 5 at a distance of 20cm from the wind outlet. The strength analysis of the upper bracket 5 shows that the deformation of the upper bracket 5 is only 1/1600, which is far better than 1/300 required by the standard. The benefits of the internal motor structure over the external motor structure are: the belt transmission device positioned right above the air outlet fairing 3 of the cooling tower is cancelled, and the upper bracket 5 is also internally arranged instead of externally arranged, so that the wind resistance on an air flow channel can be directly reduced, and the power consumption of the motor is reduced by 10% under the same power. Further, because of belt drive is cancelled, upper bracket 5 also changes by external to built-in, and the mesh that covers the net that hides on air outlet radome fairing 3 this moment distributes more evenly to make the problem of dispersing of air-out effectively controlled. In addition, after the motor is arranged, the special motor protective cover 10 is not needed, and the energy consumption caused by the manufacturing and maintenance process is reduced.
The measures for improving the environment detection capability are as follows: in the implementation case, a multi-parameter, multi-point and mutual-checking detection technology is adopted, and the running condition in the cooling tower, the atmosphere condition outside the cooling tower and the matching condition of the two conditions are accurately mastered. The temperature detection points are arranged at 6 (thermal resistance +/-0.15 ℃), wherein 3 monitoring points are arranged at the inlet, the middle section and the outlet of the cooled medium heat exchanger; the other 3 are arranged on the windward side of the cooling tower body 1, the side wall of the air outlet fairing 3 and the filler area of the cooling tower. And 2 (plus or minus 3 percent RH) humidity detection points are arranged on the windward side of the cooling tower body 1 and the filler area of the cooling tower. The 3 flow monitoring points are arranged in a cooled medium pipeline (liquid phase, 1.5 percent), a cooling tower air channel (gas phase, 1, 2.5 percent) and a water pipe (liquid phase, 1 percent). And 1 pressure sensor (+ -2.5%) is arranged outside the windward side of the cooling tower body 1 and the air outlet of the cooling tower. The current detection points are 2 (+ -2%) and are arranged on a power line of the motor and an output cable line of the frequency converter. And 1 (+/-5 mm) liquid level detection points are arranged in the water tank. The vibration monitoring points are 1 (+/-5%) and are arranged on the base of the unit. The noise sensors are arranged at 1 (+ -1 db) cooling tower about 100cm from the base. And feeding back the dynamic data acquired by the sensors of all the monitoring points to the lower computer of the central control system in real time. The lower computer of the central control system is selected from an S7-200 programmable controller and an EM series number acquisition module, is positioned in a floor type control cabinet of a cooling tower unit, is upwards connected with an upper computer (an integrated industrial computer, PPC-3150S) of the central control system, is downwards connected with a relay and an alternating current contactor, and is further connected with an electric appliance.
Compared with a three-phase asynchronous motor which runs at full load for 24 hours under the conditions that the wet bulb temperature in the daytime environment is 28 ℃ and the wet bulb temperature at night is at least 20 ℃, if a 30kW permanent magnet synchronous motor can run at low load at night, the energy-saving effect of the unit can be 40% at most. Furthermore, the noise at night can be reduced by 15 decibels under the condition of matching with temperature control according to the change of the ambient temperature at night.
The compatibility of software and hardware is perfect: the system is characterized by a linkage mechanism of a client level and a customer service level. The software and hardware compatibility improvement of the client level comprises a parameter monitoring instrument and meter arranged in a quality and quantity guaranteed manner, an upper computer human-computer interaction interface (configuration software) which is provided with a computer and mobile phone dual platform and designed based on an object-oriented concept, and a device for coordinating and matching lower computer control logic (ladder diagram language programming) and executing a control program. The perfect software and hardware compatibility of the customer service layer means that a cloud data platform is established (the running data of the equipment can be stored for more than 5 years or longer through a platform cloud data center and can be browsed and checked at any time to ensure the safety of the data), through an advanced wireless transmission technology (5G technology + remote monitoring), real-time detection data-client-customer service end is linked by a cloud message channel, once the data sent by a sensor deaf is judged by a host computer to possibly enable the cooling tower to operate in a high-energy consumption mode (judged by an onboard central control system), even potential safety hazards are generated (fault reasons are judged by a customer service data platform), early warning can be timely sent out (fault information can be obtained through a PC (personal computer) end and a mobile client end at the first time), and manual intervention and adjustment are required to be timely carried out (timeliness of customer service is guaranteed).
All the energy-saving methods are coupled, and the economic analysis result of the embodiment 1 is as follows: take a cooling tower with a 30KW motor and a 45KW motor running 24 hours a year as an example. If a traditional cooling tower is used, the electric charge is about 52.56 ten thousand yuan per year; after the energy-saving method is implemented, the electric charge is about 36.79 ten thousand yuan/year. The electricity fee can be saved by 15.77 ten thousand yuan each year. Actual units are formally operated for half a year without faults. The above description is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, several modifications and variations can be made without departing from the technical principle of the present invention, and these modifications and variations should also be regarded as the protection scope of the present invention.

