The all steel cooling tower series includes two inner product series: square cross flow and square counter flow. It includes a tower body, a tower body frame, a motor, a belt, a reducer, a wind duct, a fan, a water spreading basin cover, a water distribution nozzle, a water spraying filler, a water outlet flange, a water collection basin, an inspection door, and side plates. The tower body is composed of a tower body frame and side plates located on two opposite sides. The top of the tower body is connected to the motor and the wind duct, and the wind duct is equipped with a belt, a reducer, and a fan. The motor is connected to the reducer through the belt, and the reducer is connected to the fan. The upper part of the tower body is connected to the water spreading basin covers on both sides of the wind duct. There are several water distribution nozzles located directly below the water spreading basin cover, and the tower body is equipped with water spraying fillers located directly below the water distribution nozzles; This utility model has high cooling efficiency and low energy consumption. The advantages of electric float include less water, low noise, and long service life; At the same time, it also has the characteristics of air guidance, heat dissipation, water collection, easy cleaning, and convenient assembly and disassembly, while reducing energy consumption.
1. Product structure, technical features, and product inspection standards:
The all steel series cooling tower is a standardized product that has been gradually developed and improved based on the reference to GB/T 7190.1-2008 standard, combined with ISO9001 quality system requirements and years of practical experience. This tower has the characteristics of good cooling effect, low noise, energy saving, no floating water, small volume, compact structure, and beautiful and elegant appearance. Capable of withstanding earthquakes of magnitude 8 or above, with a wind resistance strength of up to magnitude 12. The cooling tower design ensures a large margin to cope with complex climatic conditions.
2. Main components of cooling tower
2.1. Hardware structural components of cooling tower
The cooling tower produced by our company adopts the imported Pohang PosMAC magnesium aluminum zinc coated steel plate whole roll, profile and channel steel from South Korea as the main frame, with light weight, good strength and rigidity. The structure is novel, sturdy and reliable, easy to assemble, highly interchangeable, and can smoothly withstand various loads during the operation of the cooling tower, with good stability. All hardware components are made of highly corrosion-resistant and extremely thick galvanized materials (720g) and some hot-dip galvanized parts, which have good anti rust and anti-corrosion properties. The electric welding fixation between the tower body and the foundation is both convenient and stable, ensuring that the cooling tower operates normally in strong wind and corrosive environments, and is not affected by harsh environments. This set of strict anti-corrosion measures is being implemented for treatment. Comprehensive surface treatment, good anti-corrosion effect, strong durability, and can generally be used for more than 25 years.
① Long lifespan: In suburban environments, highly corrosion-resistant and extremely thick galvanized materials and hot-dip galvanized steel can be maintained for more than 25 years without repair, while in urban or nearshore areas, they can be maintained for 25 years without repair.
② Long term use without maintenance: Compared to other coatings, highly corrosion-resistant and extremely thick galvanized materials and hot-dip galvanized steel do not require frequent maintenance, thus saving costs. The cost of maintenance in difficult to operate areas or in remote regions, as well as production suspension due to maintenance, can be significant.
③ High corrosion resistant extremely thick galvanized material (720g): To meet the demand for high corrosion resistant HG products with double-sided adhesion of 720g/m2 or more, the use of cooling tower cases can omit the coating process and Cost Down environmentally friendly materials.
2.1.1 Product Types and Features
1. As an extremely thick galvanized material, it can ensure high corrosion resistance (no red rust occurs within 1000 hours of SST), and the comparison results of SST corrosion resistance show that red rust occurs more than twice as long as 600g galvanized material.
2. Due to its excellent corrosion resistance, it can be used for uncoated appearance parts to reduce customer usage costs, and the production line is a continuous galvanizing line, resulting in superior surface quality compared to other companies (Bacth Type zinc coated).
2.1.2. Main use: Used for advanced cooling tower projects, advanced cooling tower case components, medium to high corrosion resistant building applications (such as bridge trays and corrugated steel pipes), and expanding development.
2.1.3 Quality characteristics:
1. Composition, mechanical properties, and gold plating amount.
2. Composition/mechanical properties: CQ, DQ, DDQ structures use rigidity, high tension rigidity, etc., with different design standards and various mechanical properties according to specifications and applications. (There will be no impact on the composition and mechanical properties due to surface post-treatment).
3. Gold plating amount: Production is based on the gold plating amount ordered by the customer, and there will be no changes in the gold plating amount due to post-processing. Corrosion resistance, paintability, weldability, lubricity.
