Evaporation medium

Abstract

A method and system for replacing an evaporative medium usable with an evaporative cooling apparatus including a medium housing having a predetermined size. The method and system include removing a first evaporative medium from the medium housing and installing a second evaporative medium in the medium housing. The second evaporative medium has a size complementary to the predetermined size of the medium housing and substantially equal to a size of the first evaporative medium. The second evaporative medium has a pressure drop factor different from a pressure drop factor of the first evaporative medium.

Description

Technical Field

[0001] This invention relates to evaporative cooling systems, specifically, conditioning systems that utilize the laws of thermodynamics to cool fluids. In other words, the change of a fluid from a liquid phase to a gas phase can lead to a decrease in temperature due to the heat of vaporization involved in the phase change. Background Technology

[0002] Evaporative cooling solutions include: direct evaporative coolers, in which water is evaporated into an air stream via an engineered pad to provide adiabatic cooling; and indirect evaporative coolers, in which the evaporated water is used to cool the swept air stream through a heat exchanger, thereby maintaining a constant humidity in the processed air. Both direct and indirect evaporative coolers are highly energy efficient, eliminating the need for a compressor in the cooling cycle.

[0003] Figure 8 This is a schematic diagram of a typical direct evaporative cooler 100. Water or another suitable cooling liquid is recirculated from a reservoir 110 to a distributor 116 via a supply line 112 using a pump 114. The distributor 116 distributes the supplied water evenly across a heat exchanger (such as an evaporation pad 118). Supply air 124 passes through the pad, where it is cooled and humidified to be discharged as cold air 126. Water supplied from the distributor 116 flows downwards and across the pad, evaporating when it encounters the warm supply air 124. For example, a discharge stream controlled by a valve 120 is discharged from the system to a drain 122 via a drain or discharge line 121 to control mineral buildup in the water. Fresh makeup water is added from a water supply source 128 as needed to replace the evaporated and discharged water. The makeup water may be controlled by a float valve or other level sensing device (not shown) located in the reservoir 110.

[0004] Various forms of evaporation media are known. For example, U.S. Patent No. 5,143,658 (which is incorporated herein by reference) Figure 6 and Figure 7(As shown in the diagram) An evaporation medium formed from a first group and a second group of corrugated sheet materials is depicted, with the sheets in the first group and the sheets in the second group arranged alternately. The corrugations of the sheets define pathways that extend from edge to edge through the contact body and have both vertical and horizontal directional components. The pathways are simultaneously traversed by a gas flow in one direction and a liquid flow in the other direction in a counter-current or cross-current manner. The corrugations of the first group of sheets intersect the corrugations of the second group of sheets at acute angles ranging from 15° to 80°. The corrugations of the first group of sheets have a greater angle of inclination relative to the horizontal plane of the contact device than the corrugations of the second group of sheets, and the corrugations of the first group of sheets have a smaller amplitude size than the corrugations of the second group of sheets. The corrugations in the first group of sheets are inclined upward in the gas flow direction, and the corrugations in the second group of sheets are inclined downward in the gas flow direction, thereby counteracting undesirable lateral displacement of the liquid stream caused by the gas flow, and the liquid is uniformly and evenly distributed on the sheets.

[0005] Examples of evaporation media on the market include CELdek™ and GLASdek™ pads manufactured by Munters Corporation. For example, GLASdek™ GX30™ is a high-performance evaporation media made of inorganic, non-flammable materials. GLASdek GX40™ is also made of inorganic, non-flammable materials, but is further impregnated with a ceramic double-layer coating.

