Counterflow hybrid evaporative heat exchanger

Abstract

A heat exchange system including a first inlet configured to receive a flow of air moving in a substantially vertical direction, a first water distribution system positioned below the first inlet, a plurality of coils positioned below the first water distribution system, a water collection system positioned below the plurality of coils, an opening between the plurality of coils and the water collection system, the opening configured to distribute a flow of air to a first chamber, the first chamber extending in a vertical direction that is substantially parallel to the plurality of coils, a second water distribution system positioned below the water collection system, fill media positioned below the second water distribution system, and a second inlet positioned below the fill media, the second inlet being configured to receive a flow of air moving in a substantially horizontal direction.

Description

Attorney Docket No. 00465-0013-00304COUNTERFLOW HYBRID EVAPORATIVE HEAT EXCHANGERCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of priority to U.S. Application No.19 / 573,489, filed March 20, 2026, which claims the benefit of priority to U. S.Provisional Application No. 63 / 775,487, filed March 21, 2025, which are hereby incorporated by reference in their entireties.FIELD OF INVENTION

[0002] The present disclosure relates to heat exchangers, and more particularly to a heat exchanger that includes counterflow fill below an evaporative coil.BACKGROUND

[0003] Evaporative heat exchangers are used in industrial and commercial applications for cooling process fluids. Some systems employ direct evaporative cooling, where air and water come into direct contact through fill media. Other systems are configured for indirect evaporative cooling, where a process fluid circulates through coils that are externally wetted with spray water. Hybrid heat exchangers combine both direct and indirect heat exchange elements. The integration of different heat exchange components within a single unit, while useful, presents various engineering challenges, including managing airflow paths, water distribution, and the spatial arrangement of components to achieve effective thermal performance.

[0004] While the present disclosure may overcome one or more of these above¬ referenced challenges or other problems in the art, the scope of the invention is defined by the claims and not by the ability to solve a specific problem.SUMMARY

[0005] In some aspects, a heat exchange system includes a first air inlet configured to receive a flow of air moving in a substantially vertical direction. The heat exchange system includes a first water distribution system positioned below the first inlet. The heat exchange system includes a plurality of coils positioned below the first water distribution system. The heat exchange system includes a water collection system positioned below the plurality of coils. The heat exchange system includes an opening between the plurality of coils and the water collection system, the opening configured to distribute a flow of air to a first chamber, the first chamber extending inAttorney Docket No. 00465-0013-00304a vertical direction that is substantially parallel to the plurality of coils. The heat exchange system includes a second water distribution system positioned below the water collection system. The heat exchange system includes a fill media positioned below the second water distribution system. The heat exchange system includes a second air inlet positioned below the fill media, the second inlet being configured to receive a flow of air moving in a substantially horizontal direction.

[0006] In some aspects, a heat exchange system includes a first air inlet on a first wall of the heat exchange system. The heat exchange system includes a second air inlet on a second wall of the heat exchange system, the second wall being opposite to the first wall, wherein the first air inlet and second air inlet are configured to receive air. The heat exchange system includes fill media positioned vertically above the first air inlet and second air inlet, the fill media extending between the first wall to the second wall. The heat exchange system includes a third air inlet on a third wall of the heat exchange system, the third wall connecting the first wall to the second wall. The heat exchange system includes a coil casing extending below a third wall, wherein the coil casing is fluidly downstream of the third air inlet and includes a plurality of coils. The heat exchange system includes a first chamber located vertically below the third wall, the first chamber extending vertically parallel to the coil casing. The heat exchange system includes a first opening in the coil casing, the first opening being configured to distribute air from the first air inlet, second air inlet, or third air inlet to the first chamber.

