Modular cooling tower and assembly method thereof

Abstract

The invention relates to a modular cooling tower and a method of assembling the same. A modular heat transfer system is provided. A modular heat transfer system includes an air inlet assembly disposed with a first air inlet module disposed adjacent to a second air inlet module. At least one of the first air inlet module and the second air inlet module includes an opening. The modular heat transfer system also includes a heat exchange assembly defined by at least one heat exchange module (e.g., a first heat exchange module and a second heat exchange module). The first heat exchange module and the second heat exchange module are arranged adjacently. Further, the modular heat transfer system includes a pressure ventilation assembly having at least one pressure ventilation module. The heat exchange assembly is arranged above the air inlet assembly, and the pressure ventilation assembly is arranged above the heat exchange assembly.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 715,424 (titled “Modular Cooling Tower and Method of Assembling Therewith”), filed November 1, 2024, and U.S. Provisional Patent Application No. 63 / 868,881 (titled “Filling Module for Cooling Tower”), filed August 22, 2025, both of which are currently pending, the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] This disclosure relates to modular heat exchange systems and methods for assembling them. More specifically, this disclosure discusses modular components of heat exchange towers that can be pre-assembled in a factory and transported to the work site for assembly to create a heat exchange system. Background Technology

[0004] Heat dissipation systems are commonly used in industrial, commercial, and residential environments to provide cooling. A common type of heat dissipation system is a heat exchange tower, often called a cooling tower. Cooling towers are typically assembled on-site where they will be placed. However, assembling a tower on-site is time-consuming and expensive. Assembling a tower requires a dedicated workforce trained in how to assemble one. Furthermore, weather can delay tower construction. Therefore, it is advantageous to assemble some components of the tower in a manufacturing facility and then transport the pre-built components to the site.

[0005] However, while assembling tower components in a manufacturing facility is preferable, some conventional cooling tower designs require on-site assembly. For example, factors such as the size of individual tower components and their structural strength limit their ability to be pre-assembled and transported to the site. In particular, liquid collection basins (often called cold water basins) are difficult to pre-assemble and transport. Conventional towers typically consist of a single, integrated cold water basin for receiving and retaining water that has been cooled by the tower. In some cases, the large size of the cold water basin makes transporting it to the site costly. For example, the basin is an oversized cargo that is unsuitable for loading onto the trailer of a standard semi-trailer truck. The challenge of transporting such large, single-piece cold water basins can be addressed with multi-piece, modular cold water basins, which would allow the basin to be transported to the site as smaller, modular components for final on-site assembly. Final assembly can be performed using various assembly methods, including welding the modular components of the cold water basin together, which is time-consuming and expensive. Furthermore, on-site welding is more difficult than factory welding due to limited access to the welding sites and site conditions, resulting in weld joints that are more prone to leakage.

[0006] Therefore, there is a need for an improved modular cooling tower that includes components that can be pre-assembled in a manufacturing facility, transported to the site using a semi-trailer truck trailer, and easily assembled on-site. Summary of the Invention

[0007] In one aspect, a modular heat transfer system is provided. The modular heat transfer system includes an air inlet assembly provided in a configuration where a first air inlet module is arranged adjacent to a second air inlet module. At least one of the first and second air inlet modules includes an opening. The modular heat transfer system also includes a heat exchange assembly defined by at least one heat exchange module (e.g., a first heat exchange module and a second heat exchange module). The first heat exchange module is arranged adjacent to the second heat exchange module. Furthermore, the modular heat transfer system includes a pressure ventilation assembly having at least one pressure ventilation module. The heat exchange assembly is arranged above the air inlet assembly, and the pressure ventilation assembly is arranged above the heat exchange assembly.

[0008] In some cases, the modular heat transfer system includes an airflow generator defined by a fan assembly having at least one fan blade.

[0009] In some cases, the pressure ventilation component of a modular heat transfer system includes at least a portion of an airflow generator.

[0010] In some cases, the first fan blade of the at least one fan blade extends from the first pressure ventilation module of the at least one pressure ventilation module onto the second pressure ventilation module of the at least one pressure ventilation module, the second pressure ventilation module being arranged adjacent to the first pressure ventilation module.

[0011] In some cases, the modular heat transfer system includes a door with one or more louver assemblies, wherein the door is attached to a first air inlet module or a second air inlet module via hinges. The door is designed to provide a walkway into the interior of the first or second air inlet module. In some such cases, when the door is actuated to an open configuration, the door swings toward the interior of the modular heat transfer system.

[0012] In some cases, the modular heat transfer system includes a fluid distribution system provided in the form of one or more nozzles, which are designed to distribute fluid onto the filling medium of the at least one heat exchange module.

[0013] In some cases, the pressure ventilation assembly includes a first pressure ventilation module, a second pressure ventilation module, and a third pressure ventilation module. The first pressure ventilation module is positioned adjacent to the second pressure ventilation module, and the second pressure ventilation module is positioned adjacent to the third pressure ventilation module.

[0014] In some cases, the at least one heat exchange module is a hybrid packing module, which is provided in the form of a structurally constrained packing and one or more packing assemblies.

[0015] In some cases, the modular heat transfer system includes a cold water collection basin disposed below the air inlet assembly. The cold water collection basin includes a first cold water collection basin module disposed adjacent to a second cold water collection basin module.

[0016] In another aspect, a modular heat transfer system is provided. The modular heat transfer system includes an air inlet assembly, which includes a first air inlet module. The modular heat transfer system also includes a heat exchange assembly, which includes a first heat exchange module. The modular heat transfer system further includes a pressure ventilation assembly, which includes a first pressure ventilation module. The modular heat transfer system also includes a cold water collection basin, which includes a first cold water collection basin module arranged adjacent to a second cold water collection basin module. The first cold water collection basin module and the second cold water collection basin module are in fluid connection. The cold water collection basin is located below the air inlet assembly, and the heat exchange assembly is located above the air inlet assembly. The pressure ventilation assembly is located above the heat exchange assembly.

[0017] In some cases, the cold water collection basin includes a recessed bottom plate that bisects the length of the cold water collection basin.

[0018] In some cases, the recessed bottom plate includes a first recessed bottom plate portion disposed in the first cold water collection basin module and a second recessed bottom plate portion disposed in the second cold water collection basin module.

[0019] In some cases, the first recessed bottom plate is connected to the second recessed bottom plate via a watertight flow channel.

[0020] In some cases, the length (L) of the flow channel connecting the first recessed bottom plate portion to the second recessed bottom plate portion F It is less than the length of the cold water collection basin.

[0021] In some cases, at least one of the first cold water collection basin module and the second cold water collection basin module includes an outlet.

[0022] In some cases, the first cold water collection basin module includes a first water collection tank, the second cold water collection basin module includes a second water collection tank, and the first water collection tank is fluidly connected to the second water collection tank via a conduit. In some cases, the outlet conduit is fluidly connected to the first water collection tank, and the outlet conduit is designed to remove the cooled process fluid from the modular heat transfer system.

[0023] In some cases, the first water tank, the second water tank, and the conduits are arranged within a volume defined by the frame enclosure of the modular heat transfer system.

[0024] In some cases, the first water collection tank, the second water collection tank, and the conduit connecting the first water collection tank and the second water collection tank are arranged below the frame cover of the cold water collection basin.

[0025] In some cases, the first cold water collection basin module includes a first outlet, a first water collection tank, and a first suction air inlet hood, and the second cold water collection basin module includes a second outlet, a second water collection tank, and a second suction air inlet hood.

[0026] In some cases, the first cold water collection basin module includes a first inner sidewall, the second cold water collection basin module includes a second inner sidewall, and the first and second cold water collection basin modules are fluidly connected at flow openings through the first and second inner sidewalls.

[0027] In other cases, the first cold water collection basin module is connected to the second cold water collection basin module via a sealing plate extending along the module interface above the waterline.

[0028] In some cases, one or more of the first or second cold water collection basin modules include an outlet and an anti-vortex device disposed above the outlet.

[0029] On the other hand, a modular heat transfer system is provided. The modular heat transfer system includes: an air inlet assembly including a first air inlet module; a heat exchange assembly including a first heat exchange module; a pressure ventilation assembly including a first pressure ventilation module; an airflow generator; and a first cold water collection basin. The dimensions and shape of at least one of the first air inlet module, the first heat exchange module, and the first pressure ventilation module are configured such that their dimensions do not exceed transport size limitations.

[0030] In one aspect, a modular heat exchange system is provided. The modular heat exchange system includes an air inlet assembly, a pressure ventilation assembly, and a heat exchange assembly, the heat exchange assembly including at least one heat exchange module. The at least one heat exchange module includes at least one filling module. The at least one filling module includes a plurality of filling sheets disposed on at least one support member. The at least one support member includes a first end and a second end. A plurality of filling assemblies are also disposed on the at least one support member. Each filling assembly includes a plurality of bonded filling sheets. A first filling assembly is coupled to the first end of the at least one support member, and a second filling assembly is coupled to the second end of the at least one support member.

[0031] In some cases, the at least one support member extends along an axis substantially perpendicular to the plurality of filler sheets.

[0032] In some cases, the third packing assembly is coupled to the first end of the at least one support member and positioned adjacent to the first packing assembly.

[0033] In some cases, the third packing assembly is coupled to the second end of the at least one support member and positioned adjacent to the second packing assembly.

[0034] In some cases, the at least one heat exchange module includes a first heat exchange module, a second heat exchange module, and a third heat exchange module. The first heat exchange module is arranged adjacent to the second heat exchange module, and the second heat exchange module is arranged adjacent to the third heat exchange module.

[0035] In some cases, at least one of the first heat exchange module, the second heat exchange module, and the third heat exchange module forms at least a portion of the at least one filling module.

[0036] In some cases, the heat exchange assembly also includes a fluid distribution system, which includes at least one riser.

[0037] In some cases, the at least one filling module also includes at least one opening for receiving the at least one riser.

[0038] In some cases, the modular heat exchange system also includes a cold water collection basin having at least one cold water collection basin module, wherein the cold water collection basin is positioned adjacent to and below the heat exchange component.

[0039] In some cases, the plurality of filler assemblies are designed to maintain the plurality of filler sheets in a predetermined orientation during transport.

[0040] In some cases, the plurality of filler sheets comprise approximately 50% to approximately 90% of the total volume of the at least one filler module.

[0041] In another aspect, a packing module for a heat exchange system is provided. The packing module includes a first plurality of packing sheets disposed on a first support member, the first support member including a first end positioned opposite to a second end. The packing module also includes a plurality of packing assemblies, each packing assembly including a second plurality of packing sheets bonded together. A first packing assembly is coupled to a first end of the first support member, and a second packing assembly is coupled to a second end of the first support member.

[0042] In some cases, the plurality of filler sheets are provided as suspended fillers. In other cases, the plurality of filler sheets are provided as structurally constrained fillers. In some such cases, the structurally constrained fillers are arranged on the support members of the at least one support member.

[0043] In some cases, the plurality of filler assemblies are designed to stabilize the first plurality of filler sheets during transport of the filler module.

[0044] In some cases, the first plurality of filler sheets are disposed on the second support member.

[0045] In some cases, the filling module includes at least one opening for receiving the riser.

[0046] In another aspect, a method for assembling a modular heat exchange system is provided. The method includes assembling a filled module by providing a plurality of filled sheets in a stacked manner, such that the distance between any two filled sheets in the stack is less than about 0.5 mm. The method also includes providing a plurality of filler assemblies, such that each filler assembly includes a plurality of bonded filler sheets. The method further includes providing at least one support member having a first end and a second end, arranging the plurality of filler sheets on the at least one support member, and coupling a first filler assembly to the first end of the at least one support member. The method further includes coupling a second filler assembly to the second end of the at least one support member, and mounting the filled module in a heat exchange module.

[0047] In some cases, the filler module is assembled and installed in the heat exchange module at a first location, and the heat exchange module containing the filler module is transported to a second location for assembly into the modular heat exchange system.

[0048] In some cases, the filling module includes a first filling module end, a second filling module end, a first filling module side, and a second filling module side.

