Long-term operation optimization of circulating cooling water systems under fouling conditions

Fouling caused by excess metal ions in hard water can negatively impact the performance of the circulating cooling water system(CCWS)by depositing ions on the heat exchanger's surface.Currently,the operation optimization of CCWS often prioritizes short-term flow velocity optimization for minimizing power consumption,without considering fouling.However,low flow velocity promotes fouling.Therefore,it's crucial to balance fouling and energy/water conservation for optimal CCWS long-term operation.This study proposes a mixed-integer nonlinear programming(MINLP)model to achieve this goal.The model considers fouling in the pipeline,dynamic concentration cycle,and variable frequency drive to optimize the synergy between heat transfer,pressure drop,and fouling.By optimizing the concentration cycle of the CCWS,water conservation and fouling control can be achieved.The model can obtain the optimal operating parameters for different operation intervals,including the number of pumps,frequency,and valve local resistance coefficient.Sensitivity experiments on cycle and environmental temperature reveal that as the cycle increases,the marginal benefits of energy/water conservation decrease.In periods with minimal impact on fouling rate,energy/water conservation can be achieved by increasing the cycle while maintaining a low fouling rate.Overall,the proposed model has significant energy/water saving effects and can comprehensively optimize the CCWS through its incorporation of fouling and cycle optimization.

Calculation of Mass Concrete Temperature Containing Cooling Water Pipe Based on Substructure and Iteration Algorithm

Mathematical physics equations are often utilized to describe physical phenomena in various fields of science and engineering.One such equation is the Fourier equation,which is a commonly used and effective method for evaluating the effectiveness of temperature control measures for mass concrete.One important measure for temperature control in mass concrete is the use of cooling water pipes.However,the mismatch of grids between large-scale concrete models and small-scale cooling pipe models can result in a significant waste of calculation time when using the finite element method.Moreover,the temperature of the water in the cooling pipe needs to be iteratively calculated during the thermal transfer process.The substructure method can effectively solve this problem,and it has been validated by scholars.The Abaqus/Python secondary development technology provides engineers with enough flexibility to combine the substructure method with an iteration algorithm,which enables the creation of a parametric modeling calculation for cooling water pipes.This paper proposes such a method,which involves iterating the water pipe boundary and establishing the water pipe unit substructure to numerically simulate the concrete temperature field that contains a cooling water pipe.To verify the feasibility and accuracy of the proposed method,two classic numerical examples were analyzed.The results showed that this method has good applicability in cooling pipe calculations.When the value of the iteration parameterαis 0.4,the boundary temperature of the cooling water pipes can meet the accuracy requirements after 4∼5 iterations,effectively improving the computational efficiency.Overall,this approach provides a useful tool for engineers to analyze the temperature control measures accurately and efficiently for mass concrete,such as cooling water pipes,using Abaqus/Python secondary development.

Optimization of circulating cooling water systems based on chance constrained programming

Recent research on deterministic methods for circulating cooling water systems optimization has been well developed. However, the actual operating conditions of the system are mostly variable, so the system obtained under deterministic conditions may not be stable and economical. This paper studies the optimization of circulating cooling water systems under uncertain circumstance. To improve the reliability of the system and reduce the water and energy consumption, the influence of different uncertain parameters is taken into consideration. The chance constrained programming method is used to build a model under uncertain conditions, where the confidence level indicates the degree of constraint violation. Probability distribution functions are used to describe the form of uncertain parameters. The objective is to minimize the total cost and obtain the optimal cooling network configuration simultaneously.An algorithm based on Monte Carlo method is proposed, and GAMS software is used to solve the mixed integer nonlinear programming model. A case is optimized to verify the validity of the model. Compared with the deterministic optimization method, the results show that when considering the different types of uncertain parameters, a system with better economy and reliability can be obtained(total cost can be reduced at least 2%).