[0007] In some aspects, a heat exchange system includes a first air inlet with an upward-facing opening configured to receive air flowing in a substantially downward direction. The heat exchange system includes a first spray system positioned beneath the first air inlet and configured to distribute water. The heat exchange system includes a coil section positioned beneath the first spray system, the coil section including a plurality of heat exchange coils. The heat exchange system includes a first horizontal air inlet with a laterally-facing opening configured to receive air flowing in a substantially horizontal direction. The heat exchange system includes a fill section positioned above the first horizontal air inlet, the fill section configured to facilitate evaporative cooling. The heat exchange system includes a second spray system positioned above the fill section and configured to distribute water onto the fill section. The heat exchange system includes a first chamber adjacent to the coil section, the first chamber being configured to receive air passing through the coilAttorney Docket No. 00465-0013-00304section. The heat exchange system includes a first fan configured to discharge air from the first chamber.

[0008] The foregoing general description of the illustrative embodiments and the following detailed description are exemplary aspects of the teachings of this disclosure and are not restrictive.BRIEF DESCRIPTION OF FIGURES

[0009] Non-limiting and non-exhaustive examples are described with reference to the following figures, which are incorporated in this specification and which serve to explain the principles of the disclosed embodiments.

[0010] FIG. 1 illustrates an isometric view of a heat exchange system, according to one or more embodiments.

[0011] FIG. 2A illustrates a cross-sectional view of the heat exchange system of FIG. 1 through line A-A.

[0012] FIG. 2B illustrates a cross-sectional view of the heat exchange system of FIG. 1 with air and water flow paths.

[0013] FIG. 3 illustrates an isometric view of a heat exchange system, according to one or more embodiments.

[0014] FIG. 4A illustrates a cross-sectional view of the heat exchange system of FIG. 3.

[0015] FIG. 4B illustrates a cross-sectional view of the heat exchange system of FIG. 4A with air and water flow paths.

[0016] FIG. 5 illustrates a cutaway view of the heat exchange system of FIG. 3.DETAILED DESCRIPTION

[0017] Both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the features, as claimed. As used herein, the terms “comprises,” “comprising,” “has,” “having,” “includes,” “including,” or other variations thereof, are intended to cover a non-exclusive inclusion such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements, but may include other elements not expressly listed or inherent to such a process, method, article, or apparatus. In this disclosure, unless stated otherwise, relative terms, such as, for example, “about,” “substantially,” and “approximately” are used to indicate a possible variation of ±10% in the stated value. In this disclosure, unless stated otherwise, any numeric value may include a possible variation of ±10% in the stated value.Attorney Docket No. 00465-0013-00304

[0018] The present disclosure relates to evaporative heat exchangers, and more particularly to a counterflow hybrid evaporative heat exchange system that combines counterflow fill below an evaporative coil.

[0019] Evaporative heat exchangers may utilize the evaporation of water to reject heat from a system. In some examples, evaporative heat exchanger may include direct evaporative cooling. In direct evaporative cooling, air and water may come into direct contact as both fluids pass through fill media. The fill media may provide a large surface area for heat and mass transfer between the air and water streams. As water flows over the fill media surfaces, a portion of the water may evaporate into the air stream, removing heat from the remaining water. The cooled water may then be collected and recirculated through the system. Counterflow fill, may refer to media fill arrangements where air flows through the fill media in a first direction while water flows through the fill media in a second direction, opposite to the first direction.Counterflow fill, may provide efficient heat transfer due to the temperature gradient maintained between the two streams throughout the fill media.

[0020] In some examples, evaporative heat exchanger may include indirect evaporative cooling. Indirect evaporative cooling may include circulating a process fluid through coils that may be externally wetted with a liquid (e.g., water). The process fluid, which may be a refrigerant or other heat transfer fluid, may transfer heat through the coil walls to the water film on the exterior of the coils. Air flowing over the wetted coils may cause evaporation of the water, which removes heat from the process fluid without the process fluid coming into direct contact with the air or water. Hybrid evaporative heat exchangers may combine both direct and indirect evaporative cooling in a single unit, using fill media as a direct heat exchanger and coils as an indirect heat exchanger. Such hybrid designs may maximize plan area capacity while minimizing process fluid charge within the system. The system described herein may include a hybrid evaporative heat exchanger.