Claims (6)

1. The energy-saving optimization method of the cooling tower is characterized by comprising the following four measures which are jointly implemented: the energy consumption of a driving fan is reduced, the mechanical transmission loss is reduced, the flow resistance of an air duct is reduced, the environment detection capability is improved, and the compatibility of software and hardware on a client level is perfect.
2. The energy-saving optimization method of the cooling tower according to claim 1, wherein the reduction of the energy consumption of the driving fan specifically comprises: the permanent magnet synchronous motor with the rotating speed of 50-500 rpm capable of being dynamically adjusted is used for replacing a common three-phase asynchronous motor in a cooling tower to drive a fan, a permanent magnet of the permanent magnet synchronous motor is embedded in a rotor core formed by stacking silicon steel alloys, so that the eddy current loss prevention capability is realized, and the fatal hall sweeping short circuit problem can be solved; the heat loss of the motor is reduced, a newly designed concentrated winding and end non-phase lap joint structure is adopted, and the heat productivity of the end is reduced by at least 30%; and the secondary treatment technology of epoxy encapsulation and paint dipping is adopted, so that the winding is effectively wrapped, and the heat conduction is enhanced by at least 8%; the method for reducing the mechanical transmission loss specifically comprises the following steps: a special frequency converter is additionally arranged, the rotating speed of a motor can be dynamically adjusted within the range of 10 hz-200 hz of output frequency, and the rotating speed of the motor is 50 rpm-500 rpm, so that the power consumption of a cooling tower is well matched with the load of a unit and the ambient temperature; the reduction of the flow resistance of the air channel specifically comprises the following steps: the motor double-layer sealing structure is designed, and the waterproof and anticorrosive coating of the motor is additionally coated, so that the performance is not lower than the IP56 grade, and the performance attenuation caused by environmental factors such as high temperature, humidity, water quality and the like of the external environment is prevented.
3. The energy-saving optimization method for the cooling tower according to claim 2, wherein the permanent magnet synchronous motor is directly connected with a fan of the cooling tower.
4. The energy-saving optimization method of the cooling tower according to claim 2, wherein the permanent magnet synchronous motor is built-in, the maximum sinking distance from the outlet wind is 50cm, and a transmission shaft between the permanent magnet synchronous motor and the fan is shortened.
5. The energy-saving optimization method of the cooling tower according to claim 1, wherein the improvement of the environment detection capability specifically comprises: implementing a multi-point and mutual-checking detection technology, wherein the multi-point comprises 6-10 temperature monitoring points, 2 humidity monitoring points, 2-4 pressure monitoring points, 3-6 flow monitoring points, 2-4 current monitoring points, 2 liquid level monitoring points, 2 vibration monitoring points and 2 noise monitoring points, the detection points feed dynamic monitoring data back to a lower computer of a central control system in real time, and if the errors of the detection data of the same type are between 5% and 10% or the data are contradictory, namely the relative errors are more than 10%, the sensor is reported to be in error immediately; if the detection data of the same type can be verified together with the evidence, namely the relative error is less than or equal to 5 percent, the data can be used as a data basis for implementing automatic regulation and control, and the dynamic matching operation between the unit output and the load requirement is realized.
6. The energy-saving optimization method of the cooling tower according to claim 1, wherein the software and hardware compatibility of the client layer is perfect, and the method comprises the steps of arranging parameter monitoring instruments and meters in a quality-guaranteed manner, providing an upper computer man-machine interaction interface designed based on an object-oriented concept of a computer and a mobile phone dual platform, and coordinating and matching lower computer control logic and a control program execution device; the method comprises the steps of establishing a cloud data platform, linking real-time detection data-a client-a customer service end by utilizing a cloud message channel through a wireless transmission technology, and sending early warning in time once the cooling tower is found to be in a high energy consumption mode during operation, even potential safety hazards are generated, so that manual intervention and adjustment are required in time.
CN202110752398.4A 2021-07-02 2021-07-02 Energy-saving optimization method of cooling tower Pending CN113587714A (en)

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN1848613A (en) * 2006-03-20 2006-10-18 西北工业大学 Rare-earth permanent magnetic synchro motor
JP2009250578A (en) * 2008-04-10 2009-10-29 Kawasaki Thermal Engineering Co Ltd Energy saving control operation method by stabilization of refrigerating machine cooling water temperature
CN103673742A (en) * 2013-12-16 2014-03-26 叶力忠 Industrial cooling tower draught fan intelligent drive system and working method thereof
CN105987618A (en) * 2015-02-09 2016-10-05 上海良机冷却设备有限公司 Cooling tower with permanent magnet motor driving structure design device
CN111614210A (en) * 2020-05-28 2020-09-01 沈阳工业大学 Low-eddy-current-loss high-efficiency canned motor pump
CN112833611A (en) * 2021-01-22 2021-05-25 深圳市奥宇节能技术股份有限公司 Cooling circulating water system and control method thereof

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN1848613A (en) * 2006-03-20 2006-10-18 西北工业大学 Rare-earth permanent magnetic synchro motor
JP2009250578A (en) * 2008-04-10 2009-10-29 Kawasaki Thermal Engineering Co Ltd Energy saving control operation method by stabilization of refrigerating machine cooling water temperature
CN103673742A (en) * 2013-12-16 2014-03-26 叶力忠 Industrial cooling tower draught fan intelligent drive system and working method thereof
CN105987618A (en) * 2015-02-09 2016-10-05 上海良机冷却设备有限公司 Cooling tower with permanent magnet motor driving structure design device
CN111614210A (en) * 2020-05-28 2020-09-01 沈阳工业大学 Low-eddy-current-loss high-efficiency canned motor pump
CN112833611A (en) * 2021-01-22 2021-05-25 深圳市奥宇节能技术股份有限公司 Cooling circulating water system and control method thereof

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Application publication date: 20211102