2.1.4 Processing capability:
1. The zinc adhesion of the molten galvanized steel sheet produced on the continuous galvanizing process is excellent, and the fragile iron zinc alloy layer is very thin, so the gold plating layer will not peel off after the drawing process. Compared with the previous Horizontal Furnace, the molten galvanized steel sheet produced by Vertical Furnace has excellent processability of cold-rolled steel sheet horizontally, so it can be used for various operations.
2. Compared with general galvanized steel plates, alloy coated galvanized steel plates have stronger hardness and poorer softness in the alloy layer. Therefore, during the deep drawing process, a fragile alloy layer powder will be generated.
3. As the amount of gold plating adhesion increases, it is also affected by the conditions of oil coating on the steel plate surface and the pressure conditions of processing technology. However, in order to improve the applicability and processability of new manufacturing technologies, lubrication post-treatment technologies such as high-frequency induction heaters have been developed, which has expanded the applicability of alloying galvanized steel sheets.
Magnesium aluminum zinc coated steel air duct: Our company uses high-efficiency kinetic energy recovery air ducts. The unique streamlined air inlet and precise blade air duct clearance allow the airflow to enter the duct smoothly, avoiding the generation of vortices and reducing the energy consumption of the fan. A diffusion type silencer is installed on the wind duct, which is equipped with a high-performance silencer device. This greatly reduces the noise above the air outlet, lowers the air velocity at the outlet, reduces kinetic energy loss, saves energy, and reduces the backflow of humid and hot airflow. Reduced noise. The air duct adopts a modular design, which is easy to assemble.
The air duct of the cooling tower has four major functions: firstly, it serves as a maintenance structure for the fan; The second is the guarantee structure for air volume and pressure; The third is to ensure the introduction of humid and hot air into the atmosphere to reduce backflow and improve the efficiency of the cooling tower; Fourthly, it serves as a noise reduction function by blocking the transmission path of noise and damping the consumption of sound energy.
2.1 Maintenance door
Humanized design of the access door facilitates daily maintenance and upkeep. The access door is made of high-quality magnesium aluminum zinc coated steel material, ensuring good sealing and easy disassembly;
3. Cooling Tabu Water System
The cooling towers produced by our company all use self weight internal rotating spray nozzles. Through long-term work practice, our company has learned from the strengths of many others and conducted detailed research and exploration on the water distribution system of cooling towers, especially the structure of nozzles. We have accumulated rich experimental experience in technical issues such as nozzle material, working pressure, and structure. Based on the latest design theories and calculation methods in the international cooling tower industry, an internal rotating spray nozzle with the following characteristics has been developed:
3.1. Acid resistant, alkali resistant, and high temperature resistant. To meet the requirements of different temperature conditions and water quality of cooling towers, the internal rotating spray nozzle is made of high-quality ABS injection molding. The nozzle has good plasticity, acid resistance, and alkali resistance after molding. Long term operation under high temperature (95 ℃) conditions without deformation or aging, with a long service life. According to experimental measurements, the acid resistance of the nozzle made of this material during long-term stable operation is pH 2.8, and the alkali resistance is pH 11.2.
3.2. Internal rotating spray nozzle: corrosion-resistant and aging resistant. Low energy consumption, large diameter is not easy to block or scale, and easy to disassemble, install, and maintain. The unique internal rotation design ensures continuous and uniform water distribution, forming a reliable "hollow free" square spray umbrella shaped "solid body" water distribution mode. Uniformly covering the surface of the filler effectively improves the heat exchange efficiency. Not easy to block, no dead corners in water distribution.
3.3. In terms of shape design, the nozzle is based on the principle of fluid control, and the inner hole adopts an arc-shaped structure, which can minimize the resistance when the water flows through the linear surface. Uniform water distribution, with 90% of the water distribution area having a water distribution deviation of no more than 3%.
4. Cooling tower power system
The cooling tower produced by our company adopts belt reducer transmission, which is driven by the driving wheel on the motor shaft to drive the large driven wheel on the belt reducer, and the large driven wheel drives the fan installed on the reducer shaft to rotate. The advantages of belt reduction transmission are: smooth operation, simple structure, adjustable fan speed, and good protection for the safety of electric motor use.