Corrosion Inhibition by Co-Immobilized Lysozyme and Lipase in Circulating Cooling Water System

The corrosion inhibition performance of co-immobilized lysozyme and lipase was investigated in a recirculating cooling water system. Four methods were carried out in co-immobilization, and the operating parameters were optimized by using the respond surface methodology(RSM). The corrosion inhibition performance of co-immobilized lipase and lysozyme was evaluated by weight loss measurements and electrochemical measurements. The results revealed that the optimal co-immobilization method should be the sequential immobilization of lysozyme and then lipase. The inhibition efficiency was 86.10% under the optimal co-immobilized conditions. Electrochemical data showed that co-immobilized lysozyme and lipase was a mixed-type inhibitor and the corrosion inhibition efficiency was 81%.

Laccase Immobilized on Mesoporous Silica Materials and Its Corrosion Inhibition Performance in Circulating Cooling Water System

Mesoporous SiO_2 microspheres were synthesized using the sol-gel method and were characterized by TEM, FT-IR and BET techniques. The diameter of the microspheres is about 100—150 nm, and the average mesopore diameter is 2.55 nm, while the specific surface area is 1 088.9 m2/g. Mesoporous SiO_2 microspheres adsorb glutaraldehyde and immobilize laccase by means of the aldehyde group in glutaral which can react with the amidogen of laccase. The immobilization conditions were optimized at a glutaraldehyde concentration of 0.75%, a crosslinking time of 8 h, a laccase concentration of 0.04 L/L and an immobilization time of 10 h. When diesel leakage concentration was 80 mg/L, the highest corrosion inhibition efficiency of immobilized laccase reached 49.23%, which was slightly lower than the corrosion inhibition efficiency of free laccase(59%). The diesel degradation ratio could reach up to 45%. It has been proved that the immobilized laccase could degrade diesel to inhibit corrosion.

MIC in Circulating Cooling Water System

MIC is one of the main problems of circulating cooling water system. The direct economic loss by MIC is about 300 to 500 billion dollars. It is good to understand MIC in order to control MIC. Source and species of microorganisms was introduced firstly. There are three kinds of microorganisms in the system, including bacteria, fungi and algae. Species of these microorganisms are shown in the paper. Then, mechanisms of MIC are analysed. Although there is no universal mechanism of MIC, MIC is still mainly an electrochemical corrosion in nature. Meanwhile, the mechanisms on SRB and iron bacteria are introduced in details. At last, several methods of microorganisms control are put forward in the paper.

Experimental Study on the Resistance and Splash Performances of Water Collecting Devices for Mechanical Draft Cooling Towers

In recent years,water collecting systems,with the associated advantages of energy saving and noise reduction,have become the foundation for the development of a scheme to optimize the structure of cooling towers.To explore the feasibility of this approach for mechanical draft cooling towers,a small-scale experimental device has been built to study the resistance and splash performances of three U-type water collecting devices(WCDs)for different water flow rates and wind speeds.The experimental results show that within the considered ranges of wind speed and water flow rate,the pressure drop of the different WCDs can vary significantly.The resistance and local splash performances can also be remarkably different.Some recommendations about the most suitable system are provided.Moreover,a regression analysis of the experimental data is conducted,and the resulting fitting formulas for resistance and splash performance of WCD are reported.

Ion Exchange Softening and Alkalization Treatment for Zerodischarge of Circulating Cooling Water

In order to solve the problems including pipe corrosion, scaling and microbial growth, which severely threat safe op-eration of circulating cooling water system, this paper proposes ion exchange softening and alkalization process to solve these problems and carries out a series of studies to study the feasibility of ion exchange softening and alkaliza-tion process in the simulation process of circulating cooling water system. The studies include product water quality of ion exchange softening and alkalization process, effect on the performance of carbon steel and brass, and the inhibition that suppresses microbial growth. The results indicate that ion exchange softening and alkalization process is feasible to prevent the circulating cooling water system from scaling, pipe corrosion, and microbial growth without any other chemicals. Thus circulating cooling water system can achieve zerodischarge of wastewater.