[0006] This evaporative medium is typically manufactured in the form of a housing that can be installed within the frame of an air handling unit (AHU). Within this housing, the evaporative medium is contained in a material such as reinforced steel. The frame of an AHU, such as one used for data center cooling, is designed to accommodate a housing of a specific size. While commercially available evaporative media are highly efficient from a cooling perspective, in some cases, the original media housing can provide more cooling capacity than required. Excessive cooling capacity can lead to unnecessary energy costs, such as using excessive fans to deliver air for unnecessary pressure drops and using excessive amounts of water. To reduce cooling capacity, smaller housing sizes can be used, for example, housings with less depth. However, in such cases, the AHU frame may need to be redesigned, increasing the system cost. Summary of the Invention

[0007] In one aspect, the present invention relates to a method for replacing an evaporating medium for gas-liquid contact in an evaporative cooling apparatus, the evaporative cooling apparatus comprising a medium housing having a predetermined size, and the evaporating medium being positioned within the medium housing and having a pressure drop factor representing the pressure drop of a gas flowing from an inlet side through the evaporating medium to an outlet side. The method comprises: removing a first evaporating medium from the medium housing, the first evaporating medium having a size complementary to the predetermined size of the medium housing and having a first pressure drop factor; and installing a second evaporating medium in the medium housing, the second evaporating medium having a size complementary to the predetermined size of the medium housing and substantially equal to the size of the first evaporating medium, the second evaporating medium having a second pressure drop factor different from the first pressure drop factor.

[0008] In another aspect, the present invention relates to a system employing a replaceable evaporation medium for gas-liquid contact, the system comprising an evaporative cooling device comprising: a medium housing having a predetermined size, the replaceable evaporation medium being positionable within the medium housing and having a pressure drop factor representing the pressure drop of a gas flowing from an inlet side through the evaporation medium to an outlet side; a first evaporation medium being insertable into and removable from the medium housing, the first evaporation medium having a size complementary to the predetermined size of the medium housing and having a first pressure drop factor; and a second evaporation medium being insertable into and removable from the medium housing, the second evaporation medium having a size complementary to the predetermined size of the medium housing and substantially equal to the size of the first evaporation medium, the second evaporation medium having a second pressure drop factor different from the first pressure drop factor.

[0009] In another aspect, the present invention relates to an evaporation medium for contacting a gas and a liquid, wherein the gas and the liquid flow relative to each other in a cross-flow relationship, the evaporation medium comprising: a first set of corrugated sheets having grooves of a first height; and a second set of corrugated sheets having grooves of a second height. The corrugated sheets in the first group and the corrugated sheets in the second group are arranged alternately. The grooves of the first group and the second group intersect to define a passage from one surface of the evaporating medium to the other surface. The grooves of the corrugated sheets in the first group and the second group contact at the crest of the grooves. The grooves of the first group of corrugated sheets are inclined upward with a first angle relative to the gas flow direction, while the grooves of the second group of corrugated sheets are inclined downward with a second angle relative to the gas flow direction. The absolute values ​​of the first angle and the second angle are not equal. The amplitude of the grooves of the first group of corrugated sheets from the trough to the crest is smaller than that of the grooves of the second group of corrugated sheets from the trough to the crest. The amplitude of the grooves of the first group of corrugated sheets is substantially 8 mm, and the amplitude of the grooves of the second group of corrugated sheets is substantially 10 mm.

[0010] These and other aspects and advantages will become apparent when the following description is read in conjunction with the accompanying drawings. Attached Figure Description

[0011] Figure 1 An evaporation medium housing according to an embodiment of the present invention is shown.

[0012] Figure 2 This is an enlarged view of an embodiment of the evaporation medium of the present invention.

[0013] Figure 3 This is a graph showing the relationship between pressure drop and oncoming wind speed when comparing one embodiment of the invention with a comparative example.

[0014] Figure 4 This is a graph showing the relationship between cooling efficiency and oncoming wind speed when comparing embodiments of the present invention with comparative examples.

[0015] Figure 5 An example of an evaporation medium is shown.

[0016] Figure 6 An example of an evaporation medium is shown.

[0017] Figure 7 yes Figure 6 The cross-sectional view of the evaporating medium is shown.

