Clean Technology Direct Heat Exchange Packing

Abstract

A packing sheet and a packing bag made of multiple packing sheets for cooling a cooling medium in a cooling tower, each packing sheet having multiple grooves extending obliquely from the top to the bottom of the packing sheet, the oblique orientation of the grooves being generated by multiple alternating longer oblique groove segments and shorter vertical groove segments, each of the multiple grooves having a microstructure comprising multiple alternating circular protrusions and circular recesses extending between the flat ridge edges and flat valley edges of the groove.

Description

Technical Field

[0001] This invention relates to a direct heat exchange packing material and a fill pack. Background Technology

[0002] Examples of direct heat exchange packings and packing packages are described in U.S. Patent No. 8,985,559, the disclosure of which is incorporated herein by reference.

[0003] Heat exchangers are well-known in industry and are designed to efficiently transfer heat from one medium to another. Heat exchangers come in many types and sizes, and a specific type is typically selected based on the application, such as for refrigeration, air conditioning, chemical plants, oil refineries, or power plants.

[0004] Power plants commonly use water cooling towers to transfer waste heat into the atmosphere. These towers evaporate water to carry away the waste heat and cool the hot water to near its wet-bulb temperature. One type of cooling tower that can be used in power plants is... Figure 1 The hyperboloid cooling tower 10 shown is erected on-site. Hot water flows through the hyperboloid cooling tower 10 for 12 hours and falls onto the packing assembly 14. (The text abruptly ends here.) Figure 1 As shown, ambient air AA enters from the bottom of the hyperboloid cooling tower 10 and rises through the packing assembly 14, becoming heated air HA before leaving the hyperboloid cooling tower 10; hot water 12h flows downwards (i.e., drips or drips) through the packing assembly 14 and becomes cooling water 12c before flowing out of the packing assembly 14. This arrangement is commonly referred to as "counterflow" in the industry.

[0005] The conventional packing assembly 14 includes multiple conventional packing bags 13. The packing bags 13 are arranged side-by-side inside the hyperboloid cooling tower 10. (Example...) Figure 2 and 3 As shown, each packing bag 13 includes multiple heat exchanger plates 16. The packing bag 13 is referred to as VertiClean. TM Film Fill is a trademark of EvapTech, located in Edwardsville, Kansas. Each heat exchanger plate 16 is a corrugated sheet of polyvinyl chloride (PVC) material, configured with a series of repeating vertically extending corrugations 15, defining vertically extending grooves 17 between the vertically extending corrugations 15. These heat exchanger plates 16 can be manufactured by thermoforming PVC sheets in a vacuum environment.

[0006] like Figure 4As shown in the partial top view, three heat exchanger plates 16 are secured to each other by an adhesive 18 disposed between face-to-face adhesive dots 20. Notably, the adhesive dots 20 are flush with the corresponding ridges RL of the corrugations 15. All heat exchanger plates 16 constituting the packing pack 13 are identical to each other. As is known in the art, in order to form air-water flow channels 19 between identical heat exchanger plates 16, one of two face-to-face heat exchanger plates 16 can be rotated 180° relative to a central vertical axis, such that only the front sides of the two face-to-face heat exchanger plates 16 are secured to each other, and only the rear sides of the two face-to-face heat exchanger plates 16 are secured to each other. This is a well-known manufacturing technique for producing the packing pack 13 in the art.

[0007] Another conventional packing package assembly 24 is similar to the packing package assembly 14 described above, except that, as Figure 5-7 As shown, the packing assembly 24 includes multiple packing bags 23, which are made of heat exchanger plates 26 with different configurations. The packing bags 23 are referred to as TechClean. TM Film Fill is a trademark of EvapTech, located in Edwardsville, Kansas. The heat exchanger plate 26 is a corrugated sheet made of PVC material, configured with two series of repeating, shortened, offset, vertically extending corrugations 25a and 25b.