4.1 Cooling tower specific motor: A fully enclosed waterproof cooling tower specific motor is used. This series of motors has the advantages of high efficiency and energy saving, large starting torque, good performance, low noise, small vibration, high reliability, and easy use and maintenance; The power level and installation dimensions comply with IEC standards, and the enclosure protection level is IP55. A fully enclosed waterproof rubber pad is designed between the wiring room and the machine body. There is a waterproof rubber ring professionally designed for the cooling tower usage environment at the shaft extension end, effectively solving the problem of water entering the motor interior along the shaft. The motor drive shaft is made of stainless steel, chrome plated for protection, and has an insulation level of F. The motor has good waterproof performance and low noise to meet the special requirements of the cooling tower operating conditions for the motor. The motor is installed vertically, with simple positioning and easy disassembly and maintenance.
4.2 Belt: Composed of an integral sealed belt box system, it is protected by two layers of oil and water resistant systems through the Japanese Samsung belt reduction transmission. It has good weather resistance, wear resistance, oil resistance, water resistance, aging resistance, excellent flexural performance, is not easy to elongate, runs smoothly, has a long service life, and is easy to maintain (just add butter).
4.3 Reducer: Composed of an integral sealed belt box system, it is driven by a Japanese Samsung belt reducer and equipped with two layers of oil proof and waterproof systems for protection. It has good weather resistance and is easy to maintain (just add butter). The gearbox adopts imported high-quality brand bearings, and the transmission part is inverted inside the air chamber, completely solving the problem of deformation of the wind duct under heavy pressure, improving the overall stability of the tower, and minimizing the adverse effects of tower vibration, thus minimizing the impact of tower noise.
4.4 Aluminum alloy wing type fan: Low speed hollow wing type aluminum alloy small and medium-sized cooling tower dedicated fans are selected. This series of products has been included in the National Science and Technology Achievement Key Promotion Program and the Environmental Protection Best Practical Technology Promotion Program. Its notable features are light weight, high air volume, low noise, low energy consumption, and long lifespan. The fan angle can be adjusted to meet customers' different needs for air volume and other process aspects. It has the following advantages:
① High fan efficiency: The cooling tower fan is an aluminum alloy wing type fan with high pressure coefficient and flow coefficient. It can achieve high air volume and pressure values at low speeds, and can also meet the requirements of reducing noise.
② Good strength performance: Aluminum alloy fans have good strength, good dynamic balance, stable operation, good temperature resistance, and are not easily deformed.
5. Cooling tower cooling system
The heat dissipation process of the cooling tower is mainly carried out on the surface of the cooling packing (the heat dissipation of the packing accounts for more than 85% of the entire temperature drop in the cooling tower). The water film on the surface of the packing slowly flows down, and the innermost water film is high enthalpy humid air with a humidity of 100%. Water molecules run from the high enthalpy area to the low enthalpy incoming fresh air, increasing the enthalpy of the air exiting the tower. As the concentration of water molecules decreases, the water molecules in the circulating hot water continuously evaporate from liquid to gas, thereby taking away the latent heat of vapor. According to the above principle, the quality of the packing is the key to the refrigeration effect.
5.2 The cooling tower core material produced by our company is vacuum formed from high-quality modified PVC polyvinyl chloride sheet, which integrates the functions of air guide, heat dissipation, and water collection. It has low air flow and ventilation resistance, low static pressure loss, and a small cloth pattern on the filling surface, allowing more water flow to form a thin film without splashing. The water and air come into contact more fully, and the water flow heat exchange time is long, with good hydrophilicity.
5.3 The use of honeycomb hole packing has the advantages of large heat dissipation area coefficient, good water flow distribution performance, and large disturbance when water and air flow through the plate surface.
5.4 The filler is not easy to deform, resistant to high temperature and aging, and has good flame retardancy (the index of flame retardant oxygen index is 42.5%) and small wind resistance coefficient. The technology principle of inertia impact separation is adopted at the tail end of the water spraying packing, and the packing is designed with a built-in water collector to reduce the water loss to one in 100000, meeting European environmental standards.
5.5 Packing suspension installation is the first of its kind in the cooling tower industry in China, effectively overcoming many shortcomings of commonly used bonded packing materials.
Feature 1: The filling material is installed in a tilted hanging manner, with the bottom of the filling material suspended in the air, preventing the deposition of debris, ensuring smooth water flow, and preventing the growth of algae and bacteria.