[0021] FIG. 1 illustrates an isometric view of a heat exchange system 100, according to one or more embodiments. The heat exchange system 100 includes a first wall 102, a second wall 104, a third wall 106, and a fourth wall 108 that together form the exterior casing of the unit. The first wall 102 and the second wall 104 may be positioned on opposite sides of the heat exchange system 100, while the third wall 106 and the fourth wall 108 may connect the first wall 102 to the second wall 104. Each of the first wall 102, second wall 104, third wall 106, and the fourth wallAttorney Docket No. 00465-0013-00304108 may be connected by a top portion 114 positioned at an upper portion of the heat exchange system 100.

[0022] The first wall 102 may include a first side inlet 110 positioned on a lower portion of the first wall 102. The first side inlet 110 may be configured to receive a flow of air moving in a substantially horizontal direction. In some cases, the first side inlet 110 may include louvers, openings, lattice or mesh panels, or other structures that permit air entry while providing protection from debris or weather. The second wall 104 may include a second side inlet 112 positioned on a lower portion of the second wall 104. The second side inlet 112 may similarly be configured to receive a flow of air moving in a substantially horizontal direction. In some embodiments, both the third wall 106 and the fourth wall 108 may also include inlets configured to receive horizontal airflow, allowing air to enter the heat exchange system 100 from multiple directions.

[0023] The top portion 114 may be positioned at an upper portion of the unit. The top portion 114 includes a top inlet 116 that may be configured to receive a flow of air moving in a substantially vertical direction. The top inlet 116 may include openings that permit downward airflow into the heat exchange system 100. A fan system 118 may be positioned above the top portion 114 and extend through the top portion 114. The fan system 118 may include one or more fans, two fans being shown in FIG. 1, that include protective grills. The fan system 118 may be configured to draw air through the heat exchange system 100 by creating negative pressure within the unit. The fan system 118 may be adjacent to the top inlet 116 on the top portion 114.

[0024] With continued reference to FIG. 1, pipes 120 may extend vertically along the exterior of the third wall 106 of the heat exchange system 100. The pipes 120 may connect components of the heat exchange system 100 to facilitate fluid circulation. A first coupling 121 is positioned along the pipes 120 and may connect the pipes 120 to a collection basin (e.g., the collection basin 152 shown in FIG. 2A) of the heat exchange system 100. A second coupling 123 may connect the pipes 120 to a first water distribution system (e.g., the first water distribution system 122 of FIG. 2A) of the heat exchange system 100. A pump 125 may be located at a lower portion of the heat exchange system 100 adjacent to the third wall 106. The pump 125 may be configured to circulate water from the collection basin through the pipesAttorney Docket No. 00465-0013-00304120 to the first water distribution system, enabling supply and recirculation of water through the heat exchange system 100.

[0025] FIG. 2A illustrates a front cross-sectional view along the A-A lines of the heat exchange system 100 of FIG. 1, according to one or more embodiments. The heat exchange system 100 may include a first water distribution system 122 that is positioned below the top inlet 116. The first water distribution system 122 may include a plurality of nozzles 124 configured to spray fluid onto a plurality of coils 126 positioned below the first water distribution system 122. The plurality of coils 126 may be housed within a coil casing 127, which provides structural support and defines the boundaries of a coil section of the heat exchange system 100. The plurality of coils 126 may facilitate indirect heat exchange with a process fluid circulating through the plurality of coils 126. As used herein, “a plurality of coils” should be interpreted to include: a single coil composed of a plurality of circuits, an arrangement of two or more separate coils, a pillow plate, or any other structure configured to facilitate heat transfer between a fluid flowing therethrough and an external medium. Each coil or circuit may include tubular heat exchange elements configured to convey a fluid along a flow path while facilitating thermal energy transfer between the fluid and an external medium. The plurality of coils may be constructed from various materials including metals, alloys, or other thermally conductive substances. The coils may have various cross-sectional shapes including circular, elliptical, oval, or other geometric configurations. The plurality of coils may be arranged in rows, banks, or other spatial configurations to achieve desired heat transfer characteristics.