[0049] In some cases, multiple filling modules are installed side-by-side in a heat exchange module. The combination of the first filling module ends of the multiple filling modules defines a first side of the heat exchange module, and the combination of the second filling module ends of the multiple filling modules defines a second side of the heat exchange module.

[0050] In some cases, the at least one support member extends along an axis substantially perpendicular to the plurality of filler sheets.

[0051] In some cases, the method further includes coupling a third packing assembly to a first end of the at least one support member, the third packing assembly being positioned adjacent to the first packing assembly, and coupling a fourth packing assembly to a second end of the at least one support member, the fourth packing assembly being positioned adjacent to the second packing assembly. Attached Figure Description

[0052] Figure 1 A schematic diagram illustrating a heat transfer system with a modular counterflow cooling tower and control system;

[0053] Figure 2 This is a bottom-view perspective view of the modular counterflow cooling tower provided in this disclosure;

[0054] Figure 3A for Figure 2 An exploded view of the modular counterflow cooling tower shown.

[0055] Figure 3B yes Figure 3AA partial enlarged view of the air movement device deck assembly of the modular counterflow cooling tower shown.

[0056] Figure 3C for Figure 3A A partially enlarged view of the heat exchange components of the modular counterflow cooling tower shown.

[0057] Figure 3D for Figure 3A A partial enlarged view of the modular counter-flow air inlet assembly shown;

[0058] Figure 4A A partial enlarged view of the air inlet assembly, including the louvered entry door in a closed configuration;

[0059] Figure 4B yes Figure 4A A close-up view of the central air inlet component, showing the louvered inlet door in an open configuration;

[0060] Figure 5A This is a top-view perspective view of the air inlet assembly, with some parts removed to show the inlet connection manifold, which includes conduits designed to deliver process water to be cooled to the heat transfer module.

[0061] Figure 5B yes Figure 5A A partial enlarged view of the air inlet assembly, showing the flow channel;

[0062] Figure 5C yes Figure 5A Another enlarged view of the air inlet assembly, showing the flow channel;

[0063] Figure 6A This is a schematic diagram of a top perspective view of a modular cold water collection basin provided in this disclosure;

[0064] Figure 6B This is a schematic diagram of a top perspective view of another modular cold water collection basin provided in this disclosure;

[0065] Figure 6C yes Figure 6B Top-view perspective of the modular cold water collection basin;

[0066] Figure 6D yes Figure 6B The top-view perspective view includes a modular cold water collection basin with a recessed central area, and two outlets located in separate modules;

[0067] Figure 6E yes Figure 6D A bottom-view perspective view of the modular cold water collection basin, showing a portion of the conduit connecting the two outlets;

[0068] Figure 6FThis is a top-view perspective view of another modular cold water collection basin with a recessed central area and two outlets;

[0069] Figure 6G It is along Figure 6F A schematic diagram of the cross-sectional view of line 6G-6G shows that each of the two outlets has a water collection tank, wherein the two water collection tanks are arranged within the frame enclosure of the modular heat transfer tower.

[0070] Figure 6H It is along Figure 6F Another schematic diagram of the sectional view of line 6G-6G shows that each of the two outlets has a water collection tank, wherein the two water collection tanks are arranged below the frame enclosure of the modular heat transfer tower.

[0071] Figure 6I It is a top perspective view of a modular cold water collection basin with a basin module connected via a suction inlet hood and a single outlet.

[0072] Figure 6J It is along Figure 6I A schematic diagram of the cross-sectional view of line 6J-6J;

[0073] Figure 7A This is a top perspective view of a heat transfer assembly and associated fluid manifold spray system for use with modular counterflow cooling towers (such as those described herein), featuring riser assemblies;

[0074] Figure 7B yes Figure 7A A bottom perspective view of a heat transfer assembly with riser components and an associated fluid manifold spray system.

[0075] Figure 7C It is a bottom-view perspective view of the heat transfer components and the associated fluid manifold spray system;

[0076] Figure 7D It is along Figure 7A A schematic diagram of the cross-sectional view taken by line 7D-7D in the diagram;

[0077] Figure 7E It is along Figure 7A Another schematic diagram of the cross-sectional view taken by line 7D-7D in the middle;

[0078] Figure 8A It is a top-view perspective view of a hybrid infill module with supporting components;

[0079] Figure 8B yes Figure 8A A top view of the mixed-fill module;

[0080] Figure 9A This is a side view of a hybrid infill module with supporting members;

[0081] Figure 9B yes Figure 9A The front view of the mixed fill module;

[0082] Figure 10 This is a schematic top view of a heat exchange assembly, which includes three heat exchange modules, each heat exchange module comprising a plurality of hybrid fill modules arranged adjacent to each other, and each heat exchange module further comprising a hybrid fill module having an opening configured to receive a riser.

[0083] Figure 11 This is a schematic diagram showing a top view of a heat exchange module comprising a plurality of hybrid fill modules arranged adjacent to each other, the heat exchange module including hybrid fill modules having openings configured to receive risers;

[0084] Figure 12 This is a schematic top perspective view of a hybrid filling module, which includes an opening configured to receive a riser, wherein the riser is shown as being positioned in the opening.

[0085] Figure 13 This is a top-view perspective view of the heat exchange module, showing a feasible arrangement of the packing sheets within the heat exchange module; and

[0086] Figure 14 This is a flowchart illustrating the methods for assembling modular cooling towers according to various aspects of this article.

[0087] While this disclosure may have various variations and alternatives, specific embodiments thereof are illustrated by way of example in the accompanying drawings and described in detail herein. However, it should be understood that the accompanying drawings and detailed descriptions provided herein are not intended to limit this disclosure to the specific instances disclosed; rather, they are intended to cover all variations, equivalents, and alternatives falling within the spirit and scope of this disclosure as defined by the appended claims. Detailed Implementation

[0088] Before describing any embodiment in detail, it should be understood that this disclosure is not limited in its application to the construction details and component arrangements set forth in the following description or shown in the following figures, which are limited only by the claims appended to this disclosure. This disclosure is capable of having other embodiments and can be implemented or performed in various ways. Furthermore, it should be understood that the wording and terminology used herein are for descriptive purposes and should not be considered limiting. The use of “comprising,” “including,” or “having,” and variations thereof herein is intended to cover items listed after them and their equivalents, as well as additional items. Unless otherwise stated or limited, the terms “mounted,” “connected,” “supported,” and “linked,” and variations thereof are used broadly and cover direct and indirect mounting, connection, support, and linking. Moreover, “connected” and “linked” are not limited to physical or mechanical connections or links.

[0089] The following description is given to enable those skilled in the art to make and use embodiments of the present disclosure. Those skilled in the art will readily understand various variations to the illustrated embodiments, and that the general principles herein can be applied to other embodiments and applications without departing from the embodiments of the present disclosure. Therefore, embodiments of the present disclosure are not intended to be limited to the embodiments shown, but should be given the widest scope consistent with the principles and features disclosed herein. The following detailed description should be read with reference to the accompanying drawings, in which similar elements have similar reference numerals. Those skilled in the art will recognize that the examples provided herein have many available alternatives and fall within the scope of embodiments of the present disclosure.

[0090] Additionally, while the following discussion may describe features associated with a particular device or embodiment, it should be understood that the systems and methods described may use additional devices and / or features, and the devices and features discussed are intended to provide examples of possible embodiments, not to limit them.

[0091] This disclosure provides a modular heat transfer tower employing a fluid distribution system. The fluid distribution system may include a series of hot water basins or troughs and / or a series of conduits and nozzles. Fluid may flow through the water distribution system to be cooled. During operation, a thermal process fluid (e.g., water) may be sprayed via the water distribution system such that the thermal process fluid flows vertically through the modular heat transfer tower. As the hot water travels along the length of the tower, it is cooled by ambient air at a lower temperature, which enters the tower through one or more air inlets. The modular heat transfer tower may be designed such that ambient air flows through the tower in a first direction, while the thermal process fluid flows in a second direction, substantially opposite to the flow direction of the ambient air. For example, the thermal process fluid may flow vertically but opposite to the flow direction of the ambient air (i.e., the ambient air may flow counter-currently relative to the thermal process fluid). When the process fluid reaches the bottom of the tower, the fluid is cooled and collected in a basin. Furthermore, the ambient air already used to cool the process fluid is heated and drawn upwards and exits the modular heat transfer tower (e.g., by a fan located in the exhaust gas flow and drawing air through the tower).

[0092] The systems and methods disclosed herein provide modular counter-flow cooling towers with multiple water collection basin designs (e.g., dual-basin designs). The multi-basin design allows individual basins to be pre-assembled in the factory and transported to the work site for installation in the cooling tower. Each basin can have dimensions that allow for economical transport to the work site. The multi-basin design allows the cooling tower to be assembled with smaller basins and other components than conventional cooling towers without sacrificing cooling capacity. In fact, greater capacity can be achieved than with previously conventional factory-assembled cooling towers. Furthermore, by using larger fans that were previously unavailable or uncommissioned in conventional factory-assembled towers, power consumption per unit of cooling can be reduced. Therefore, these systems and methods provide customers with a high-capacity cooling product that requires less on-site assembly time, less shelving space, and reduces transportation costs, installation costs, safety issues associated with on-site assembly, and downtime.

[0093] The systems and methods disclosed herein can avoid the transportation problems associated with existing cooling towers by providing cooling towers assembled from various modular components that do not exceed certain transport size limits. For example, the systems and methods disclosed herein can provide a cooling tower with at least nine (9) modular components: two (2) air inlet modules (e.g., a first air inlet module and a second air inlet module), three (3) heat exchange modules (e.g., a first heat exchange module, a second heat exchange module, and a third heat exchange module), three (3) pressure ventilation modules (e.g., a first pressure ventilation module, a second pressure ventilation module, and a third pressure ventilation module), and an airflow generator. In other cases, additional or fewer modular components can be provided in the cooling tower. Each of these components can have a size that does not exceed certain transport size limits. Therefore, the components can be transported without special oversized cargo requirements, thereby reducing transportation costs.

[0094] The systems and methods disclosed herein can also provide cooling towers with at least eleven (11) modular components: two (2) air inlet modules (e.g., a first air inlet module and a second air inlet module), two (2) water collection basin modules (e.g., a first water collection basin module and a second water collection basin module), three (3) heat exchange modules (e.g., a first heat exchange module, a second heat exchange module, and a third heat exchange module), three (3) pressure ventilation modules (e.g., a first pressure ventilation module, a second pressure ventilation module, and a third pressure ventilation module), and an airflow generator. In other cases, additional or fewer modular components may be provided in the cooling tower. Each of these components may have a size not exceeding certain transport size limits. Therefore, the components can be transported without special oversized cargo requirements, thereby reducing transport costs.

[0095] The systems and methods disclosed herein can also provide cooling towers with at least ten (10) modular components: two (2) air inlet modules (e.g., a first air inlet module and a second air inlet module), two (2) water collection basin modules (e.g., a first water collection basin module and a second water collection basin module), three (3) heat exchange modules (e.g., a first heat exchange module, a second heat exchange module, and a third heat exchange module), and three (3) combined pressure ventilation and airflow generator modules (e.g., a first combined pressure ventilation and airflow generator, a second combined pressure ventilation and airflow generator, and a third combined pressure ventilation and airflow generator). In other cases, additional or fewer modular components may be provided in the cooling tower. Each of these components may have a size not exceeding certain transport size limits. Therefore, the components can be transported without special oversized cargo requirements, thereby reducing transport costs.

[0096] The systems and methods disclosed herein can also provide cooling towers with at least eight (8) modular components: two (2) air inlet modules (e.g., a first air inlet module and a second air inlet module), three (3) heat exchange modules (e.g., a first heat exchange module, a second heat exchange module, and a third heat exchange module), and three (3) combined pressure ventilation and airflow generator modules (e.g., a first combined pressure ventilation and airflow generator, a second combined pressure ventilation and airflow generator, and a third combined pressure ventilation and airflow generator). In other cases, additional or fewer modular components may be provided in the cooling tower. Each of these components may have a size not exceeding certain transport size limits. Therefore, the components can be transported without special oversized cargo requirements, thereby reducing transport costs.