[0008] The heat exchanger plate 26 includes a top edge 28, a bottom edge 30 separate from and parallel to the top edge 28, and a pair of side edges 32. The side edges 32 are arranged to be separate from and parallel to each other, and the pair of side edges 32 connects the top edge 28 and the bottom edge 30, forming a shape as shown. Figure 7 The structure shown is roughly rectangular. A series of repeating, shortened, vertically extending upper corrugations 25a extend downwards from near the top edge 28. Figure 7 The heat exchanger plate 26 is positioned at least approximately at the horizontal midpoint line HMPL. Another series of repeating, shortened, vertically extending lower corrugations 25b extend upwards from near the bottom edge 30 to at least approximately the horizontal midpoint line HMPL of the heat exchanger plate 26. Notably, the upper corrugations 25a and lower corrugations 25b are horizontally offset from each other in the width direction, as... Figure 7 As shown. Figure 8 This is an example of two packing sheets connected top to bottom in the prior art, wherein the groove has short sloping sections at its top and bottom, and microstructures thereon. Summary of the Invention

[0009] This invention is an improvement on the above-described packing structure and design (but includes the basic structure, manufacturing and assembly), wherein the number of plates is reduced, the spacing between plates is increased by higher grooves, but the strength and rigidity of the packing pack are maintained by additional connection points, and heat transfer is improved due to the novel surface geometry, while significantly reducing costs.

[0010] Therefore, the present invention provides a packing sheet for assembling into a packing pack for cooling a cooling medium in an evaporative cooling tower, the packing sheet comprising: a first end; a second end extending substantially parallel to the first end and substantially perpendicular to a longitudinal axis (relative to the direction of travel of air and water), the first end and the second end extending substantially parallel to a transverse axis of the packing sheet; a plurality of grooves extending toward the second end at a first groove angle greater than 17 degrees; and microstructures defined on the plurality of grooves; the plurality of grooves comprising a plurality of alternating oblique groove segments having an oblique groove segment length and a vertical groove segment having a vertical groove segment length, the oblique groove segment having an oblique groove segment length parallel to the first groove angle, the vertical groove segment being parallel to the longitudinal axis, the oblique groove segment length being 6.1 times the vertical groove segment length; wherein the microstructure comprises a plurality of alternating circular protrusions and circular recesses extending between the ridge edges and valley edges of the grooves.

[0011] According to a preferred embodiment of the invention, the microstructure extends substantially parallel to the lateral axis, and / or the first groove angle is approximately 12 to 22 degrees, and / or the plurality of grooves define a groove height, and / or the groove height is approximately 1.44 inches, and / or the circular protrusion microstructure has a height of 0.05 inches and a spacing of 0.11 to 0.12 inches along the groove.

[0012] Another embodiment of the invention provides a cross-corrugated packing pack assembly for cooling fluid flowing through the packing pack by gas flowing through the packing pack in substantially opposite directions. The packing pack assembly includes a plurality of identical packing plates as described above and described in more detail below, wherein the plurality of packing plates are arranged such that adjacent packing plates are oriented 180 degrees relative to each other and are connected to each other at corresponding connecting notches located on the flat ridges of adjacent packing plates. Attached Figure Description

[0013] Figure 1 It is a partially cut-away perspective view of a prior art hyperboloid water cooling tower, in which conventional packing assemblies are installed;

[0014] Figure 2 yes Figure 1 A partial perspective view of one type of prior art filler pack assembly is shown;

[0015] Figure 3 yes Figure 2 An exploded perspective view of a prior art filler packing assembly is shown;

[0016] Figure 4 yes Figure 2 and Figure 3 A partial top view of a prior art filler pack assembly is shown;

[0017] Figure 5 This is a partial perspective view of another filler pack assembly in the prior art;

[0018] Figure 6 yes Figure 5 An exploded perspective view of a prior art filler packing assembly is shown;

[0019] Figure 7 yes Figure 5 and Figure 6 A front view of a conventional packing package assembly;

[0020] Figure 8 It is a front view of two existing corrugated packing sheets connected vertically, wherein the grooves are mainly vertically oriented, with short oblique portions and microstructures;

[0021] Figure 9 This is a perspective view of a packing sheet with a height of 2 feet (2') and a width of 1 foot (1') provided in an embodiment of the present invention;

[0022] Figure 10 It is by Figure 9 The perspective view of a packing bag formed by assembling packing sheets, which is 2 feet (2') high, 1 foot (1') wide and 1 foot (1') deep;

[0023] Figure 11 This is a schematic cross-sectional view of the groove of the packing sheet provided in an embodiment of the present invention;

[0024] Figure 12 This is a 12-inch (12”) longitudinal cross-sectional view of the groove of the packing sheet provided in an embodiment of the present invention, with the microstructure removed to show the details of the groove shape more clearly;

[0025] Figure 13 This is a three-dimensional schematic diagram of the groove of the packing sheet provided in an embodiment of the present invention, which does not show the microstructure in order to show the details of the groove shape more clearly;