Design and analysis of a high loss density motor cooling system with water cold plates

Aiming at reducing the difficulty of cooling the interior of high-density motors,this study proposed the placement of a water cold plate cooling structure between the axial laminations of the motor stator.The effect of the cooling water flow,thickness of the plate,and motor loss density on the cooling effect of the water cold plate were studied.To compare the cooling performance of water cold plate and outer spiral water jacket cooling structures,a high-speed permanent magnet motor with a high loss density was used to establish two motor models with the two cooling structures.Consequently,the cooling effects of the two models were analyzed using the finite element method under the same loss density,coolant flow,and main dimensions.The results were as follows.(1)The maximum and average temperatures of the water cold plate structure were reduced by 25.5%and 30.5%,respectively,compared to that of the outer spiral water jacket motor;(2)Compared with the outer spiral water jacket structure,the water cold plate structure can reduce the overall mass and volume of the motor.Considering a 100 kW high-speed permanent magnet motor as an example,a water cold plate cooling system was designed,and the temperature distribution is analyzed,with the result indicating that the cooling structure satisfied the cooling requirements of the high loss density motor.

Effects of Nutrients on Biofouling Formation and Preponderant Bacteria Diversity in Recirculating Cooling Water System

A series of orthogonal array experiments were conducted using carbon source, ammonia nitrogen and total phosphorus （TP） as major influencing factors to investigate the effects of nutrients on biofouling formation and preponderant bacteria diversity in the recirculatiug cooling water system. Carbon source was demonstrated to be the most significant determinant affecting the biofouling formation. A minimum biofouling outcome was obtained when BOD2, NHa＋-N and TP were 25, 10, and 1 mg/L, respectively. Then the preponderant bacteria strains in biofouling mass under two typical culture conditions （negative and favorable） were identified applying both traditional biochemical methods and further molecular biology technology with phylogenetic affiliation analysis, which indicated that Enterobacteriaceae Enterobacter, Micrococcaceae Staphylococcus, Bacillaceae Bacillus, Enterobacteriaceae Proteus, Neisseriaceae Neisseria and Pseudomonadaceae Pseudomonas were dominant under negative condition, while Enterobacteriaceae Klebsiella, Enterobacteriaceae Enterobacter and Microbacterium - under favorable one.

Formation of Water Quality of Surface Water Bodies Used in the Material Processing

In the process of production or processing of materials by various methods,there is a need for a large volume of water of the required quality.Today in many regions of the world,there is an acute problem of providing industry with water of a required quality.Its solution is an urgent and difficult task.The water quality of surface water bodies is formed by a combination of a large number of both natural and anthropogenic factors,and is often significantly heterogeneous not only in the water area,but also in depth.As a rule,the water supply of large industrial enterprises is located along the river network.Mergers are the most important nodes of river systems.Understanding the mechanism of transport of pollutants at the confluence of rivers is critical for assessing water quality.In recent years,thanks to the data of satellite images,the interest of researchers in the phenomenon of mixing the waters of merging rivers has increased.The nature of the merger is influenced by the formation of transverse circulation.Within the framework of this work,a study of vorticity,as well as the width of the mixing zone,depending on the distance from the confluence,the speeds of the merging rivers and the angle of confluence was carried out.Since the consumer properties of water are largely determined by its chemical and physical indicators,the intensity of mixing,determined largely by the nature of the secondary circulation,is of fundamental importance for assessing the distribution of hydrochemical indicators of water quality in the mixing zone.These characteristics are important not only for organizing water intake for drinking and technical purposes with the best consumer properties,but also for organizing an effective monitoring system for confluence zones.

Cooling and Optimization in the Groove of the Outer Rotor HubMotor

The external rotor hub motor adopts direct drive mode,no deceleration drive device,and has a compact structure.Its axial size is smaller than that of a deceleration-driven hub motor,which greatly reduces the weight of the vehicle and increases the cruising range of the vehicle.Because of the limited special working environment and performance requirements,the hub motor has a small internal space and a large heat generation,so it puts forward higher requirements for heat dissipation capacity.For the external rotor hub motor,a new type of in-tank watercooled structure of hub motor was proposed to improve its cooling effect and performance.Firstly,the threedimensional finite element model of the motor is established to analyze the characteristics of motor loss and temperature field distribution.Secondly,the cooling performance of different cooling structures in the tank was studied.Finally,the thermal network model and three-dimensional finite element analysis were used to optimize the water-cooled structure in the tank,and the power density of themotor was improved by improving the cooling performance under the condition of volume limitation of the hub motor.The results show that the cooling effect of the proposed water-cooled structure in the tank is significant under the condition of constant power density.Compared to natural ventilation,the maximum temperature was reduced by 33.13°C and the cooling effect was increased by about 27.7%.