[0097] The systems and methods disclosed herein can also provide cooling towers with at least eight (8) modular components: two (2) combined air inlet and water collection basin modules (e.g., a first combined air inlet and water collection basin module and a second combined air inlet and water collection basin module), three (3) heat exchange modules (e.g., a first heat exchange module, a second heat exchange module, and a third heat exchange module), and three (3) combined pressure ventilation and airflow generator modules (e.g., a first combined pressure ventilation and airflow generator, a second combined pressure ventilation and airflow generator, and a third combined pressure ventilation and airflow generator). In other cases, additional or fewer modular components may be provided in the cooling tower. Each of these components may have a size not exceeding certain transport size limits. Therefore, components can be transported without special oversized cargo requirements, thereby reducing transport costs.

[0098] Typically, very few U.S. states impose significant travel restrictions on cargo with a width of ten (10) feet or less (or three (3) meters or less). Cargo with a width greater than eight and a half (8.5) feet is considered oversized or wide, and the standard truck bed width is eight (8) feet. Therefore, the system and method disclosed herein can provide a cooling tower that can be assembled from various components, each with a width of ten (10) feet or less (or three (3) meters or less) or eight and a half feet or less (or two and a half meters or less), thereby meeting certain transport size restrictions. While these modular components require additional trucks to transport to the work site—for example, multiple trucks are needed to transport the individual components instead of one oversized truck to transport the entire cooling tower—the cost savings associated with not having oversized cargo (e.g., not having to pay for certain permit requirements) may outweigh the additional costs of having additional trucks. Furthermore, fewer towers or units are required on site when using larger capacity towers in high-capacity applications that require multiple towers (e.g., units). Moreover, this system and method can provide a way to transport and assemble cooling towers in areas where transporting oversized cargo is not permitted, using factory-assembled components.

[0099] This disclosure also relates to a hybrid packing component (also called a hybrid packing module) for use in cooling towers, particularly modular cooling towers or heat exchange systems. The hybrid packing component may include mechanically constrained or structurally constrained packing and one or more packing assemblies. The structurally constrained packing may be supported, connected to, received by, or received by one or more support members (e.g., pipes, pipe seats, rails, guides, etc.), the support members being designed to provide structural support to the packing. Additionally, in some cases, the structurally constrained packing may be supported by one or more components located below the structurally constrained packing, wherein the one or more components abut against the bottom surface or bottom of the structurally constrained packing. The hybrid packing and packing modules disclosed herein provide a modular packing solution that combines the advantages of structurally constrained packing and packing assemblies while minimizing the disadvantages of each type of packing. By combining structurally constrained packing and packing assemblies, the hybrid packing design reduces air gaps in the final packing module because the structurally constrained packing has fewer or even no air gaps. In addition, the packing assembly also serves to stabilize the structurally constrained packing sheets and maintain them in the correct orientation (e.g., a predetermined orientation), for example, during transport. Maintaining the correct orientation of the structurally constrained packing sheets is particularly important during the transport of the packing modules, when the sheets may be exposed to wind. Therefore, the structurally constrained packing and packing assembly can be pre-assembled together in the factory and installed into the heat exchange modules, and efficiently transported to the work site to construct the cooling tower. Thus, hybrid packing designs contribute to high-capacity cooling products that require less on-site assembly time and reduce transportation costs.

[0100] This disclosure also relates to a hybrid packing component (also called a hybrid packing module) for use in cooling towers, particularly modular cooling towers or heat exchange systems. The hybrid packing component may include suspended packing and one or more packing assemblies. The hybrid packing and packing modules disclosed herein provide a modular packing solution that combines the advantages of suspended packing and packing assemblies while minimizing the disadvantages of each type of packing. By combining suspended packing and packing assemblies, the hybrid packing design reduces air gaps in the final packing module because the suspended packing has fewer or even no air gaps. Additionally, the packing assembly also serves to stabilize the suspended packing sheets and maintain their correct orientation, for example, during transport. Maintaining the correct orientation of the suspended packing sheets is particularly important during the transport of the packing module, when the suspended packing sheets may be exposed to wind. Therefore, the suspended packing and packing assemblies can be pre-assembled together in the factory and installed into the heat exchange module, and efficiently transported to the work site to be constructed into a cooling tower. Thus, the hybrid packing design contributes to high-capacity cooling products that require less on-site assembly time and reduce transportation costs.

[0101] It should be understood that, in some cases, modular cooling towers or heat exchange systems can employ both suspended packing and structurally constrained packing simultaneously.

[0102] refer to Figure 1 A schematic diagram of a heat transfer system 90 is depicted. System 90 is provided in the form of at least one modular counter-flow cooling tower 100 designed to cool the fluid and a central controller or control system 110 designed to electronically communicate with and / or control one or more components of the modular counter-flow cooling tower 100. Control system 110 may be communicatively coupled to tower 100 to control, receive, and / or store data from tower 100. For example, control system 110 may be provided for wireless or wired communication with user equipment 120 and / or network 130 to directly or indirectly communicate with and / or operate tower 100 and / or one or more components of tower 100. For example, control system 110 may be designed to operate fluid distribution systems, pumps, valves, sensors, air movement devices, and / or other system components included in tower 100 as discussed herein.

[0103] Specifically, the control system 110 can intelligently manage the fluid flow within and / or into and out of the tower 100. The control system 110 may be provided as a data processing device configured to send and receive data relative to the system 90. For example, the control system 110 may receive information at a receiver (not shown). A processor (not shown) included in the control system 110 can analyze the received data and determine instructions to be sent back to the tower 100. A transmitter (not shown) of the control system 110 can send instructions from the processor to one or more components of the system 90. The control system 110 may also include a memory (not shown). The memory may be configured to store data received from the tower 100. The memory may be implemented as a separate memory unit and / or as part of a processor included in the control system 110. Furthermore, in some cases, the network 130 may be coupled to a memory that may include program instructions stored in the memory and executable by a processor to perform one or more control methods.

[0104] Network 130 may be provided in the form of a network interface, local area network (LAN), or other communication connection, and is not limited to multiple communication connections. Those skilled in the art will recognize that the communication connection can use a variety of communication protocols to send and receive data, including but not limited to wired, wireless, Bluetooth, cellular, satellite, GPS, RS-485, RF, MODBUS, CAN, CANBUS, DeviceNet, ControlNet, Ethernet TCP / IP, RS-232, Universal Serial Bus (USB), FireWire, Thread, proprietary protocols, or other applicable communication protocols. In some examples, network 130 is located near one or more components of system 90. Network 130 may include the Internet, intranet, extranet, wide area network (“WAN”), local area network (“LAN”), wired network, wireless network, cloud network, or other suitable network, or any combination of two or more networks, Ethernet network, and other types of networks. Network 130 may be configured to communicate directly or indirectly with system 90 and / or user device 120, which is provided in the form of a personal computer, tablet, mobile phone, monitor or other similar electronic device that allows the user to interface with control system 110 (e.g., use an application on the device).

[0105] although Figure 1 The control system 110 is depicted communicating with user equipment 120 and network 130, but various communication methods and connections may be implemented to operate together with or independently of one or more local controllers associated with one or more individual components associated with tower 100 discussed herein.

[0106] Figure 2 A modular counter-flow cooling tower 200 is depicted. In some cases, tower 200 can be... Figure 1 Tower 100. In countercurrent towers like tower 200, ambient air and the process fluid to be cooled (e.g., water) flow in opposite directions. For example, a hot process fluid (e.g., hot water from an industrial process or HVAC system) may enter the top of the tower via a fluid inlet and then be distributed onto the packing medium. Cold ambient air may be drawn upwards from the bottom of the tower through the packing medium. As the cold air flows upwards and the hot process fluid flows downwards through the tower, the cold air absorbs heat from the hot process fluid through evaporation and convection. Therefore, the temperature difference between the descending hot process fluid and the rising cold air is maximized at any point along the countercurrent tower, resulting in a higher heat transfer rate.

[0107] Tower 200 may include an air inlet assembly 210 and a heat exchange assembly 220. The air inlet assembly 210 may be designed to allow ambient air to enter tower 200 (e.g., the interior of tower 200) and may be in fluid communication with the external environment. The air inlet assembly 210 may include at least one air inlet module 212 or multiple air inlet modules 212a, 212b. Figure 2 As shown, tower 200 includes two air inlet modules 212a and 212b. The number of air inlet modules in a tower (e.g., tower 200) can be selected according to system requirements. When a tower includes more than one or more air inlet modules, the air inlet modules can be the same or different. In some cases, as described herein, air inlet modules can be mirror images of each other. In other cases, as described herein, each of the multiple air inlet modules can have a different structure.

[0108] The air inlet assembly 210 may also include a cold water collection basin 214 designed to collect cooled process fluid passing through the tower 200. The cold water collection basin 214 may include at least one cold water collection basin module 216 or multiple cold water collection basin modules 216a, 216b. Air inlet modules 212a, 212b may be arranged above or immediately above the cold water collection basin modules 216a, 216b. The air inlet assembly 210 may also include one or more louvers designed to control fluid splashing and / or promote uniform airflow through the tower 200. The louvers may be provided in the form of bonded PVC corrugated sheets, but may also be provided in other materials.

[0109] Heat exchange assembly 220 may include multiple heat exchange modules 222. As shown, tower 200 includes three heat exchange modules, specifically heat exchange modules 222a, 222b, and 222c. The number of heat exchange modules in the tower can be selected according to system requirements. When the tower includes more than one or more heat exchange modules, the heat exchange modules may be the same or different. In some cases, each of the multiple heat exchange modules may have the same design or structure. Heat exchange assembly 220 and / or each heat exchange module may include a packing or packing medium that can be designed to enhance heat transfer between the process fluid flowing downward through tower 200 and the air flowing upward through tower 200 by increasing the surface area of ​​the process fluid exposed to air. The packing may be provided in the form of splash packing or film packing, etc. Splash packing can break up and interrupt the vertical flow of the process fluid, for example, by cascading it through parallel splash bars of successively offset stages. Film packing can disperse water into a thin film, for example, by flowing over a large vertical area.

[0110] In some cases, the packing is provided as a splash packing, comprising multiple elongated, horizontally arranged, and staggered splash bars supported at spaced intervals by an upright grid structure or frame assembly. In other cases, the packing may be provided as a membrane packing, comprising a series of packing assemblies (fill packs or fill packing) consisting of multiple membrane-filled sheets. During the assembly of an evaporative cooling tower, the shell or support structure may be constructed first, followed by the installation of the packing medium. In the case of a splash packing, supports or grid supports can be secured to the support shell, and then the splash bars can be inserted into the supports. The splash bars provide a surface for consistently and predictably dispersing and breaking down water droplets within the water load range typically encountered during cooling tower operation. Typically, the splash bars are long and thin, and the packing structure comprises a large number of splash bars. In the case of a membrane packing, packing assemblies can be used and installed into the support structure of the cooling tower. The packing assemblies may be constructed by bonding or otherwise attaching individual sheets to each other to form a block. Alternatively, the packing assemblies may be constructed by suspending sheets from support members. Successive sheets can be placed from one end onto a support member and pushed downwards along the member until the support member is occupied by the desired number of sheets. The filler assembly is then placed within the support structure. Suitable filler assemblies include, for example, counterflow membrane fillers with cross-corrugations and uniform spacing between the filler sheets. In some cases, the filler can be provided in the form of a hybrid filler module, such as referenced... Figures 8A-14 The discussion focuses on the hybrid fill module.

[0111] Still referencing Figure 2In some cases, tower 200 may be mounted on a lattice or column 240 above ground level. In some cases, cold water collection basin 214 may be placed on column 240. Column 240 may provide space for piping (e.g., inlet water conduit 250 and / or outlet water conduit 260).