[0026] The plurality of coils 126 may include an inlet configured to receive a process fluid, such as a refrigerant, and an outlet configured to expel the process fluid after heat exchange has occurred. As the refrigerant flows through the coils 126 (e.g., along a coil path) from the inlet to the outlet, heat may transfer from the refrigerant through the tube walls of the coils 126 to the water film on the exterior surfaces of the coils 126. The heat transfer may cause the refrigerant to decrease in temperature as it progresses along the coil path, such that the refrigerant exiting the outlet may be at a lower temperature than the refrigerant entering the inlet. In some examples, the coils 126 may include sensi coils with elliptical tubes oriented on a vertical axis. For example, the coils 126 may have varying numbers of rows, ranging from 4 rows to 20 rows. The number of rows in the coils 126 may be selected basedAttorney Docket No. 00465-0013-00304on the number of fill layers present in the heat exchange system 100. For example, a configuration with two layers of fill may support coils 126 having 4 rows to 8 rows, while a configuration with four layers of fill may support coils 126 having 16 rows to 20 rows of coils.

[0027] The heat exchange system 100 may include an opening 156 positioned between the coil casing 127 and a water collection unit 128. The opening 156 may be configured to distribute a flow of air to a chamber 158. The chamber 158 may extend in a vertical direction that is substantially parallel to the plurality of coils 126. The chamber 158 may be fluidly connected to the fan system 118, allowing air to be discharged from the heat exchange system 100.

[0028] A water collection unit 128 may be positioned vertically below the plurality of coils 126. The water collection unit 128 may include a sloped wall 129 configured to direct water falling from the plurality of coils 126 towards an opening 132 that allows the water to pass into a second water distribution system 133. The sloped wall 129 may be located between third wall 106 and the fourth wall 108 and may be vertically aligned with the plurality of coils 126. The sloped wall 129 may be configured to direct water from the plurality of coils 126 towards the second water distribution system 133. In some embodiments, the water collection unit 128 may include alternative configurations such as a funnel shape with two sloped walls angled inward toward a central opening, a conical collector, or a series of angled baffles that converge toward the opening 132.

[0029] The second water distribution system 133 may include a floor 131 that may distribute water outwards into a trough 130 (e.g., one or more troughs). The trough 130 of the second water distribution system 133 may include a plurality of nozzles 134 configured to spray fluid onto fill media 140 positioned below the second water distribution system 133.

[0030] As further shown in FIG. 2A, the fill media 140 is positioned below the second water distribution system 133. The fill media 140 may include various types of media configured to provide surface area for heat and mass transfer between air and water. In some embodiments, the film fill media, splash fill media, trickle fill media, cellular fill media, or a combinations thereof. The fill media 140 may be constructed from various materials including polyvinyl chloride (PVC), polypropylene, acrylonitrile butadiene styrene (ABS), fiberglass-reinforced plastic, treated wood, ceramic, metal, or other suitable materials. The fill media 140 may extend betweenAttorney Docket No. 00465-0013-00304the first wall 102 and the second wall 104. The fill media 140 may include a plurality of stacked block layers of fill, where block layer of fill may also be referred to as a layer of fill. For example, the fill media 140 may have one to four block layers of fill, with the number of block layers selected based on the coil configuration and heat transfer requirements. A block layer of fill may refer to a horizontal arrangement of fill blocks positioned at a common vertical level within the fill media 140. Each block layer of fill may include a plurality of fill blocks arranged side by side to span the width and depth of the heat exchange system 100. A fill block may include a stack of fill sheets that are assembled together to form a unitary structure. The fill sheets within a block may be corrugated or textured to provide surface area for water distribution and air contact. The sheets may be bonded or otherwise secured together at their edges or at periodic intervals to maintain the block configuration during operation. In some examples, the fill blocks may be made of polyvinyl chloride (" PVC") sheets that are corrugated and stacked in alternating A sheet and B sheet configurations to create flutes for air and water passage. In some cases, the fill media blocks may be one foot wide by one foot deep with variable length, and may be arranged in alternating orientations between adjacent layers for improved performance.