Feature 2: No need for adhesive bonding, no deformation, no brittleness, effectively solving the problem of filler scaling. The old installation method used adhesive bonding, where the fillers were stacked and placed in the cooling tower. During use, the bonding points of the fillers were prone to scaling, which accumulated over time and caused severe bending and deformation before collapsing, thereby affecting the cooling performance.
Feature 3: Increased effective air intake area. The bottom of the bonded filler requires more steel frame support, which reduces the effective air intake area of the filler, while the suspended installation of the filler does not require a supporting steel frame.
Feature 4: The installation, transportation, and maintenance of fillers are simple and convenient.
6. Other auxiliary parts
The auxiliary components of a cooling tower include a water replenishment system, an overflow device, an internal maintenance channel, and so on.
6.1 Water replenishment system: The cooling tower experiences water loss and evaporation loss during the cooling process, so a water replenishment device needs to be installed to replenish this water loss to ensure the normal operation of the cooling tower. The open/closed cooling tower produced by Guangdong Zejia has a particularly large water storage capacity during normal operation, leaving enough margin for shutdown water storage. When starting up, it pumps water and has two sets of water replenishment systems (automatic and manual) to ensure normal operation under special circumstances, successfully solving the problems of water overflow during shutdown and emptying during startup.
6.2 Overflow device: To prevent water from overflowing outside the tower, our company's cooling tower is equipped with an overflow port on the bottom basin, which can adjust the water level height within the standard limit.
7. Introduction to anti floating water in cooling tower
Severe water drift in cooling towers is a problem encountered by many cooling tower manufacturers that has not been well solved. Our engineers and technicians have more than ten years of experience in the production of cooling towers, and have conducted in-depth research on the causes of water drifting in cooling towers. They have identified the reasons for water drifting and adopted many practical and feasible solutions.
There are three main reasons for water drifting:
① The cooling tower is powered by a fan to extract smaller water droplets from the air duct outlet outside the cooling tower.
② After leaving the cooling tower, saturated moist and hot air encounters external moist and cold air and reaches supersaturation, condensing into small water droplets and forming floating water.
③ Water floats out from the filler inlet.
To prevent the cooling tower from drifting due to the above reasons, the following measures can be taken:
① The cooling tower produced by our company adopts aluminum alloy wing type fans. With a certain air volume, increasing the windward side of the air can reduce the fan speed, thereby reducing the speed of water droplets and minimizing the drifting of the air duct.
② Install a layer of anti floating water collector at the bottom of the fan, which is honeycomb shaped. After the water containing air passes through the collector, the air is drawn out by the wind, and the water droplets are filtered by the collector and flow into the tower. This collector can reduce an additional 70% of floating water, and the effect is excellent.
③ After packing assembly, the air inlet surface is a honeycomb shaped guide, which has a good uniform air distribution effect and improves and stabilizes the heat exchange intensity of water and gas. The inlet end is inclined at a 30 ° angle, allowing the airflow to be directed in while preventing water droplets from splashing out, effectively reducing water loss.
8. Factory self inspection standards for cooling towers
Ensure the circulating cooling water volume, cooling effect, operating noise, and product quality under design conditions.
8.1. Trial assembly of the main frame before shipment.
8.2 Framework inspection.
All galvanized steel parts must be carefully inspected for warping and deformation before trial installation. If any, they need to be corrected before being delivered to the customer to ensure the stability of the cooling tower operation.
Check whether the size and position of each hole are correct to ensure the smooth installation and use of the cooling tower.
8.4 Cooling Tower Acceptance Project
① Appearance inspection: Check the overall flatness of the cooling tower, the appearance quality of the fiberglass components, and the installation quality of the water filling material.
② Noise inspection: Check the operating noise of the cooling tower power system. In the direction of the tower inlet, the distance is the equivalent diameter
Dm=1.13, L and W are the side lengths of the tower, respectively. This inspection point is the standard point noise. Inspect the impact of the overall operating noise of the cooling tower on the surrounding environment.
③ Airflow measurement: After the above inspection of the cooling tower, it is necessary to conduct a test of the airflow, that is, to measure the wind speed at the inlet of the cooling tower (intake air volume=wind speed x intake area). Using an anemometer to measure wind speed at different positions and heights of the cooling tower, it is necessary to ensure that the incoming air volume reaches the design air volume of the cooling tower to meet its cooling capacity requirements. If the wind volume is insufficient or too large, the angle of the fan blades can be adjusted to meet the requirements.