[0018] Figure 8 This is a schematic diagram of a typical direct evaporative cooling system. Detailed Implementation

[0019] Figure 1 An evaporation medium housing according to a preferred embodiment of the invention is shown. The evaporation medium housing 10 is formed of a frame 12 made of a rigid material (such as stainless steel) and includes an evaporation medium 14 held by the frame. It is designed to be installed in and removed from the housing of a cooling device (such as an evaporative cooler for a data center). The housing 10 can be of any suitable shape and size and is typically designed based on the cooling requirements of its intended use. As shown, the frame 12 is rectangular in shape with specified height, width, and depth dimensions to hold evaporation medium of similar size. The dimensions of the housing 10 are designed to be complementary to, and substantially equal to, the dimensions of the cooling device housing. In one aspect, the evaporation medium 14 is designed to have a lower pressure drop of air passing through it compared to other media products with comparable depths on the market. The evaporation medium 14 may have a... Figure 5 The GX 30™ product shown has a similar design, but with significant design changes to improve (i.e. reduce) voltage drop.

[0020] In this regard, refer to Figure 6 In this embodiment, the evaporation medium 14 is similarly formed by corrugations, as in the GX30™ product. The evaporation medium 14 is formed from a first set of corrugated sheets 202 and a second set of corrugated sheets 204, each set having corrugations of different heights. The corrugated sheets 202 in the first set and 204 in the second set are arranged alternately, with the corrugations of the first set intersecting to define a pathway from one surface of the evaporation medium to the other. The corrugations of the corrugated sheets 202 in the first set and the corrugations of the corrugated sheets 204 in the second set contact at the crests of the corrugations. The corrugations of the first set of corrugated sheets 202 are inclined upwards at a first angle A relative to the gas flow direction, while the corrugations of the second set of corrugated sheets are inclined downwards at a second angle B relative to the gas flow direction. The absolute values ​​of the first angle A and the second angle B are not equal. The amplitude X of the grooves in the first group of corrugated sheets 202 from the trough to the crest is smaller than the amplitude Y of the grooves in the second group of corrugated sheets 204 from the trough to the crest. In a preferred embodiment, to reduce pressure drop at similar thicknesses or depths, the amplitude X of the grooves in the first group of corrugated sheets 202 is substantially 8 mm, and the amplitude Y of the grooves in the second group of corrugated sheets 204 is substantially 10 mm. In this preferred embodiment, the tilt angle A of the grooves in the first group of sheets 202 is substantially 15° relative to the horizontal, and the tilt angle B of the grooves in the second group of sheets 204 is substantially 45° relative to the horizontal.

[0021] Comparative tests were conducted between the embodiments of the present invention described above and two comparative examples. The embodiments of the present invention have the same external dimensions as Comparative Example I, while Comparative Example II has a smaller depth, i.e., 8 inches (200 mm) vs. 12 inches (300 mm). Graphs showing the relationship between pressure drop and oncoming air velocity, and the relationship between cooling efficiency and oncoming air velocity, are shown respectively. Figure 3 and Figure 4 In the middle. For example Figure 3 As shown, the pressure drop of the evaporation medium in this embodiment is significantly lower than that in Comparative Example I, but very similar to that in Comparative Example II. Similarly, as... Figure 4 As shown, the cooling efficiency of this embodiment is lower than that of Comparative Example I, and somewhat similar to that of Comparative Example II. The cooling efficiency is determined based on the wet-bulb and dry-bulb temperatures using known formulas. However, since the evaporating medium of this embodiment has the same external dimensions as Comparative Example I, it can be easily installed within the frame of the air handling unit without any modifications. Due to its smaller depth, Comparative Example II would require frame modifications.

[0022] In the method of the present invention, when lower cooling efficiency is required, the evaporating medium of the preferred embodiment can be easily replaced with the original evaporating medium. This results in cost savings because the replaced evaporating medium leads to a lower pressure drop across the medium, thereby reducing fan usage and requiring less water.

[0023] Therefore, compared to existing media of the same size and similar benefits, the evaporation medium of the present invention provides a more energy-efficient alternative with a lower pressure drop. The evaporation medium of the present invention can be manufactured at the same depth as existing media, thus eliminating the need for modifications to the frame or water distribution system. That is, the evaporation medium of the present invention achieves energy and water savings by reducing excess cooling capacity in existing facilities. The low pressure drop design saves energy and water while still achieving acceptable cooling efficiency.