[0112] Tower 200 includes multiple openings designed to control the flow of fluids (e.g., water, air, etc.) into and out of the system. For example, inlet water conduit 250 may be designed to deliver hot process fluids to a fluid distribution system. Additionally, outlet water conduit 260 may be designed to remove cooled process fluids from a cold water collection basin 214. Inlet water conduit 250 and outlet water conduit 260 may pass beneath tower 200, but they may also be positioned at other locations relative to tower 200. In some cases, as discussed in detail below, piping and / or other fluid distribution components may be arranged beneath tower 200. Generally, as those skilled in the art will understand, piping and / or fluid distribution components can have various configurations (e.g., side discharge, or separate piping for each spray system).

[0113] Figure 3A It shows Figure 1 and Figure 2 Exploded view of modular counterflow cooling towers 100 and 200. Figure 3A The decomposition tower provided is labeled tower 300. For example... Figure 3A As shown in the exploded view, tower 300 may include a pressure ventilation assembly 330. The pressure ventilation assembly 330 may include at least one or more pressure ventilation modules (e.g., pressure ventilation modules 332a, 332b, 332c), an airflow generator 334 (e.g., an impeller / impeller assembly or a fan / fan assembly), and an optional airflow generator cylinder or optional airflow generator cylinder group 336 that houses the airflow generator 334. The airflow generator 334 may be defined by a fan assembly having at least one fan blade. Pressure ventilation modules 332a, 332b, 332c may be designed to hold and / or support the airflow generator 334. As shown, tower 300 includes three pressure ventilation modules 332a, 332b, 332c. However, depending on system requirements, tower 300 may have more or fewer pressure ventilation modules, and the provided pressure ventilation modules may be the same or different. In some cases, as referenced... Figure 3AAs shown and described in more detail, each pressure ventilation module 332a, 332b, 332c may have a different structure or shape. The pressure ventilation assembly 330 and / or each pressure ventilation module 332a, 332b, 332c may be shaped and configured to house or support the airflow generator 334. In some examples, the pressure ventilation assembly 330 includes an airflow generator group 336, which may be designed to improve the efficiency of the airflow generator 334 by causing the airflow generated by the airflow generator 334 to flow upwards, which can reduce energy losses in the tower 300. In some cases, at least one of the pressure ventilation modules 332a, 332b, 332c includes at least a portion of the airflow generator 334. In some cases, at least one fan blade extends from one pressure ventilation module onto another (e.g., an adjacent) pressure ventilation module.

[0114] Figures 3B-3D Additional views of the components of the modular counter-flow cooling tower 300 are shown. More specifically, Figure 3B The pressure ventilation assembly 330 is further shown. Figure 3C The heat exchange assembly 320 is further shown, and Figure 3D The air inlet assembly 310 is further shown. (As shown) Figure 3AAs shown in the exploded view, the components of tower 300 (e.g., air inlet assembly 310, heat exchange assembly 320, and pressure ventilation assembly 330) are stacked on top of each other along the Y direction to form tower 300. Specifically, air inlet assembly 310 includes a first air inlet module 312a and a second air inlet module 312b, which are positioned parallel to or along the X-axis and parallel to each other. The second air inlet module 312b may be positioned adjacent to the first air inlet module 312a. Heat exchange assembly 320 includes a first heat exchange module 322a, a second heat exchange module 322b, and a third heat exchange module 322c, which are positioned parallel to or along the Z-axis. The second heat exchange module 322b may be located between the first heat exchange module 322a and the third heat exchange module 322c. Thus, each of heat exchange modules 322a-322c is located above at least a portion of each of the first air inlet module 312a and the second air inlet module 312b. In other words, heat exchange modules 322a-322c are positioned perpendicular to air inlet modules 312a, 312b. The pressure ventilation assembly 330 may include a first pressure ventilation module 332a, a second pressure ventilation module 332b, and a third pressure ventilation module 332c, which are positioned parallel to or along the Z-axis. The second pressure ventilation module 332b may be located between the first pressure ventilation module 332a and the third pressure ventilation module 332c. Therefore, the first pressure ventilation module 332a may be located above the first heat exchange module 322a, the second pressure ventilation module 332b may be located above the second heat exchange module 322b, and the third pressure ventilation module 332c may be located above the third heat exchange module 322c. An airflow generator 334 may be disposed in or above one or more of the pressure ventilation modules 332a-332c. In some cases, at least one of the pressure ventilation modules 332a, 332b, and 332c includes at least a portion of an airflow generator 334 or a fan assembly. In some cases, at least one fan blade extends from one pressure ventilation module onto an adjacent pressure ventilation module. In cases where tower 300 includes an airflow generator assembly 336 (e.g., a fan assembly), the airflow generator assembly 336 may be disposed on one or more pressure ventilation modules 332a-332c.

[0115] In some aspects, the heat transfer system may include two modular counter-current cooling towers, such as a first cooling tower and a second cooling tower (not shown). The first cooling tower and / or the second cooling tower may be... Figure 1 Tower 100 and / or Figure 2 Tower 200 and / or Figure 3AThe first cooling tower is 300. In some cases, the towers can be arranged in series. In other words, the cold process fluid of the first cooling tower (e.g., process fluid from a cold water basin) can be the hot process fluid of the second cooling tower (e.g., process fluid distributed on the packing medium by a fluid distribution system). In other cases, the first and second cooling towers can be arranged in parallel. In other words, each tower can operate as an independent unit or independently of each other. Furthermore, it should be understood that, depending on the system requirements, the system can include more modular cooling towers (whether arranged in series or in parallel).

[0116] Figure 4A and Figure 4BThe images show the louvered door 400 included in the air inlet assembly 410 in both closed and open configurations. The air inlet assembly 410 can be air inlet assemblies 210 and / or 310. The louvered door 400 can be provided as a hinged full-height door. The door height can range from about 72 inches to about 85 inches or from about 80 inches to about 85 inches (e.g., about 83 inches), and the door width can range from about 30 inches to 35 inches (e.g., 33 inches). In some cases, the door height can range from about 1.8 meters to about 2.2 meters, and the door width can range from about 0.8 meters to about 0.9 meters. The door can be designed to provide a walkway into the interior of the air inlet assembly (e.g., a first air inlet module or a second air inlet module) and allow access to internal components of the air inlet assembly 410, including, for example, a cold water collection basin. The louvered door 400 may include a steel frame (e.g., made of 304 stainless steel) and one or more louvers disposed within the frame. One or more louvers may be designed to allow air to enter through a closed door during tower operation, which can reduce airside pressure drop near the louver door 400. In some cases, the door comprises one or more honeycomb air inlet louvers or louver assemblies disposed within a frame. Suitable honeycomb air inlet louvers have a similar structure to the honeycomb drift eliminator described in U.S. Patent 4,514,202, the entire disclosure of which is incorporated herein by reference. The honeycomb air inlet louver may be described as having a main flow axis over its width. The honeycomb air inlet louver may discharge air at an upward angle relative to its main flow axis, for example, at an angle of about 10° to about 60° (or 10° to 60°), or about 30° (or 30°), as described in U.S. Patent 4,514,202, the entire disclosure of which is incorporated herein by reference. The honeycomb air inlet louvers can be made of PVC thermoformed sheets that are bonded or otherwise attached together to form blocks or assemblies, wherein the thickness of each sheet can be in the range of about 12 mm to about 15 mm (or 12 mm to 15 mm), and the sheet assemblies can have a uniform sheet spacing.

[0117] In some aspects, the louvered door 400 allows air passage but is substantially watertight or watertight. In some aspects, the periphery of the louvered door 400 may have a seal or flange to help prevent water leakage from the air inlet assembly 410. In some aspects, the louvered door 400 may include a flanged steel frame, wherein the flange extends around at least part or the entire periphery of the frame. In some aspects, the louvered door 400 extends entirely between the upper and lower edges of the air inlet assembly 410. In some examples, the height of the louvered door 400 may be about 60% to about 95% (or 60% to 95%) of the height of the air inlet assembly 410, but the height of the louvered door 410 may also be less than or greater than these values. In some cases, one or more steps (e.g., two steps) may be provided below the lower edge of the louvered door 400. The louvered door 400 may be in a closed configuration when the tower is in use, such as... Figure 4A As shown. The louvered door 400 can be opened inward toward the internal components of the air inlet assembly 410 or toward the cooling tower (e.g., during maintenance and / or when the tower is not running). Figure 1 , Figure 2 , Figure 3A The louvered door 400 can be opened internally to the air inlet assembly 410 or to the cooling tower (e.g., towers 100, 200, 300). In other cases, the louvered door 400 can be opened externally to internal components of the air inlet assembly 410 or to the cooling tower (e.g., during maintenance and / or when the tower is not operating) away from the cooling tower. Figure 1 , Figure 2 , Figure 3A The interior of towers 100, 200, and 300 can be opened.

[0118] Figures 5A-5C Various internal components of the air inlet assembly 510 are shown. The air inlet assembly 510 can be... Figure 2 , Figure 3A , Figure 4A and Figure 4B Air inlet assemblies 210, 310, and 410. For example... Figure 5AAs shown, the air inlet assembly 510 may be provided in the form of a first air inlet module 512a and a second air inlet module 512b. The air inlet assembly 510 may include a flow channel 550 that defines a flow path to allow fluid to flow from one cold water collection basin module 516a, 516b (e.g., cold water collection basin module 516a) to another cold water collection basin module 516a, 516b (e.g., cold water collection basin module 516b) and to an outlet 530. Therefore, the flow channel 550 may serve two main purposes: to transfer water from the cold water collection basin modules 516a, 516b to the outlet 530 and / or to equalize the liquid level between the cold water collection basin modules 516a, 516b. The flow channel 550 may be coupled to the cold water collection basin modules 516a, 516b to form a fluid-impermeable (e.g., watertight or substantially watertight) connection. In some cases, the flow channel 550 can be welded to the cold water collection basin modules 516a, 516b, and the welding can be performed in the field. Alternatively, the flow channel 550 can be joined to the cold water collection basin modules 516a, 516b using a waterproof sealant, which can be applied to one or more mating surfaces of the flow channel 550 and / or the cold water collection basin modules 516a, 516b. Figure 5B As shown, one or more bolts 556 or other attachment mechanisms can also be used to secure the flow channel 550 to the cold water collection basin modules 516a, 516b, but the one or more bolts 556 can be omitted (e.g., when the flow channel 550 is welded to the cold water collection basin modules 516a, 516b). Figure 5B and Figure 5C As best shown in the enlarged view, the flow channel 550 can be given a trapezoidal shape. The flow channel 550 may include a base 552 and a pair of sidewalls 554a, 554b extending therefrom. Each sidewall 554a, 554b may be inclined at a certain angle. In some cases, the base 552 and the two opposing sidewalls 554a, 554b are provided as an integral construction.

[0119] The air inlet assembly 510 may also include a manifold assembly 560 (which may also be referred to as an inlet connection manifold). The manifold assembly 560 may further include a manifold box 562, which is in fluid communication with a heat transfer module (not shown) via at least one conduit 564a, 564b, 564c (which may also be referred to as a manifold inlet riser pipe or manifold inlet riser conduit). The manifold inlet riser conduits 564a-564c deliver process water to be cooled and are fluidly connected to pipes or conduits within the heat transfer module, whereby water is distributed through nozzles onto a heat transfer medium (e.g., a packing material). Figure 5AAs shown, manifold assembly 560 is provided in the form of three conduits 564a-564c. However, it is to be understood that manifold assembly 560 may include more or fewer conduits depending on the system requirements and / or the number of heat transfer modules. In some cases, the number of conduits may be the same as the number of heat transfer modules provided in the system. Air inlet assembly 510 may optionally include more than one manifold assembly (e.g., one manifold assembly for each fluid distribution assembly).

[0120] Figures 6A-6J Depicting its use in modular heat transfer towers (e.g., Figure 1 , Figure 2 and Figure 3A Various components of the cold water collection basin 614 in towers 100, 200, and 300. The cold water collection basin 614 can be provided in the form of a modular cold water collection basin 614 defined by at least one cold water collection basin module 616a, 616b (or multiple cold water collection basin modules 616a, 616b) and a flow channel 650, which can be coupled to the cold water collection basin modules 616a, 616b to connect the cold water collection basin modules 616a, 616b (see, for example...). Figures 6A-6D In some cases, the flow channel 650 can be welded to the cold water collection basin modules 616a, 616b. In some cases, welding can be performed on-site. Therefore, the modular cooling tower may include one or more cold water collection basin modules 616a, 616b, which can be connected together to form a cold water collection basin 614.