[0031] In one example, the fill media 140 includes a first block layer of fill 142 and a second block layer of fill 144 positioned vertically above the first block layer of fill 142. The first block layer of fill 142 may include a plurality of fill blocks, the plurality of fill blocks including a first fill block 146 and a second fill block 148. The second layer of fill 144 may include a plurality of fill blocks, includes a third fill block 150. The first fill block 146 and the second fill block 148 of the first layer of fill 142 may extend in a first direction D1, while the third fill block 150 of the second layer of fill 144 may extend in a second direction D2. The first direction D1 and the second direction D2 may be aligned forty-five degrees to one-hundred-five degrees apart. In one example, the direct may be aligned ninety degrees apart. In some cases, the first direction D1 and the second direction D2 may be substantially perpendicular to each other, such that the fill sheets in adjacent layers are arranged in alternating orientations.

[0032] The heat exchange system 100 may include a collection basin 152 positioned vertically beneath the fill media 140. The collection basin 152 may be configured to collect water that has passed through the fill media 140. The collectedAttorney Docket No. 00465-0013-00304water in the collection basin 152 may be pumped (e.g., by pump 125 shown in FIG.1) from the collection basin 152 through pipes (e.g., pipes 120 shown in FIG. 1) to the first water distribution system 122. The collection basin 152 may encompass the entirety of the fill plan area of the heat exchange system 100. The collection basin 152 may be sloped or stepped to reduce the total volume of water required for operation of the unit. In some embodiments, the collection basin 152 may include one or more volume reducing steps that decrease the water capacity while maintaining sufficient water depth for pump operation.

[0033] The heat exchange system 100 may include frames 154 that provide structural support for the fill media 140 and the components above. The frames 154 may support and hold up the heat exchange system 100. The frames 154 may be constructed from steel, aluminum, or other load-bearing materials capable of withstanding the weight of the fill media 140, water collection unit 128, coils 126, and associated water loads during operation. The frames 154 may be positioned at the corners and along the perimeter of the heat exchange system 100 to distribute loads evenly and maintain structural integrity under varying operating conditions. The frames 154 shown in FIG. 2A may include structural members that support the volume reducing step within the collection basin 152

[0034] FIG. 2B illustrates a cross-sectional view of the heat exchange system 100 with a flow path of air A and a flow path of water W indicated by arrows. The flow path of air A and the flow path of water W illustrate the movement of air and water through the various sections of the heat exchange system 100 during operation.

[0035] With continued reference to FIG. 2B, air may enter the heat exchange system 100 through the top inlet 116 and flow in a substantially downward direction through the coils 126. Simultaneously, water may be sprayed from the first water distribution system 122 through the plurality of nozzles 124 onto the coils 126. The flow path of air A and the flow path of water W through the coil section are concurrent, meaning both the air and the water move in the same or substantially the same vertically downward direction through the coil section. The concurrent flow arrangement may assist in spreading the water film uniformly across the exterior surfaces of the coils 126 as the air flow helps distribute the water over the coil tubes.

[0036] As further shown in FIG. 2B, air may also enter the heat exchange system 100 through the first side inlet 110 positioned on the first wall 102 and through theAttorney Docket No. 00465-0013-00304second side inlet 112 positioned on the second wall 104. The first side inlet 110 and the second side inlet 112 may each be configured to receive a flow of air moving in a substantially horizontal direction. Air entering through the first side inlet 110 and the second side inlet 112 may flow upward through the fill media 140 in a counterflow arrangement with respect to the water, in the counterflow arrangement, the flow path of water W moves downward through the fill media 140 from trough 130 and the plurality of nozzles 134 of the second water distribution system 133, while the flow path of air A moves upward through the fill media 140 from the first side inlet 110 and the second side inlet 112. The counterflow arrangement may maintain a temperature gradient between the air and water streams throughout the fill media 140. Air flowing upward through the fill media 140 may pass around the troughs 130 of the second water distribution system 133 and continue upward into the chamber 158. The second water distribution system 133 may be capable of allowing air to bypass around the troughs 130 to the chamber 158. The troughs may be spaced apart to provide passages for the airflow, allowing the air to navigate around the water distribution components and merge with the air exiting the coil section before being drawn upward by the fan system 118.