[0024] Of course, this invention is not intended to be limited to the dimensions described above. That is, although specific dimensions (e.g., the angles and dimensions of the corrugated sheet) are described in this invention, it is important that the replacement evaporating medium has external dimensions comparable to the original evaporating medium, but is designed to have a lower pressure drop while still maintaining the desired level of cooling efficiency. This invention is also not intended to be limited to the specific types of evaporating media described herein. Many types of evaporating media are known, such as cellulose, poplar fiber, and synthetic fiber media, and various designs have been proposed based on these materials. Redesigning materials to change the pressure drop while maintaining the same external dimensions can be considered within the scope of this invention.

[0025] Although the invention has been described in conjunction with certain specific exemplary embodiments, many additional modifications and variations will be apparent to those skilled in the art based on this disclosure. Therefore, it should be understood that the invention may be practiced in ways other than those specifically described. Accordingly, exemplary embodiments of the invention should be considered illustrative rather than restrictive in all respects, and the scope of the invention should be determined by any of the claims supported by this application and their equivalents, rather than by the foregoing description.

Claims

1. A method for replacing an evaporating medium for gas-liquid contact in an evaporative cooling apparatus, the evaporative cooling apparatus comprising a medium housing having a predetermined size, the evaporating medium being positioned within the medium housing and having a pressure drop factor representing the pressure drop of a gas flowing from the inlet side through the evaporating medium to the outlet side, the method comprising: Remove a first evaporating medium from the medium housing, the first evaporating medium having dimensions complementary to the predetermined dimensions of the medium housing, and the first evaporating medium having a first pressure drop factor; as well as A second evaporating medium is installed in the medium housing. The second evaporating medium has a size that is complementary to the predetermined size of the medium housing and substantially equal to the size of the first evaporating medium. The second evaporating medium has a second pressure drop factor that is different from the first pressure drop factor.

2. The method according to claim 1, wherein, Under the same conditions, the pressure drop generated by the second evaporating medium having the second pressure drop factor on the gas flowing from the inlet side through the evaporating medium to the outlet side is lower than the pressure drop generated by the first evaporating medium.

3. The method according to claim 1, wherein, The second evaporation medium is formed by a first group of corrugated sheets and a second group of corrugated sheets. The corrugated grooves of the first group of corrugated sheets have a first amplitude from the trough to the crest, and the corrugated grooves of the second group of corrugated sheets have a second amplitude from the trough to the crest. The corrugated sheets in the first group and the corrugated sheets in the second group are arranged alternately. The corrugated grooves of the first group of corrugated sheets are inclined upward with a first tilt angle relative to the gas flow direction, and the corrugated grooves of the second group of corrugated sheets are inclined downward with a second tilt angle relative to the gas flow direction. The absolute values ​​of the first tilt angle and the second tilt angle are not equal.

4. The method according to claim 3, wherein, The first amplitude of the groove in the first set of sheets is substantially 8 mm.

5. The method according to claim 3, wherein, The second amplitude of the corrugation of the second set of sheets is approximately 10 mm.

6. The method according to claim 3, wherein, The first tilt angle of the groove of the first set of sheets is approximately 45° relative to the horizontal.

7. The method according to claim 3, wherein, The second tilt angle of the groove of the second set of sheets is approximately 15° relative to the horizontal.

8. The method according to claim 1, wherein, The first evaporating medium has a first cooling efficiency factor, and the second evaporating medium has a second cooling efficiency factor that is substantially different from the first cooling efficiency factor.

9. The method according to claim 8, wherein, Under the same conditions, the second evaporating medium having the second cooling efficiency factor is less efficient than the first evaporating medium in cooling the gas flowing from the inlet side through the evaporating medium to the outlet side.