[0121] When multiple cold water collection basin modules are connected together, not every cold water collection basin module includes a fluid outlet 630. For example, as Figures 6A-6C As shown, only the first cold water collection basin module 616a includes a fluid outlet 630. A second cold water collection basin module 616b (which may not include a fluid outlet 630) may be fluidly connected (e.g., via a channel or conduit) to the first cold water collection basin module 616a. The first cold water collection basin module 616a may be close to or adjacent to the second cold water collection basin module 616b. Fluid in the second cold water collection basin module 616b can flow through a channel 650 to the fluid outlet 630 in the first cold water collection basin module 616a. One or more of the cold water collection basin modules may include a recessed base plate portion 640 (see...). Figure 6A ).

[0122] like Figure 6AAs shown, the first cold water collection basin module 616a includes a recessed bottom plate portion 640, whereby fluid can flow from the second cold water collection basin module 616b through a flow channel 650 and to a fluid outlet 630. After being supplied to the fluid outlet 630, the fluid can flow out of the cooling tower. In some cases, the flow channel 650 may be impermeable to fluids (e.g., water), and fluid leakage is not permitted at the points where the flow channel 650 connects to or is coupled to the cold water collection basin modules 616a, 616b.

[0123] In some cases, it is advantageous to limit or reduce the amount or length of welding required to connect the cold water collection basin modules 616a and 616b together. For example, as... Figure 6A As shown, providing a fluid-impermeable (or substantially fluid-impermeable) seal along the entire length of the cold water collection basin 614 between the flow channel 650 and the cold water collection basin modules 616a, 616b would require a significant amount of time and effort. Furthermore, the more welds are made or the longer the welded joints are, the greater the likelihood of leakage, especially when welding is performed in the field under challenging conditions (e.g., extreme temperatures).

[0124] Figure 6B , Figure 6C and Figure 6D The modular cold water collection basin 614 is shown to have a relative Figure 6A The recessed bottom plate portion 640 shown is rotated by 90°. Figure 6B and Figure 6C The first cold water collection basin module 616a and the second cold water collection basin module 616b share a flow channel 650, but the flow channel 650 does not span the entire length (L) of the cold water collection basin 614. C In some aspects, such as Figure 6B , Figure 6C and Figure 6D As shown, the cold water collection basin 614 can be defined by a first cold water collection basin module 616a and a second cold water collection basin module 616b, as well as a first recessed bottom plate portion 640a and a second recessed bottom plate portion 640b. The first recessed bottom plate portion and the second recessed bottom plate portion extend along the Y-axis and together span the width of the first cold water collection basin module 616a and the second cold water collection basin module 616b. Figure 6B and Figure 6C As shown, the flow channel 650 connects the cold water collection basin modules 616a and 616b, extends along the X-axis, and has a span smaller than the length (L) of the cold water collection basin 614. C In some respects, fluid can flow from the second recessed bottom plate portion 640b in the second cold water collection basin module 616b to the first recessed bottom plate portion 640a in the first cold water collection basin module 616a, flowing through the width (W) extending along the X-axis and spanning the first recessed bottom plate portion 640a and the second recessed bottom plate portion 640b. FThe flow channel 650 leads to the fluid outlet 630, where the fluid can exit the cooling tower. In some cases, the length (L) of the flow channel 650... F It can be smaller than the length of the collection basin (L) C However, the length of the flow channel 650 (LF) can be approximately equal to or equal to the length of the collection basin (L). C In some cases, the length of the flow channel 650 may be approximately 5% to approximately 90% of the length of the cold water collection basin 614, or approximately 10% to approximately 80%, or approximately 20% to approximately 70%, or approximately 30% to approximately 60%. In other cases, the length of the flow channel 650 may be 5% to 90% of the length of the cold water collection basin 614, or 10% to 80%, or 20% to 70%, or 30% to 60%. The first cold water collection basin module 616a and the second cold water collection basin module 616b can be connected by a sealing plate 652 connecting the module interface above the waterline. The sealing plate 652 may be bolted, welded, or otherwise coupled to the first cold water collection basin module 616a and the second cold water collection basin module 616b. It is advantageous to reduce or avoid expensive and time-consuming welding. The length of the flow channel 650 (L) F It can be less than the length of the sealing plate 652.

[0125] Turning Figure 6D and Figure 6E In some cases, the cold water collection basin 614 may be provided as a first cold water collection basin module 616a fluidly connected to a second cold water collection basin module 616b, wherein the first cold water collection basin module 616a includes a first outlet 630a and the second cold water collection basin module 616b includes a second outlet 630b. The first outlet 630a and the second outlet 630b may be connected or coupled via a conduit 660 disposed below the cold water collection basin 614 or below the first cold water collection basin module 616a and the second cold water collection basin module 616b. In some cases, the cold water collection basin 614 may be defined by the first cold water collection basin module 616a and the second cold water collection basin module 616b, and a first recessed bottom plate portion 640a and a second recessed bottom plate portion 640b, the first recessed bottom plate portion and the second recessed bottom plate portion extending along the Y-axis and together spanning the width (W) of the first cold water collection basin module 616a and the second cold water collection basin module 616b. CThe first outlet 630a and the second outlet 630b may optionally include water collection tanks 632a and 632b disposed below the first outlet 630a and the second outlet 630b. One or more of the first outlet 630a and the second outlet 630b, or one or more of the water collection tanks 632a and 632b, may include a fluid outlet or outlet pipe through which fluid exits the cooling tower. The first cold water collection basin module 616a and the second cold water collection basin module 616b can be connected via a sealing plate 652, which connects the module interface above the waterline. (See sealing plate 652). Figure 6D The first and second cold water collection basin modules 616a and 616b can be bolted, welded, or otherwise connected. By using a pipe disposed below the collection basins for fluid connection of the first and second collection basin modules, welding can be reduced or completely avoided, as the first and second collection basin modules can be connected or joined via a connection module interface above the waterline or a sealing plate extending along the module interface.

[0126] Turning Figure 6F In some cases, the cold water collection basin 614 may be provided as a first cold water collection basin module 616a fluidly connected to a second cold water collection basin module 616b. The first cold water collection basin module 616a may include a first outlet 630a positioned near or adjacent to the inner wall 618a of the first cold water collection basin module 616a, and the second cold water collection basin module 616b may include a second outlet 630b positioned near or adjacent to the side wall or inner wall 618 of the second cold water collection basin module 616b. Figure 6G and Figure 6H As shown, the first outlet 630a and the second outlet 630b may each include a collection tank (e.g., a collection tank 632a for the first outlet 630a and a collection tank 632b for the second outlet 630b). Collection tanks 632a and 632b may be respectively disposed below the first outlet 630a and the second outlet 630b, and the collection tanks 632a and 632b may be connected via conduit 660. In some cases, each of the collection tanks 632a and 632b may be connected to an outlet conduit designed to remove fluid from the tower (e.g., Figure 2The outlet water conduit 260). In other cases, only one of the collection tanks 632a and 632b can be connected to an outlet conduit designed to remove fluid from the tower. In such a case, when fluid leaves the first collection tank (e.g., collection tank 632a) via the outlet conduit, fluid supplied from the second collection tank (e.g., collection tank 632b) can leave the cooling tower by flowing through conduit 660, to the first collection tank, and then to the supplied outlet conduit. In the case of a tower comprising more than two chilled water basin modules, similarly, by making each chilled water collection basin module fluidly connected to each other, water can leave a single chilled water collection basin module via an outlet conduit.

[0127] like Figure 6G As shown, water collection tanks 632a and 632b and the conduit 660 connecting them can be housed within the frame enclosure 622 of the cold water collection basin 614. For example, water collection tanks 632a and 632b and the conduit 660 connecting them can be positioned within the volume defined by the frame enclosure 622. In other words, when the tower is assembled, water collection tanks 632a and 632b do not extend below or beyond the dimensions of the tower. Therefore, the tower can be erected directly on the ground without needing to be raised above ground level to avoid water collection tanks 632a and 632b. Alternatively, as... Figure 6H As shown, water collection tanks 632a and 632b and the conduit 660 connecting them can be disposed outside (e.g., outside the volume) or below the frame enclosure 622 of the cold water collection basin 614. Therefore, since water collection tanks 632a and 632b and the conduit 660 connecting them are all disposed below the frame enclosure 622, the conduit can be directly connected or joined (e.g., by welding) to the water collection tanks 632a and 632b. Figure 6G Compared to examples, such as Figure 6H As shown, the conduit 660 does not need to pass through the inner walls 618a, 618b of the first cold water collection basin module 616a and the second cold water collection basin module 616b to reach the collection tanks 632a, 632b. However, the tower can be raised above the ground (e.g., via columns or latticework) to provide adequate clearance for the collection tanks 632a, 632b. Vortexing can occur when the water level in the collection tank is low relative to the flow rate. In some cases, anti-vortex plates or fittings can be installed above the collection tank outlet to help prevent vortexing.

[0128] like Figure 6I and Figure 6JAs shown, the cold water collection basin 614 can be provided as a first cold water collection basin module 616a fluidly connected to the second cold water collection basin module 616b via one or more suction inlet hoods 620a, 620b. One or more suction inlet hoods 620a, 620b can be connected at flow openings through the inner walls 618a, 618b of the first and second cold water collection basin modules 616a and 616b. In some cases, the conduit 660 can be welded to the suction inlet hoods 620a, 620b.

[0129] Modular towers (e.g.) Figure 1 , Figure 2 and Figure 3A Towers 100, 200, and 300 can also employ fluid distribution systems (e.g., Figures 7A-7E The fluid distribution system 750 may include a hot fluid basin or tank (e.g., a series of fluid basins or tanks) and one or more conduits and / or nozzles (e.g., a series of conduits and nozzles) through which a process fluid (e.g., a process fluid to be cooled) flows. The fluid distribution system may be designed to distribute the process fluid onto a packing medium disposed within the tower. The fluid distribution system may be defined by a first fluid distribution assembly disposed in a first heat transfer module, a second fluid distribution assembly disposed in a second heat transfer module, and a third fluid distribution assembly disposed in a third heat transfer module. More specifically, the first fluid distribution assembly may be disposed at the top of the first heat transfer module, the second fluid distribution assembly may be disposed at the top of the second heat transfer module, and the third fluid distribution assembly may be disposed at the top of the third heat transfer module. Each fluid distribution assembly may include multiple nozzles configured to spray liquid into a lower region of the modular heat transfer tower, specifically, into a packing section or section disposed within the heat transfer module. Multiple fluid distribution assemblies may be field-connected to form a unified fluid distribution system having a single fluid inlet connection.

[0130] like Figures 7A-7E As shown, the heat transfer assembly 770 can be designed to include one or more heat transfer modules 722a, 722b, 722c and a fluid distribution system 750. The fluid distribution system 750 may include a hot fluid basin (not shown), a manifold assembly 771 (which includes manifolds 772 and manifold boxes 773a, 773b, 773c) in fluid communication with the hot fluid basin, one or more distribution pipes or conduits 776 in fluid communication with the manifold assembly, and a plurality of spray nozzles 774 in fluid communication with the one or more conduits 776. In a counter-current cooling tower, high-temperature fluid can be vertically distributed through the tower by gravity and / or a spray system (e.g., under pressure).