Pressure fluctuation and its influencing factors in circulating water pump

In order to investigate the effect of sampling frequency and time on pressure fluctuations, the three-dimensional unsteady numerical simulations were conducted in a circulating water pump. Through comparison of turbulence models with hydraulic performance experiment, SST k-co model was confirmed to study the rational determination of sampling frequency and time better. The Fast Fourier Transform （FFT） technology was then adopted to process those fluctuating pressure signals obtained. On these bases, the characteristics of pressure fluctuations acting on the tongue were discussed. It is found that aliasing errors decrease at higher sampling frequency of 17 640 Hz, but not at a lower sampling frequency of 1 764 Hz. Correspondingly, an output frequency range ten-times wider is obtained at 17 640 Hz. Compared with 8R, when the sampling time is shorter, the amplitudes may be overvalued, and the frequencies and amplitudes of low-frequency fluctuations can not be well predicted. The frequencies at the tongue are in good agreement with the values calculated by formula and the frequency compositions less than the blade passing frequency are accurately predicted.

Effect of temperature, chloride ions and sulfide ions on the electrochemical properties of 316L stainless steel in simulated cooling water

The influence of temperature, chloride ions and sulfide ions on the anticorrosion behavior of 316L stainless steel in simulated cooling water was studied by electrochemical impedance spectroscopy and anodic polarization curves. The results show that the film resistance increases with the solution temperature but decreases after 8 days’ immersion, which indicates that the film formed at higher temperature has inferior anticorrosion behavior; Chloride ions and sulfide ions have remarkable effects on the electrochemical property of 316L stainless steel in simulated cooling water and the pitting potential declines with the concentration of chloride ions; the passivation current has no obvious effect; the rise of the concentration of sulfide ions obviously increases the passivation current, but the pitting potential changes little, which indicates that the two types of ions may have different effects on destructing passive film of stainless steel. The critical concentration of chloride ions causing anodic potential curve’s change in simulated cooling water is 250 mg/L for 316 L stainless. The effect of sulfide ions on the corrosion resistance behavior of stainless steel is increasing the passivation current density Ip. The addition of 6 mg/L sulfide ions to the solution makes Ip of 316 L increase by 0.5 times.

Application of a water cooling treatment and its effect on coal-based reduction of high-chromium vanadium and titanium iron ore

A water cooling treatment was applied in the coal-based reduction of high-chromium vanadium and titanium （V-Ti-Cr） iron ore from the Hongge region of Panzhihua, China. Its effects on the metallization ratio （η）, S removal ratio （Rs）, and P removal ratio （Rp） were studied and analyzed on the basis of chemical composition determined via inductively coupled plasma optical emission spectroscopy. The metallic iron particle size and the element distribution of Fe, V, Cr, and Ti in a reduced briquette after water cooling treatment at 1350℃ were determined and observed via scanning electron microscopy. The results show that the water cooling treatment improved the η, Rs, and Rp in the coal-based reduction of V-Ti-Cr iron ore compared to those obtained with a furnace cooling treatment. Meanwhile, the particle size of metallic iron obtained via the water cooling treatment was smaller than that of metallic iron obtained via the furnace cooling treatment; however, the particle size reached 70 μm at 1350℃, which is substantially larger than the minimum particle size required （20 μm） for magnetic separation. Therefore, the water cooling treatment described in this work is a good method for improving the quality of metallic iron in coal-based reduction and it could be applied in the coal-based reduction of V-Ti-Cr iron ore followed by magnetic separation.