[0037] With continued reference to FIG. 2B, air passing through the plurality of coils 126 may exit through the opening 156 positioned between the coil casing 127 and the water collection unit 128. The opening 156 may distribute the flow of air A into the chamber 158. The fan system 118 may be fluidly connected downstream of the chamber 158. A fan of the fan system 118 may have a substantially vertical axis of rotation. The fan system 118 may draw air through both the coil section and the fill media 140 by creating negative pressure within the heat exchange system 100 and may discharge the air from the heat exchange system 100.

[0038] As described previously, the collection basin 152 may collect water that has passed through the fill media 140. Pipes 120 may be configured to distribute liquid from the collection basin 152 to the first water distribution system 122. The pump 125 (FIG. 1) may circulate water from the collection basin 152 through the pipes 120 to the first water distribution system 122, enabling continuous recirculation of water through the heat exchange system 100.

[0039] FIG. 3 illustrates an isometric view of a heat exchange system 200, according to one or more embodiments. The heat exchange system 200 includes a first wall 202, a second wall 204, a third wall 206, and a fourth wall 208 that togetherAttorney Docket No. 00465-0013-00304form the exterior casing of the unit. The first wall 202 and the second wall 204 may be positioned on opposite sides of the heat exchange system 200, while the third wall 206 and the fourth wall 208 may connect the first wall 202 to the second wall 204. The third wall 206 may connect the first wall 202 to the second wall 204 along one edge of the heat exchange system 200.

[0040] With continued reference to FIG. 3, the first wall 202 may include a first side inlet 210 positioned on a lower portion of the first wall 202. The first side inlet 210 may be a first horizontal air inlet with a laterally facing opening configured to receive air flowing in a substantially horizontal direction. In some cases, the first side inlet 210 may include louvers or other structures that permit air entry while providing protection from debris or weather. The second wall 204 may include a second inlet positioned on a lower portion of the second wall 204. The second inlet may similarly be configured to receive air flowing in a substantially horizontal direction. The first inlet and the second inlet may be configured to receive air into the heat exchange system 200. In some embodiments, both the third wall 206 and the fourth wall 208 may also include inlets configured to receive horizontal airflow, allowing air to enter the heat exchange system 200 from multiple directions.

[0041] As also shown in FIG. 3, the heat exchange system 200 includes a top portion 214 positioned at an upper portion of the unit. The top portion 214 includes a top inlet 216 that may be configured as a first air inlet with an upward-facing opening configured to receive air flowing in a substantially downward direction. The top inlet 216 may include openings that permit downward airflow into the heat exchange system 200. The top inlet 216 may extend from the third wall 206 to the fourth wall 208.

[0042] A first fan system 218 and a second fan system 219 may be included in the top portion 214. The first fan system 218 may be positioned adjacent to the top inlet 216 on a first side, the second fan system 219 may be positioned adjacent to the top inlet 216 on a second side of the top inlet, the second side being opposite to the first side. Each of the first fan system 218 and the second fan system 219 may include one or more fans (e.g., two fans, three fans, etc.) having substantially vertical axes of rotation. The first fan system 218 may include one or more fans configured to discharge air from a first chamber (e.g., the first chamber 258 of FIG. 4A) of the heat exchange system 200. The second fan system 219 may include one or more fans configured to discharge air from a second chamber (e.g., the second chamber 260 ofAttorney Docket No. 00465-0013-00304FIG. 4A) of the heat exchange system 200. The first fan system 218 and the second fan system 219 may be configured to draw air through the heat exchange system 200 by creating negative pressure within the unit

[0043] With continued reference to FIG. 3, pipes 220 extend vertically along the exterior of the third wall 206 of the heat exchange system 200. The pipes 220 may connect various components of the system to facilitate fluid circulation. A first coupling 221 is positioned along the pipes 220 and may connect the pipes 220 to a collection basin (e.g., the collection basin 252 shown in FIG. 4A) of the heat exchange system 100. A second coupling 223 may be positioned along the pipes 220 and may connect the pipes 220 to a first water distribution system (e.g., the first water distribution system 222 of FIG. 4A) of the heat exchange system 200. A pump 225 may be located at a lower portion of the heat exchange system 200 adjacent to the third wall 206. The pump 225 may be configured to circulate water from the collection basin through the pipes 220 to the first water distribution system, enabling recirculation of water through the heat exchange system 200.