[0131] Figure 7D and Figure 7EFluid distribution systems 750 including a centerline manifold assembly 771 and eccentric manifold assembly 771 are shown respectively. The manifold 772 may optionally be centrally located such that the manifold covers the width (W) of the heat transfer assembly 770. H Divide into two equal parts. Manifold boxes 773a, 773b, and 773c can be supplied in steel or PVC, but other materials may also be used. Manifold 772 can also be supplied in steel or PVC, but other materials may also be used. For example... Figure 7D and Figure 7E As shown, nozzles 774 can be arranged or designed to uniformly distribute (or substantially uniformly distribute) fluid onto the packing medium 778. Once the fluid has passed through the packing medium 778, it can be collected at the bottom of the tower in a cold liquid collection basin assembly (not shown). Nozzles 774 and conduits 776 can be made of PVC or polypropylene. Each of the plurality of nozzles 774 can be spaced from each adjacent nozzle by about 15 inches to about 30 inches (or about 38 cm to about 76 cm). In other cases, each of the plurality of nozzles 774 can be spaced from each adjacent nozzle by 15 inches to 30 inches (or 38 cm to 76 cm). In some cases, the plurality of nozzles 774 can be located about 5 inches to about 20 inches (or about 13 cm to about 50 cm) above the packing medium 778. In other cases, the plurality of nozzles 774 can be located about 5 inches to 20 inches (or 13 cm to 50 cm) above the packing medium 778. In other cases, the gaps between the nozzles and the distance between the multiple nozzles 774 positioned above the filling medium 778 may be less than or greater than the values ​​described herein.

[0132] The fluid distribution system 750 may also include a riser assembly provided in the form of piping, which provides fluid communication between the circulating fluid supply lines of the distribution system from the tower base level or the supply manifold level to the tower, such as... Figure 7A and Figure 7B As shown. The supply piping arrangement in a countercurrent tower can position the supply lines close to or adjacent to the long side of the tower and extend along its entire length. Vertical risers (e.g., one riser per unit) connect the supply lines to the inlet connections at the height of the tower's fluid distribution system. For example... Figure 7B and Figure 7CAs shown, the fluid distribution system 750 includes a riser assembly 779, which includes one or more riser manifolds 777a, 777b, 777c and one or more vertical risers 775a, 775b, 775c. Each vertical riser can be connected to a riser manifold. In some cases, each heat transfer module 722a, 722b, 722c includes vertical risers 775a, 775b, 775c connected to riser manifolds 777a, 777b, 777c. The fluid distribution system 750 may also include one or more distribution pipes or conduits 776 (see...). Figure 7A , Figure 7D and Figure 7E The riser can carry water from the air inlet assembly 510 to the manifold assembly 560 (see...). Figure 5A The water is conveyed through the filling medium to a distance above the filling medium, at which point it can then be distributed through one or more distribution pipes or conduits 776. Each distribution pipe or conduit 776 may have one or more orifices (e.g., a series of orifices) for supplying water flow through one or more nozzles (e.g., a series of nozzles) mounted thereon, for distributing water. The water can be evenly distributed to the top of the filling medium. In some cases, the fluid distribution system 750 includes a centerline manifold assembly 771 made of steel (e.g., ...). Figure 7A (as shown) and riser assembly 779.

[0133] Turn now Figure 8A , Figure 8B , Figure 9A and Figure 9B It shows its use in cooling towers (such as...) Figure 1 , Figure 2 and Figure 3A The modular counterflow cooling towers 100, 200, and 300 shown in the diagram have mixed filling modules 800 and 900. Figure 8A , Figure 8B , Figure 9A and Figure 9B Various internal components of the hybrid filling modules 800 and 900 are shown. For example... Figure 8A and Figure 8B As shown, the hybrid filling module 800 includes at least one support member, which is provided in the form of a first support member 802, a second support member 803, an optional third support member 805, and an optional fourth support member 807. Alternatively, as Figure 9A and Figure 9BAs shown, the hybrid filling module 900 may include fewer support members, such as a first support member 902 and a second support member 903. It should be understood that, in some cases, the hybrid filling module 800 may also include more than four support members or fewer than four support members. In some aspects, each support member may have a first end 802a, 803a, 805a, 807a, 902a, 903a and a second end 802b, 803b, 805b, 807b, 903b. In some aspects, at least one end 802a, 803a, 805a, 807a, 902a, 903a, 802b, 803b, 805b, 807b, 903b of the support member may be capped, for example, with a retainer cap. At least one support member may be in the form of a pipe or tube, and therefore have a substantially near-circular cross-section (e.g., Figure 8A , Figure 8B , Figure 9A and Figure 9B (As shown). In other aspects, at least one support member 802, 803, 805, 807, 902, 903 may alternatively include a non-circular cross-section, such as a square shape, a rectangular shape, or other polygonal shape. In some cases, at least one support member 802, 803, 805, 807, 902, 903 may include a non-circular near-circular shape, such as an oval or elliptical shape. Furthermore, the hybrid filling modules 800, 900 may include a plurality of filling sheets 804, 904. The individual filling sheets among the plurality of filling sheets 804, 904 may have the same size, substantially the same size, or different sizes. In some aspects, the individual filling sheets among the plurality of filling sheets 804, 904 have the same size.

[0134] In some aspects, the individual sheets of the plurality of filler sheets are loose, unbonded, or not bonded together. In some aspects, the plurality of filler sheets 804, 904 are arranged on at least one support member (e.g., support members 802, 803, 805, 807, 902, 903). As used herein, the phrase "arranged on..." includes directly or indirectly connecting or attaching, suspending, mounting, or otherwise suspending the filler sheets on at least one support member. In some aspects, the plurality of filler sheets 804, 904 may be arranged in a suspended manner on at least one support member 802, 803, 805, 807, 902, 903, for example, to provide a suspended filler construction, or in some cases, to provide a structurally constrained filler construction. It should be understood that both structurally constrained filler constructions and suspended filler constructions may employ at least one support member 802, 803, 805, 807, 902, 903. However, compared to suspended infill constructions and as previously described, the bottom surface or base of the infill in a structurally constrained infill construction can be supported to provide additional stability to the infill. Additionally, in some cases, as a supplement or alternative to at least one support member 802, 803, 805, 807, 902, 903, the structurally constrained infill construction may also employ guides, tracks, and other similar structures. In some aspects, each individual infill sheet among the plurality of infill sheets 804, 904 may include an opening, the size and / or shape of which is configured to allow at least one support member 802, 803, 805, 807, 902, 903 to pass through the opening in each of the plurality of infill sheets 804, 904. Alternatively, the size and / or shape of at least one support member 802, 803, 805, 807, 902, 903 may be configured to pass through the opening provided in each of the plurality of infill sheets 804, 904.

[0135] In some aspects, at least one support member 802, 803, 805, 807, 902, 903 may be wholly or at least partially along the length L of the hybrid filling modules 800, 900. F Further. In some aspects, at least one support member 802, 803, 805, 807, 902, 903 may be substantially perpendicular or perpendicular to the plurality of filler sheets 804, 904. That is, as Figure 8A , Figure 8B and Figure 9BAs shown, multiple filler sheets 804, 904 can be suspended downwards from at least one support member 802, 803, 805, 807, 902, 903, wherein at least one support member 802, 803, 805, 807, 902, 903 can be substantially parallel or parallel to the base of the cooling tower and / or the ground. In some cases, the ends 802a, 803a, 805a, 807a, 902a, 903a, 802b, 803b, 805b, 807b, 903b of at least one support member can extend beyond the length L of the hybrid filler modules 800, 900. F (For example, the length of at least one support member can be greater than the length L of the hybrid filling modules 800 and 900) F This document takes into account any and all aspects of arranging multiple filler sheets 804, 904 on at least one support member 802, 803, 805, 807, 902, 903.

[0136] In some aspects, when multiple filler sheets are arranged on at least one support member 802, 803, 805, 807, 902, 903, the distance between each of the multiple filler sheets 804, 904 may be about 0.5 mm (or 0.5 mm), but the distance between each of the multiple filler sheets 804, 904 may be slightly less than or even greater than about 0.5 mm (or 0.5 mm). In some cases, the distance between adjacent filler sheets of the multiple filler sheets 804, 904 may not be greater than about 1 mm, or not greater than about 0.9 mm, or not greater than about 0.8 mm, or not greater than about 0.7 mm, or not greater than about 0.6 mm, or not greater than about 0.5 mm, or not greater than about 0.4 mm, or not greater than about 0.3 mm, or not greater than about 0.2 mm, or not greater than about 0.1 mm. In other cases, the distance between adjacent filler sheets in a plurality of filler sheets 804 and 904 may be no greater than 1 mm, or no greater than 0.9 mm, or no greater than 0.8 mm, or no greater than 0.7 mm, or no greater than 0.6 mm, or no greater than 0.5 mm, or no greater than 0.4 mm, or no greater than 0.3 mm, or no greater than 0.2 mm, or no greater than 0.1 mm.

[0137] Continue to refer to Figure 8A , Figure 8B , Figure 9A and Figure 9BThe hybrid filling module 800 may further include multiple filling assemblies 806a, 806b, 906a, 906b. Each of the multiple filling assemblies 806a, 806b, 906a, 906b may include multiple filling sheets bonded together. In other words, the difference between the multiple filling sheets 804, 904 arranged on at least one support member 802, 803, 805, 807, 902, 903 and the multiple sheets forming each of the multiple filling assemblies 806a, 806b, 906a, 906b is that the sheets in the filling assembly are bonded together, as described above. The multiple filling assemblies 806a, 806b, 906a, 906b may have different dimensions, including height, width, and length, which can be selected to optimize the efficiency of the hybrid filling modules 800, 900. In some aspects, the hybrid filling modules 800, 900 may include any number of filling assemblies 806a, 806b, 906a, 906b, wherein one or more filling assemblies are given different dimensions relative to the other filling assemblies. For example, the hybrid filling modules 800, 900 may include one or more filling assemblies 806a, 906a given a first set of dimensions and one or more filling assemblies 806b, 906b given a second set of dimensions. Figure 8A , Figure 8B and Figure 9B As shown, the hybrid filling modules 800 and 900 may include two filling assemblies (a first filling assembly and a second filling assembly 806a, 906a) having substantially the same dimensions. The first filling assemblies 806a and 906a are connected to first ends 802a, 803a, 805a, 807a, 902a, and 903a, and the second filling assemblies 806a and 906a are connected to the second ends 802b, 803b, 805b, 807b, and 903b of the corresponding support members 802, 803, 805, 807, 902, and 903. Additionally, as... Figure 8A , Figure 8B and Figure 9B As shown, the mixing filling modules 800 and 900 may include third filling assemblies 806b and 906b, which have dimensions different from those of the first filling assembly and the second filling assemblies 806a and 906a. For example, as Figure 9BAs shown, the third packing assembly 906b can be given a thickness and height smaller than that of the first packing assembly and the second packing assembly 906a. It should be understood that any individual dimension (e.g., width, length, height) of the third packing assemblies 806b and 906b can be smaller than, equal to, or larger than the corresponding individual dimensions of the first and second packing assemblies 806a and 906a. Furthermore, the third packing assemblies 806b and 906b can be coupled to the first ends 802a, 803a, 805a, 807a, 902a, and 903a of the respective support members 802, 803, 805, 807, 902, and 903, and positioned close to or adjacent to the first packing assemblies 806a and 906a. In some cases, the third packing assemblies 806b and 906b can abut against the first and second packing assemblies 806a and 906a. In some respects, at least one support member 802, 803, 805, 807, 902, 903 may be substantially perpendicular to the plurality of packing assemblies 806a, 906a, 806b, 906b. That is, as Figure 8A , Figure 8B and Figure 9B As shown, multiple packing assemblies 806a, 906a, 806b, 906b can be suspended downward from at least one support member 802, 803, 805, 807, 902, 903, wherein at least one support member 802, 803, 805, 807, 902, 903 can be substantially parallel or parallel to the base of the cooling tower and / or the ground.