[0026] Figure 14 This is a partial schematic diagram of a single groove in a packing sheet according to an embodiment of the present invention, showing the relative positions and dimensions of certain microstructures;

[0027] Figure 15This is a three-dimensional schematic diagram of a packing sheet groove with a ribbed microstructure according to an embodiment of the present invention;

[0028] Figure 16 This is a top perspective view of a packing sheet with a ribbed microstructure according to an embodiment of the present invention;

[0029] Figure 17 This is a top perspective view of the packing sheet with a rhomboid microstructure provided in an embodiment of the present invention;

[0030] Figure 18 This is a top perspective view of a packing sheet with a ribbed microstructure attached to a packing sheet with a rhomboid microstructure, according to an embodiment of the present invention.

[0031] Figure 19 yes Figure 18 A partial detail diagram of the embodiment shown;

[0032] Figure 20 yes Figure 1 End perspective view of the embodiment shown;

[0033] Figure 21 yes Figure 18-20 Partial detail schematic diagram of the embodiment shown;

[0034] Figure 22 yes Figure 16 Partial perspective view of the embodiment shown;

[0035] Figure 23 yes Figure 9 Top view of the embodiment shown;

[0036] Figure 24 yes Figure 9 Left side view of the embodiment shown;

[0037] Figure 25 yes Figure 9 The right-side view of the embodiment shown;

[0038] Figure 26 yes Figure 9 A front view of the embodiment shown;

[0039] Figure 27 yes Figure 9 Rear view of the embodiment shown;

[0040] Figure 28 yes Figure 10 Top view of the embodiment shown;

[0041] Figure 29 yes Figure 10 The bottom view of the embodiment shown;

[0042] Figure 30 It shows Figure 10 Front and rear views of the illustrated embodiment;

[0043] Figure 31 It shows Figure 10 The left and right views of the illustrated embodiment.

[0044] The features in the accompanying drawings are numbered using the following reference numerals:

[0045] 200 packing bag 208d second side

[0046] 202 packing sheet 210 groove

[0047] 204 longitudinal axis 212 flat ridge

[0048] 206 transverse axis 214 horizontal side

[0049] 208a First end 216 Pinggu

[0050] 208b second end 218 longer inclined groove section

[0051] 208c First side 220 shorter vertical groove segment

[0052] 222 Connection notch 230 Circular recessed microstructure

[0053] 224 Raised plateau 232 Flat grooved side section

[0054] The 226 connection points form a row 234 rhomboid platform microstructure

[0055] 228 Circular protruding microstructures 236 Rhomboid concave microstructures Detailed Implementation

[0056] Please refer to the example. Figure 9 and Figure 10This invention relates to a cross-corrugated medium, packing bag, or assembly 200 comprising a plurality of identical stacked and joined packing sheets 202. In a most preferred embodiment, the cross-corrugated medium or packing bag 200, having a width of one foot (1'), comprises ten (10) stacked and joined packing sheets 202, wherein the width of the packing bag 200 is measured from the foremost packing sheet to the last packing sheet. The cross-corrugated medium or packing 200 and each packing sheet 202 define a longitudinal axis 204 extending generally perpendicularly (in the direction of airflow) and a transverse axis 206 extending generally laterally relative to the packing sheet 202. Air and water flow through the packing bag 200 generally flows along the longitudinal axis 204 between a first end 208a and a second end 208b of the packing sheet 202. The ends 208a and second end 208b of the packing sheet 202 are connected by a first side 208c and a second side 208d. The first end 208a is substantially parallel to the second end 208b and extends generally perpendicularly relative to the longitudinal axis 204. The first end 208a and the second end 208b extend substantially parallel to the transverse axis 206. Each packing sheet is preferably made of polyvinyl chloride (PVC) and preferably has a thickness of 0.010 to 0.025 inches (10 to 20 mils), more preferably 0.015 to 0.020 inches (15 to 20 mils).

[0057] Each consecutive packing strip 202 in the packing pack 200 is rotated 180 degrees (180°) relative to the adjacent packing strip 202 to define the transverse corrugations of the packing pack 200. Thus, a preferred packing pack 200 includes alternating first ends 208a and second ends 208b throughout its thickness to define the cross corrugations of the packing pack 200.