10. A system employing a replaceable evaporation medium for contacting a gas with a liquid, the system comprising: An evaporative cooling device includes a medium housing of predetermined size, wherein a replaceable evaporative medium can be positioned within the medium housing and has a pressure drop factor, the pressure drop factor representing the pressure drop of gas flowing from the inlet side through the evaporative medium to the outlet side; A first evaporating medium capable of being inserted into and removed from the medium housing, the first evaporating medium having dimensions complementary to the predetermined dimensions of the medium housing, and the first evaporating medium having a first pressure drop factor; as well as A second evaporating medium capable of being inserted into and removed from the medium housing, the second evaporating medium having a size complementary to the predetermined size of the medium housing and substantially equal to the size of the first evaporating medium, and the second evaporating medium having a second pressure drop factor different from the first pressure drop factor.

11. The system according to claim 10, wherein, Under the same conditions, the pressure drop generated by the second evaporating medium having the second pressure drop factor on the gas flowing from the inlet side through the evaporating medium to the outlet side is lower than the pressure drop generated by the first evaporating medium.

12. The system according to claim 10, wherein, Each of the first evaporating medium and the second evaporating medium is formed by a first group of corrugated sheets and a second group of corrugated sheets. The corrugated grooves of the first group of corrugated sheets have a first amplitude from the trough to the crest, and the corrugated grooves of the second group of corrugated sheets have a second amplitude from the trough to the crest. The corrugated sheets in the first group and the corrugated sheets in the second group are arranged alternately. The corrugated grooves of the first group of corrugated sheets are inclined upward with a first tilt angle relative to the gas flow direction, and the corrugated grooves of the second group of corrugated sheets are inclined downward with a second tilt angle relative to the gas flow direction. The absolute values ​​of the first tilt angle and the second tilt angle are not equal.

13. The system according to claim 12, wherein, The first amplitude of the groove in the first set of sheets is substantially 8 mm.

14. The system according to claim 12, wherein, The second amplitude of the corrugation of the second set of sheets is approximately 10 mm.

15. The system according to claim 12, wherein, The first tilt angle of the groove of the first set of sheets is approximately 45° relative to the horizontal.

16. The system according to claim 12, wherein, The second tilt angle of the groove of the second set of sheets is approximately 15° relative to the horizontal.

17. The system according to claim 10, wherein, The first evaporating medium has a first cooling efficiency factor, and the second evaporating medium has a second cooling efficiency factor that is substantially different from the first cooling efficiency factor.

18. The system according to claim 17, wherein, Under the same conditions, the second evaporating medium having the second cooling efficiency factor is less efficient than the first evaporating medium in cooling the gas flowing from the inlet side through the evaporating medium to the outlet side.

19. An evaporation medium for contacting a gas and a liquid, wherein the gas and liquid flow relative to each other in a cross-flow relationship, the evaporation medium comprising: The first group of corrugated sheets has a first height of corrugated grooves; The second group of corrugated sheets has grooves of a second height, wherein the corrugated sheets in the first group and the corrugated sheets in the second group are arranged alternately, the grooves of the first group and the second group intersect to define a path from one surface of the evaporating medium to another, and the grooves of the corrugated sheets in the first group and the corrugated sheets in the second group contact at the crests of the grooves. The grooves of the first group of corrugated sheets are inclined upward at a first angle relative to the gas flow direction, while the grooves of the second group of corrugated sheets are inclined downward at a second angle relative to the gas flow direction. The absolute values ​​of the first tilt angle and the second tilt angle are not equal. The amplitude of the corrugated grooves in the first group of corrugated sheets from the trough to the crest is smaller than the amplitude of the corrugated grooves in the second group of corrugated sheets from the trough to the crest. The first group of corrugated sheets has a groove amplitude of approximately 8 mm, and the second group of corrugated sheets has a groove amplitude of approximately 10 mm.

20. The evaporation medium according to claim 19, wherein, The first tilt angle of the corrugation of the first set of sheets is substantially 45° relative to the horizontal, and the second tilt angle of the corrugation of the second set of sheets is substantially 15° relative to the horizontal.

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