[0138] Connecting the filler assemblies 806a, 906a, 806b, 906b to the first ends 802a, 803a, 805a, 807a, 902a, 903a and the second ends 802b, 803b, 805b, 807b, 903b of the corresponding support members 802, 803, 805, 807, 903b can surround multiple filler sheets 804, 904, thereby forming a "bounded" structure of the hybrid filler modules 800, 900. Therefore, the hybrid filling modules 800, 900 may include a plurality of filling assemblies 806a, 906a, 806b, 906b at the ends 802a, 803a, 805a, 807a, 902a, 903a, 802b, 803b, 805b, 807b, 903b of at least one support member 802, 803, 806b, and a plurality of filling sheets arranged between the filling assemblies 806a, 906a, 806b, 906b on at least one support member 802, 803, 805, 807, 902, 903. As described above, the “bounded” construction of the hybrid filling modules 800, 900 is advantageous compared to existing structurally constrained or suspended filling constructions that are open or unbounded at the module ends. For example, transporting heat exchange modules consisting solely of structurally constrained or suspended filler structures is challenging because the individual filler sheets may shift or move during transport or otherwise fail to maintain proper orientation. In fact, in some cases, the individual filler sheets may detach from their respective support members during transport. The hybrid filler described in this disclosure (e.g., hybrid filler modules 800, 900) addresses this challenge by defining the structurally constrained or suspended filler at each end with one or more filler assemblies, thereby stabilizing the multiple filler sheets within the structurally constrained or suspended filler.

[0139] Continue to refer to Figure 8A , Figure 8B , Figure 9A and Figure 9BIn some aspects, multiple packing sheets 804, 904 may form the largest segment or region of the hybrid packing module 800, 900. The hybrid packing module 800, 900 may be provided in or as part of any heat exchange module described herein. In such cases, the multiple packing sheets 804, 904 may be positioned or disposed in the central segment or central region of the hybrid packing module 800, 900. Similarly, multiple packing assemblies 806a, 906a, 806b, 906b may form smaller segments or regions of the hybrid packing module 800, 900. In such cases, the multiple packing assemblies 806a, 906a, 806b, 906b may be positioned or disposed at the end segments or end regions of the hybrid packing module 800, 900. In some aspects, multiple filler sheets 804, 904 may form approximately 50% to approximately 90% (or 50% to 90%) of the total volume of the hybrid filler modules 800, 900, while multiple filler assemblies 806a, 906a, 806b, 906b may form approximately 10% to approximately 50% (or 10% to 50%) of the total volume of the hybrid filler modules 800, 900. For example, multiple filler sheets 804, 904 may form or occupy at least approximately 50%, or at least approximately 60%, or at least approximately 70%, or at least approximately 80%, or no more than approximately 90% of the total volume of the hybrid filler modules 800, 900. As another example, multiple filler assemblies 806a, 906a, 806b, 906b may form at least approximately 10%, or at least approximately 20%, or at least approximately 30%, or at least approximately 40%, or no more than approximately 50% of the total volume of the hybrid filler modules 800, 900. As another example, multiple filler sheets 804, 904 may form at least 50%, or at least 60%, or at least 70%, or at least 80%, or no more than 90% of the total volume of the hybrid filler modules 800, 900. As yet another example, multiple filler assemblies 806a, 906a, 806b, 906b may form at least 10%, or at least 20%, or at least 30%, or at least 40%, or no more than 50% of the total volume of the hybrid filler modules 800, 900. It should be understood that the multiple filler sheets 804, 904 and the multiple filler assemblies 806a, 906a, 806b, 906b may include percentages of the total volume of the hybrid filler modules 800, 900 that differ from the percentages expressly stated herein.

[0140] refer to Figure 10 The diagram illustrates a heat exchange assembly 1000 comprising three heat exchange modules 1010a, 1010b, and 1010c. Each heat exchange module 1010a, 1010b, and 1010c may include multiple filling modules 1008a-1008r. Figure 10As shown, heat exchange modules 1010a, 1010b, and 1010c can be arranged close to or adjacent to each other, and in some cases, can abut against each other. In some aspects, the first heat exchange module 1010a can be arranged close to or adjacent to the second heat exchange module 1010b, and the second heat exchange module 1010b can be arranged close to or adjacent to the third heat exchange module 1010c. Each heat exchange module 1010a, 1010b, and 1010c may include one to ten filler modules 1008a-1008r. As an example, Figure 10 Each heat exchange module 1010a, 1010b, 1010c includes six of the multiple filling modules 1008a-1008r. Figure 13 A heat exchange module 1310 without any internal filling module is shown. Meanwhile, Figure 13 Feasible arrangements of the filler sheets 1304a-1304f are shown. Figure 13 The filler sheets 1304a-1304f are shown in dashed lines, where each filler sheet 1304a-1304f represents a filler module. In some cases, when coupled to at least one support member and disposed within the heat exchange module 1310, the filler sheets 1304a-1304f may be provided in a suspended filler configuration. In other cases, the filler sheets 1304a-1304f may be provided in a structurally constrained filler configuration, wherein the bottom surface or base of the filler sheets 1304a-1304f is supported by one or more support structures and / or the inner surface of the heat exchange module 1310 located below the filler sheets 1304a-1304f. Furthermore, when disposed within the heat exchange module 1310, the structurally constrained filler configuration may also employ guides, tracks, and other similar structures as a supplement to or alternative to the at least one support member. In some respects, each of the first heat exchange module 1010a, the second heat exchange module 1010b, and the third heat exchange module 1010c includes six filler modules 1008a-1008r, but each of the first, second, and third heat exchange modules 1010a, 1010b, and 1010c may also include a different number of filler modules.

[0141] Refer again Figure 10 In some respects, the first plurality of filling modules 1008a-1008f can be installed in the first heat exchange module 1010a, the second plurality of filling modules 1008g-1008l can be installed in the second heat exchange module 1010b, and the third plurality of filling modules 1008m-1008r can be installed in the third heat exchange module 1010c. For example... Figure 10As shown, the first plurality of filling modules 1008a-1008f can be installed side-by-side in the first heat exchange module 1010a, and the collective first ends 1014a-1024a of the first plurality of filling modules 1008a-1008f define a first side 1026a of the first heat exchange module 1010a. Similarly, the collective second ends 1014b-1024b of the first plurality of filling modules 1008a-1008f can similarly define a second side 1026b of the first heat exchange module 1010a. Furthermore, each of the first side 1026a and the second side 1026b can define a length L of the first heat exchange module 1010a. M Similarly, a second plurality of filling modules 1008g-1008l can be installed side-by-side in the second heat exchange module 1010b, with the first end of the collective of the second plurality of filling modules 1008g-1008l defining a first side of the second heat exchange module 1010b, and the second end of the collective of the second plurality of filling modules 1008g-1008l defining a second side of the second heat exchange module 1010b. Additionally, a third plurality of filling modules 1008m-1008r can be installed side-by-side in the third heat exchange module 1010c, with the first end of the collective of the third plurality of filling modules 1008m-1008r defining a first side of the third heat exchange module 1010c, and the second end of the collective of the third plurality of filling modules 1008m-1008r defining a second side of the third heat exchange module 1010c. Similarly, Figure 11 A plurality of filling modules 1108a-1108f are shown mounted side-by-side in a heat exchange module 1110, wherein each of the first side 1126a and the second side 1126b of the heat exchange module 1110 defines a length L of the heat exchange module 1110. M .

[0142] In some cases, each of the plurality of filling modules 1008a-1008r includes a plurality of structurally constrained filling sheets or suspended filling sheets 1004 (hereinafter referred to as suspended filling sheets 1004) arranged on at least one support member 1002, 1003, and a plurality of filling assemblies 1006a, 1006b. In such cases, at least one support member 1002, 1003 may extend along the length L of each of the plurality of filling modules 1008a-1008r. F Extending, and each of the plurality of filler assemblies 1006a, 1006b may extend along the width W of each of the plurality of filler modules 1008a-1008r. F Extension. For example... Figure 10As shown, the filling modules 1008a-1008r may include a first filling assembly and a second filling assembly 1006a. The first and second filling assemblies have substantially the same dimensions and are connected to the first ends 1002a, 1003a and the second ends 1002b, 1003b of the respective support members 1002, 1003. The filling modules 1008a-1008r may also include a third filling assembly 1006b, the dimensions of which may differ from those of the first and second filling assemblies 1006a. The third filling assembly 1006b may also be connected to the first ends 1002a, 1003a of the respective support members 1002, 1003 and positioned close to or adjacent to the first filling assembly 1006a. In some aspects, the packing modules (such as packing modules 1008g-1008l in the second heat exchange module 1010b) may include a third packing assembly and a fourth packing assembly 1006b, the third and fourth packing assemblies having dimensions different from those of the first and second packing assemblies 1006a. The third and fourth packing assemblies 1006b are respectively connected to the first ends 1002a, 1003a and the second ends 1002b, 1003b of corresponding support members 1002, 1003, and are respectively positioned close to or adjacent to the first and second packing assemblies 1006a. In some aspects, at least one support member 1002, 1003 may be positioned or arranged substantially perpendicular to the plurality of packing assemblies 1006a, 1006b, but at least one support member may alternatively be positioned or arranged relative to the plurality of packing assemblies 1006a, 1006b.

[0143] As discussed in detail above, heat transfer components may include fluid distribution systems (e.g., Figures 7A-7E A fluid distribution system 750 may include one or more vertical risers. For example, a counterflow tower (e.g., Figure 1 , Figure 2 and Figure 3A The supply piping arrangement in towers 100, 200, and 300 can position the supply lines close to or adjacent to the long side of the tower extending along its entire length, with at least one vertical riser (e.g., one vertical riser per unit or heat transfer module) connecting the supply lines to the inlet connection at the height of the tower's distribution system. In some aspects, Figure 10 The heat exchange assembly 1000 may include three heat exchange modules 1010a, 1010b, and 1010c, wherein each heat exchange module 1010a, 1010b, and 1010c includes a vertical riser (in Figure 10(Not shown in the diagram) and multiple filling modules 1008a-1008r. For example, a first riser may be disposed in a first heat exchange module 1010a, a second riser may be disposed in a second heat exchange module 1010b, and a third riser may be disposed in a third heat exchange module 1010c. In some aspects, the first plurality of filling modules 1008a-1008f includes a filling module 1008d having an opening 1012 for receiving the riser, the second plurality of filling modules 1008g-1008l includes a filling module 1008j having an opening 1012 for receiving the riser, and / or the third plurality of filling modules 1008m-1008r includes a filling module 1008p having an opening 1012 for receiving the riser. For example, the openings 1012 of the filling modules 1008d, 1008j, and 1008p may be designed to receive the first, second, and third risers of the first, second, and third heat exchange modules 1010a, 1010b, and 1010c, respectively. In some aspects, at least one filling module 1008d within the first heat exchange module 1010a, at least one filling module 1008j within the second heat exchange module 1010b, and at least one filling module 1008p within the third heat exchange module 1010c include openings 1012 for receiving risers. It should be understood that the risers of the heat exchange module 1000 may alternatively be located in locations different from those described herein (e.g., within different filling modules). Reference Figure 11 The heat exchange module 1110 may include a plurality of packing modules 1108a-1008f, wherein packing module 1108d is provided with or has an opening 1112 for receiving riser 1114. In some aspects, the openings 1012, 1112 may be partially, substantially, or completely surrounded and / or reinforced by one or more packing assemblies 1006c, 1006d, 1106a. It should be understood that the size, shape, and / or design of the opening 1112 may be configured to receive riser (e.g., the size of the opening 1112 may be selected to accommodate riser).