[0058] Each packing piece 202 is characterized by an assembly of corrugations or "grooves" 210 extending from the first end 208a in a generally oblique direction relative to the longitudinal axis 204, and guiding air and water flow through the packing piece. Figure 11 As shown, each groove 210 has a trapezoidal cross-sectional shape, with a flat ridge 212 at the top and inclined sides 214. Valleys 216 separate adjacent grooves 210. The opposite faces of each packing piece 202 are mirror images of each other, and the flat ridge 212 of one face of the packing piece 202 forms the valley 216 of the opposite face of the packing piece, and vice versa.

[0059] The groove height Hf of each groove 210 of the filler sheet 202 is preferably about 1.44 inches, but can be in the range of about 1.72 to 1.15 inches. The preferred groove width (valley to valley, ridge to adjacent ridge) is 2.0 inches, but can be in the range of 2.4 to 1.6 inches. The width of each ridge 212 (and corresponding valley) is preferably 0.19 inches, but can be in the range of 0.23 to 0.15 inches.

[0060] The angle of the groove 210 relative to the longitudinal axis 204 (groove angle Δf) is preferably approximately 17 degrees, but can be in the range of 12 to 22 degrees. Since the groove 210 is along a diagonal direction, only the grooves in the more central positions will extend through the entire length of the packing sheet 202. See example... Figure 9 and Figure 10 The groove 210 located on the outside of the packing sheet 202 can start or end at the first side 208c or the second side 208d.

[0061] like Figure 12 and 13 As shown, more specifically, the entire length of each groove 210 along a generally oblique direction is defined by a series of long, oblique groove segments 218, interspersed with short, vertical groove segments 220. The longer oblique groove segments 218 are preferably 3.42 inches in length, without being interrupted by packing sheet sides 208c or 208d. The shorter vertical groove segments 220 are preferably 0.56 inches in length, and the ratio of the longer oblique groove segments to the shorter vertical groove segments is preferably 6.1.

[0062] Each groove ridge 212 on a single packing sheet 202 has connection notches 222 spaced regularly along the ridge 212 at the connection with an adjacent packing sheet. According to the most preferred embodiment, each groove ridge 212 has connection notches 222 at the midpoint between the top 208, bottom 208b, and top 208a and bottom 208b of the packing sheet 202, and additionally four equally spaced connection notches 222 between the top 208a and bottom 208b of the packing sheet, resulting in a total of eight connection notches 222 on each ridge 212 (spanning 2 feet (2')). Figure 9 and Figure 10 (As shown). As described above, the opposite faces of the packing sheet 202 are mirror images of each other; therefore, each connecting notch 222 on the flat ridge 212 on one side of the packing sheet 202 corresponds to a raised platform 224 of the same shape in the flat valley 216 on the back side of the packing sheet. Thus, each flat ridge 212 has a series of connecting notches 222, and each flat valley 216 has a series of raised platforms 224. Figure 9 and Figure 10As shown, the connecting notches 222 and platforms 224 on each groove 210 of the packing sheet 202 preferably span the packing sheet 202 between the two sides 208c and 208d and are arranged in rows 226, wherein there is a row 226a at the first end 208a, a row 226b at the second end 208b, two adjacent rows 226e and 226f (merged together) at the midpoint between the first end 208a and the second end 208b, and four additional rows 226c and 226d evenly spaced between the first end 208a and the second end 208b, for a total of eight rows 226 spanning the packing sheet 202.

[0063] The connecting notch 222 is designed and configured to align with and nest into the corresponding notch on the adjacent packing sheet 202, and to connect the packing sheet 202 to the packing package 200, for example by compression locking, fastening, clamping, bonding or other connecting mechanisms or methods.

[0064] Each groove 210 of each packing sheet 202 includes microstructures to force water to diffuse across the width of the packing sheet 202 or along its transverse axis 206 during use, thereby improving the dispersion of water as it passes through the packing pack 200 and its mixing with air. According to an embodiment of the first “rib”-shaped microstructure, a series of evenly spaced, elongated, circular protrusions 228 and recesses 230 traverse the inclined side surface 214 of each groove 210, separated by undeformed or flat groove side surface portions 232. See also Figure 14 It shows the relative position and spacing of the microstructures with respect to each groove 210 and with respect to each other, see [link to relevant documentation]. Figure 15 This diagram shows a three-dimensional schematic of a single (inverted) groove, illustrating the preferred microstructure on two angled sides 214. The optimal height of each elongated, rounded protrusion 228 (and each elongated, rounded recess 230) is 0.05 inches. The optimal spacing between adjacent protrusions 228 and recesses 230 (unchanged / flat groove sides 232) is 0.11 to 0.12 inches. For each elongated, rounded protrusion 228 and recess 230, the optimal radius of curvature is 0.12 inches. Figure 15 As shown, in addition to the presence of connecting notches 222 or ridges 224, elongated and rounded protrusions and recesses extend between the adjacent edges of adjacent valleys 216 and ridges 212. In this case, the rounded protrusions and recesses exist between adjacent connecting notches and raised ridges, but do not extend the entire length between them. Figure 9 , Figure 10 and Figure 22 As shown, elongated and rounded protrusions 228 and recesses 230 exist on each groove 210 of the packing sheet 202 and cover the entire length of each groove 210. Figure 16This is a top perspective view of a packing sheet with a ribbed microstructure embodiment.