Application of Cooling Water in Controlled Runout Table Cooling on Hot Strip Mill

The controlled runout table cooling is essential in determining the final mechanical properties and flatness of steel strip.The heat of a hot steel strip is mainly extracted by cooling water during runout.In order to study the heat transfer by water jet impingement boiling during runout,apilot facility was constructed at the University of British Columbia.On this pilot facility,the water jet impingement tests were carried out under various cooling conditions to investigate the effect of processing parameters,such as cooling water temperature,water jet impingement velocity,initial strip temperature,water flow rate,water nozzle diameter and array of water nozzles,on the heat transfer of heated strip.The results obtained contribute to the optimization of cooling water during runout.

Transient Heat Transfer Study of Direct Contact Condensation of Steam in Spray Cooling Water

We conducted a transient experimental investigation of steam–water direct contact condensation in the absence of noncondensible gas in a laboratory-scale column with the inner diameter of 325 mm and the height of 1045 mm. We applied a new analysis method for the steam state equation to analyze the molar quantity change in steam over the course of the experiment and determined the transient steam variation. We also investigated the influence of flow rates and temperatures ofcooling water on the efficiency ofsteam condensation. Our experimental results show that appropriate increasing of the cooling water flow rate can significantly accelerate the steam condensation. We achieved a rapid increase in the total volumetric heat transfer coefficient by increasing the flow rate of cooling water, which indicated a higher thermal convection between the steam and the cooling water with higher flow rates. We found that the temperature ofcooling water did not play an important role on steam condensation. This method was confirmed to be effective for rapid recovering ofsteam.

Uncertainty Analysis for Ship-Bank Interaction Tests in A Circulating Water Channel

This paper presents a systematic model test program to assess the uncertainty of the ship-bank interaction forces,using the planar motion mechanism(PMM)system in a circulating water channel(CWC).Therefore,the uncertainties due to ship-bank distance and water depth are considered,and they are calculated via the partial differentials of the regression formulae based on the test data.The general part of the uncertainty analysis(UA)is performed according to the ITTC recommended procedure 7.5-02-06.04,while the uncertainty of speed is identified as the bias limit due to the flow velocity maldistribution in the CWC.In each example test for the UA of ship-bank interaction forces,12 repeated measurements were conducted.Results from the UA show that the contribution of water depth error and flow velocity maldistribution to the total uncertainty is noticeable,and the paper explains how they increase with the change of the test conditions.The present study will be useful in understanding the uncertainty regarding the ship-bank interaction force measurement in a CWC.

CFD Analysis and Optimization of a Diesel Engine Cooling Water Jacket

The STAR-CCM+software is used to investigate the flow inside a cooling water jacket of an in-line six-cylinder diesel engine.The results show that the average flow velocity of the cooling water inside the jacket is 1.669 m/s while the flow velocity distribution is not uniform for each cylinder.Moreover,the fluid velocity in proximity to the cylinder head is too low,thereby affecting the cooling performances of the water jacket.Two corresponding structural optimization schemes are proposed to mitigate this issue and the post-optimization performances of the water jacket are discussed in detail.

Simulation of Gas-Fired Triple-Effect LiBr/Water Absorption Cooling System with Exhaust Heat Recovery Generator

An exhaust heat recovery generator is proposed to be integrated with conventional gas-fired triple-effect LiBr/water absorption cooling cycles to improve system energy efficiency. As a case study, simulation of the novel cycle based on promising parallel flow with cooling capacity of 1 150 kW is carried out under various heat recovery generator vapor production ratios ranging from 0 to 3.5%. The life cycle saving economic analysis, for which the annual gas conservation is estimated with Bin method, is employed to prove the worthiness of extra expenditure. Results show that the optimum gas saving revenue is obtained at 2.8% heat recovery generator vapor production ratio with 42 kW exhaust heat recovered, and the system energy efficiency is improved from 1.78 to 1.83. The initial investment of exchanger can be paid back within 7 years and 9 000 CNY of gas saving revenue will be achieved over the 15-year life cycle of the machine. This technology can be easily implemented and present desirable economic effects, which is feasible to the development of triple-effect absorption cycles.