[0144] like Figure 10 , Figure 11 and Figure 12 As shown, the openings 1012, 1112, 1212 for receiving risers may be partially, substantially, or completely surrounded and / or reinforced by one or more packing assemblies 1006c, 1006d, 1106a, 1206b. The dimensions of the packing assemblies 1006c, 1006d, 1106a, 1206b surrounding the openings 1012, 1112, 1212 may be selected according to the dimensions of the openings 1012, 1112, 1212 and the dimensions of the risers. For example, as Figure 10As shown, the dimensions of the first packing assembly 1006c, which partially surrounds opening 1012, are different from the dimensions of the second packing assembly 1006d, which partially surrounds opening 1012. Alternatively, openings 1012, 1112, 1212 may be partially or substantially surrounded by one or more packing assemblies, wherein each of the one or more packing assemblies is given the same dimensions, or alternatively, is given different dimensions. Figure 12 As shown, opening 1212 can be optionally reinforced by frame 1216 (such as a steel frame), but frames comprising other materials may also be used. A packing assembly can be placed around frame 1216. In some cases, the packing assembly may substantially surround frame 1216. Figure 10 , Figure 11 and Figure 12 As shown, filling modules 1008d, 1008j, 1008p, 1108d, 1208, including openings 1012, 1112, 1212 for receiving risers (e.g., riser 1214), can be formed by a smaller percentage of structurally constrained or suspended filling sheets 1004, 1104, 1204 and a larger percentage of filling assemblies 1006a, 1006b, 1006c, 1006d, 1106a, 1106b, 1106c, 1106d, 1206a, 1206b, 1206c. A frame 1216 can surround the riser longitudinally or laterally. Furthermore, in other respects, the frame 1216 can surround the riser in all directions. The smaller percentage of structurally constrained or suspended filler sheets 1004, 1104, and 1204 compared to other filler modules 1008a-1108c, 1008e-1008i, 1008k-1008o, 1008q, 1008r, 1108a-1108c, 1108e, and 1108f in heat exchange modules 1010a, 1010b, 1010c, and 1110 may be due to the fact that filler assemblies 1006c, 1006d, 1106a, and 1206b can be used to substantially surround the opening 1112. In some respects, the composition of the filling modules 1008d, 1008j, 1008p, 1108d, 1208 having openings 1012, 1112, 1212 for receiving riser 1214 may differ from the composition of other filling modules 1008a-1108c, 1008e-1008i, 1008k-1008o, 1008q, 1008r, 1108a-1108c, 1108e, 1108f.

[0145] Refer again Figure 10 and Figure 11 The dimensions of the packing assemblies 1006c, 1006d, and 1106a surrounding each opening 1012 and 1112 can be selected based on the dimensions of the openings 1012 and 1112 and the dimensions of the riser. For example... Figure 10 As shown, the dimensions of the first packing assembly 1006c, which partially surrounds openings 1012 and 1112, are different from the dimensions of the second packing assembly 1006d, which also partially surrounds openings 1012 and 1112. Alternatively, each opening 1012 and 1112 may be partially or substantially surrounded by one or more packing assemblies, wherein the one or more packing assemblies have the same dimensions. Figure 11 As shown, compared to other filling modules 1108a-1108c, 1108e, and 1108f, the filling module 1108d having an opening 1112 for receiving the riser can be formed by a smaller percentage of structurally constrained or suspended filling sheet 1104 and a larger percentage of the filling assembly 1106a that substantially surrounds the opening 1112. In some aspects, the composition of the filling module 1108d having an opening 1112 for receiving the riser can differ from the composition of the other filling modules 1108a-1108c, 1108e, and 1108f.

[0146] Typically, the dimensions of the hybrid fill modules disclosed herein can be selected based on the dimensions of the corresponding heat exchange module or heat exchange assembly. For example, the dimensions, shape, and / or design of the hybrid fill modules disclosed herein can be configured to be received within a corresponding heat exchange module or heat exchange assembly. Furthermore, the number of hybrid fill modules disposed within a heat exchange module or heat exchange assembly may depend in part on the dimensions of the provided heat exchange module or heat exchange assembly. In some cases, the number of hybrid fill modules disposed within a heat exchange module or heat exchange assembly may differ from the number of hybrid fill modules explicitly disclosed herein.

[0147] In some aspects, the multiple packing sheets and bonded packing assemblies disclosed herein are manufactured at a first location and then transported to a second location where various modules of the modular cooling tower can be manufactured. As mentioned above, transporting the bonded packing assemblies can involve transporting large amounts of air, as air can become trapped in the gaps between the packing sheets within the packing assembly. Advantageously, the use of suspended packing sheets avoids the problem of transporting air, as the individual sheets can be tightly compressed together, minimizing or eliminating air gaps and thus reducing transport costs. Therefore, the hybrid packing modules described herein allow for reduced transport costs due to the proportion of suspended packing employed in the hybrid packing modules. Furthermore, the packing assemblies in the hybrid packing modules define and maintain the suspended packing sheets in the correct orientation or position. The hybrid packing modules can be constructed at the same location where the cooling tower modules are built and installed into the heat exchange modules, and then transported to the cooling tower site. During transport, the heat exchange modules and the packing modules contained within them may be exposed to the environment. Therefore, defining the suspended packing by the packing assemblies during transport is particularly advantageous.

[0148] refer to Figure 14A flowchart of an exemplary method 1400 for manufacturing a modular cooling tower is depicted. Block 1402 describes an aspect of method 1400 involving providing multiple filler sheets in a stacked manner, wherein the distance between any two filler sheets in the stack may be less than about 0.5 mm (or less than 0.5 mm). In some cases, the distance between adjacent filler sheets of the multiple filler sheets may be no greater than about 1 mm, or no greater than about 0.9 mm, or no greater than about 0.8 mm, or no greater than about 0.7 mm, or no greater than about 0.6 mm, or no greater than about 0.5 mm, or no greater than about 0.4 mm, or no greater than about 0.3 mm, or no greater than about 0.2 mm, or no greater than about 0.1 mm. In other cases, the distance between adjacent filler sheets of multiple filler sheets may be no greater than 1 mm, or no greater than 0.9 mm, or no greater than 0.8 mm, or no greater than 0.7 mm, or no greater than 0.6 mm, or no greater than 0.5 mm, or no greater than 0.4 mm, or no greater than 0.3 mm, or no greater than 0.2 mm, or no greater than 0.1 mm.

[0149] Block 1404 describes one aspect of method 1400, relating to providing a plurality of packing assemblies, wherein each packing assembly includes a plurality of packing sheets bonded together. Block 1406 describes one aspect of method 1400, relating to providing at least one support member having a first end and a second end. Block 1408 describes one aspect of method 1400, relating to constructing a packing module by arranging a plurality of packing sheets on at least one support member, coupling a first packing assembly to a first end of at least one support member, and coupling a second packing assembly to a second end of at least one support member. Block 1410 describes one aspect of method 1400, relating to providing a heat exchange assembly including at least one heat exchange module. Block 1412 describes one aspect of method 1400, relating to mounting a packing module in at least one heat exchange module. In some aspects, method 1400 may include not being in Figure 14 Additional steps described herein. For example, method 1400 may also describe the filling modules being assembled and installed in at least one heat exchange module at a first location, and then transported to a second location for assembly in a cooling tower. Furthermore, the method may also describe the mounting of a plurality of filling modules side-by-side in at least one heat exchange module, a first end of a collective of the plurality of filling modules defining a first side of at least one heat exchange module, and a second end of a collective of the plurality of filling modules defining a second side of at least one heat exchange module, wherein the first side and the second side may define the length of at least one heat exchange module.

[0150] The steps of method 1400 can be initiated multiple times at predetermined time intervals and performed in any order. Furthermore, any step of method 1400 can be omitted. It should be understood that method 1400 can be implemented for any cooling tower discussed herein (e.g., Figure 1 , Figure 2 and Figure 3A Towers 100, 200, and 300.

[0151] Those skilled in the art will recognize that although the above disclosure has been described in conjunction with specific embodiments and examples, it is not to be limited thereto, but is intended to be covered by the appended claims to cover many other embodiments, examples, uses, and variations and deviations from those embodiments, examples, and uses. The full disclosure of each patent and publication cited herein is incorporated by reference as if each such patent or publication were individually incorporated by reference. Various features and advantages of the above disclosure are set forth in the following claims.

Claims

1. A modular heat transfer system, comprising: An air inlet assembly is arranged such that a first air inlet module is adjacent to a second air inlet module, wherein at least one of the first air inlet module and the second air inlet module includes an opening; A heat exchange assembly, defined by at least one heat exchange module, wherein a first heat exchange module of the at least one heat exchange module is disposed adjacent to a second heat exchange module of the at least one heat exchange module; and A pressure ventilation assembly having at least one pressure ventilation module; The heat exchange component is located above the air inlet component, and the pressure ventilation component is located above the heat exchange component.

2. The modular heat transfer system according to claim 1, wherein, The modular heat transfer system also includes an airflow generator defined by a fan assembly having at least one fan blade.

3. The modular heat transfer system according to claim 2, wherein, The first fan blade of the at least one fan blade extends from the first pressure ventilation module of the at least one pressure ventilation module to the second pressure ventilation module of the at least one pressure ventilation module, and the second pressure ventilation module is disposed adjacent to the first pressure ventilation module.

4. The modular heat transfer system of claim 1 further includes a door, the door having one or more louver assemblies, wherein, The door is attached to the first air inlet module or the second air inlet module via hinges, and the door is designed to provide a walkway into the interior of the first air inlet module or the second air inlet module.

5. The modular heat transfer system according to claim 4, wherein, When the door is actuated to the open configuration, the door swings toward the interior of the modular heat transfer system.

6. The modular heat transfer system according to claim 1, wherein, The at least one heat exchange module is a hybrid packing module provided in the form of structurally constrained packing and one or more packing assemblies.

7. The modular heat transfer system according to claim 1 further includes a cold water collection basin disposed below the air inlet assembly, the cold water collection basin including a first cold water collection basin module disposed adjacent to the second cold water collection basin module.

8. A modular heat transfer system, comprising: An air inlet assembly, including a first air inlet module; The heat exchange assembly includes a first heat exchange module; A pressure ventilation assembly, including a first pressure ventilation module; as well as The cold water collection basin includes a first cold water collection basin module disposed adjacent to the second cold water collection basin module, wherein the first cold water collection basin module and the second cold water collection basin module are fluidly connected. The cold water collection basin is located below the air inlet assembly, the heat exchange assembly is located above the air inlet assembly, and the pressure ventilation assembly is located above the heat exchange assembly.

9. The modular heat transfer system according to claim 8, wherein, The cold water collection basin includes a recessed bottom plate, which measures the length (L) of the cold water collection basin. C Divide into two equal parts.

10. The modular heat transfer system according to claim 9, wherein, The recessed bottom plate also includes a first recessed bottom plate portion disposed in the first cold water collection basin module and a second recessed bottom plate portion disposed in the second cold water collection basin module.

11. The modular heat transfer system according to claim 10, wherein, The first recessed bottom plate is connected to the second recessed bottom plate via a watertight flow channel.

12. The modular heat transfer system according to claim 10, wherein, The length (L) of the flow channel connecting the first recessed bottom plate to the second recessed bottom plate F () smaller than the length of the cold water collection basin (L) C ).

13. The modular heat transfer system according to claim 8, wherein, At least one of the first cold water collection basin module and the second cold water collection basin module includes an outlet.

14. The modular heat transfer system according to claim 8, wherein: The first cold water collection basin module includes a first water collection tank. The second cold water collection basin module includes a second water collection tank. The first water collection tank is fluidly connected to the second water collection tank via a conduit. The outlet conduit is fluidly connected to the first manifold tank and is designed to remove the cooled process fluid from the modular heat transfer system.

15. The modular heat transfer system according to claim 14, wherein, The first water tank, the second water tank, and the conduits are arranged within a volume defined by the frame enclosure of the modular heat transfer system.

16. The modular heat transfer system according to claim 8, wherein, The first cold water collection basin module includes a first outlet, a first water collection tank, and a first suction air inlet hood; the second cold water collection basin module includes a second outlet, a second water collection tank, and a second suction air inlet hood.

17. The modular heat transfer system according to claim 8, wherein, The first cold water collection basin module includes a first inner sidewall, the second cold water collection basin module includes a second inner sidewall, and the first cold water collection basin module and the second cold water collection basin module are fluidly connected at flow openings passing through the first inner sidewall and the second inner sidewall.

18. The modular heat transfer system according to claim 8, wherein, The first cold water collection basin module is connected to the second cold water collection basin module via a sealing plate extending along the module interface above the waterline.

19. The modular heat transfer system according to claim 18, wherein, One or more of the first cold water collection basin module and the second cold water collection basin module include an outlet and an anti-vortex device disposed above the outlet.

20. A modular heat transfer system, comprising: An air inlet assembly, including a first air inlet module; The heat exchange assembly includes a first heat exchange module; A pressure ventilation assembly, including a first pressure ventilation module; Airflow generator; as well as First cold water collection basin; The size and shape of at least one of the first air inlet module, the first heat exchange module, and the first pressure ventilation module are configured such that their size does not exceed the transport size limit.

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