[0065] Figure 17 A second microstructure is shown, having a rhomboid platform 234 and a rhomboid recess 236 embossed into the side of the groove 210. Similar to the embodiment of the ribbed microstructure, the rhomboid microstructure embodiment does not exist on the flat ridge 212 or flat valley 216 of the groove 210.

[0066] Figure 18 The present invention illustrates a packing sheet having a ribbed microstructure embodiment in one half of the packing sheet 202, and a rhomboid microstructure embodiment in the other half of the packing sheet 202 according to the present invention. Figure 19 yes Figure 18 A partial detail diagram of the embodiment shown.

[0067] Figure 20 and Figure 21 It shows Figure 18 A schematic diagram of two packing plates 202 of the type shown is connected together, wherein the connecting notch 222 on the flat ridge 212 of the first packing plate mates with the connecting notch 222 on the flat ridge 212 of the second packing plate and is nested within the connecting notch 222 on the flat ridge 212 of the second packing plate.

[0068] The preferred packing pack of the present invention, filled with 10 packing sheets per cubic foot, has the disclosed groove structure (an overall oblique orientation achieved by longer oblique segments separated by shorter vertical segments), combined with the disclosed microstructure embodiment and eight rows of connecting notches / platforms, unexpectedly resulting in a better cost-performance ratio than prior art packing packs.

[0069] For these reasons, the design of the preferred cross-corrugated medium or packing sheet 202 and the assembled packing package 200 is novel and inventive, and has significant commercial value relative to existing commercial products available on the market.

[0070] Those skilled in the art will recognize that changes can be made to the preferred embodiments described above without departing from the inventive concept. Therefore, it should be understood that the invention is not limited to the specific embodiments disclosed, but is intended to cover modifications within the spirit and scope of the invention as defined by the broadest and most reasonable interpretation of the following claims as outlined in this disclosure and read in this specification.

Claims

1. A packing sheet for assembling into a packing bag, the packing bag being used to cool a cooling medium in an evaporative cooling tower, the packing sheet comprising: First end; The second end extends substantially parallel to the first end and is generally perpendicular to the longitudinal axis, which corresponds to the air and water flow direction during the use of the evaporative cooling tower. The first end and the second end extend substantially parallel to the transverse axis of the packing sheet. Multiple grooves, the multiple grooves extending from the first end toward the second end at a first groove angle greater than 17 degrees relative to the longitudinal axis; as well as Microstructures defined on the plurality of grooves; The plurality of grooves includes a plurality of alternating oblique groove segments with an oblique groove segment length and vertical groove segments with a vertical groove segment length, wherein the oblique groove segments are parallel to the direction extending with the first groove angle, and the vertical groove segments are parallel to the longitudinal axis, wherein the length of the oblique groove segment is 6.1 times the length of the vertical groove segment; The microstructure includes multiple alternating circular protrusions and circular recesses, which extend between the ridge edges and valley edges of the multiple grooves.

2. The packing sheet according to claim 1, wherein, The microstructure extends substantially parallel to the lateral axis.

3. The packing sheet according to claim 1, wherein, The first groove angle is 17 to 22 degrees.

4. The packing sheet according to claim 1, wherein, The plurality of grooves define a groove height, which is in the range of 1.15 inches to 1.72 inches.

5. The packing sheet according to claim 1, wherein, The circular protrusions have a height of 0.05 inches and are spaced 0.11 to 0.12 inches apart along the grooves.

6. A cross-corrugated packing assembly for cooling fluid flowing through the packing by gas flowing through the packing in substantially opposite directions, the packing assembly comprising a plurality of packing plates according to any one of claims 1-5, wherein the plurality of packing plates are arranged such that adjacent packing plates are oriented 180 degrees relative to each other and are connected to each other at corresponding connecting notches located on the flat ridges of adjacent packing plates.

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