[0044] FIG. 4A illustrates a front cross-sectional view along the B-B lines of the heat exchange system 200 of FIG. 3, according to one or more embodiments. The heat exchange system 200 may include a first water distribution system 222 that is positioned below the top inlet 216. The top inlet 216 may be configured to receive air flowing vertically in a substantially downward direction.

[0045] The heat exchange system 200 may include a first water distribution system 222 positioned below the top inlet 216. The first water distribution system 222 may be configured to distribute water onto coils 226. The first water distribution system 222 may include a plurality of nozzles 224 configured to spray fluid onto coils 226 positioned below.

[0046] The heat exchange system 200 may include a plurality of coils 226 housed within a coil casing 227, where the coil casing 227 provides structural support and defines the boundaries of a coil section of the heat exchange system 200. The plurality of coils 226 may facilitate indirect heat exchange with a process fluid circulating through the plurality of coils 226. The coil casing 227 may be centered between the first wall 202 and the second wall 204. The coil casing 227 may be vertically aligned with the first water distribution system 222. The plurality of coils 226 may include all technical and structural properties of coils 126 described in FIG. 2A.Attorney Docket No. 00465-0013-00304

[0047] The heat exchange system 200 may include a first opening 256 that is positioned between the coil casing 227 and a water collection unit 228 and a second opening 257 that is positioned between the coil casing 227 and the water collection unit 228. The first opening 256 and second opening 257 may be horizontally aligned and located on opposite side of the coil casing 227. The first opening 256 may be configured to distribute a flow of air to a first chamber 258. The second opening 257 may be configured to distribute a flow of air to a second chamber 260. The first chamber 258 extends in a vertical direction that is substantially parallel to the plurality of coils 226 and is located to a first side of the coil casing 227. The first chamber 258 may be fluidly connected to the first fan system 218, allowing air to be discharged from the heat exchange system 200. The second chamber 260 may extend in a vertical direction that is substantially parallel to the plurality of coils 226 and is located to a second side of the coil casing 227, the second side being opposite to the first side of the coil casing 227. The second chamber 260 may be fluidly connected to the second fan system 219, allowing air to be discharged from the heat exchange system 200.

[0048] As further shown in FIG. 4A, a water collection unit 228 may be positioned below the coils 226. The water collection unit 228 may include a first sloped wall 229a and a second sloped wall 229b configured to direct water from the coils 226 toward an opening 232 leading to a second water distribution system 233. The first sloped wall 229a and the second sloped wall 229b may be angled inward toward a central region of the water collection unit 228, forming a funnel shape that channels water toward an opening 232. The opening 232 may be positioned in the water collection unit 228 to allow water to pass through to a second water distribution system 233 positioned below. The second water distribution system 233 may function as a second spray system positioned above the fill media 240 and configured to distribute water onto the fill media 240. The second water distribution system 233 may include a floor 231 that may hold collected water and distribute the water outwards into one or more troughs 230. The one or more troughs 230 of the second water distribution system 233 may include a plurality of nozzles 234 configured to spray fluid onto fill media 240 positioned below the second water distribution system 233.

[0049] The fill media 240 may be positioned vertically above the first side inlet 210 and the second side inlet 212. The fill media 240 may extend between the firstAttorney Docket No. 00465-0013-00304wall 202 and the second wall 204. The fill media 240 may function as a fill section configured to facilitate evaporative cooling as water flows downward and air flows upward through the fill media 240 in a counterflow arrangement The fill media 240 may include all technical features, structural arrangements, and configurations described with respect to the fill media 140 of FIG. 2A. The first layer of fill 242 and the second layer of fill 244 may include all properties and arrangements described with respect to the first layer of fill 142 and the second layer of fill 144, respectively. Similarly, the first fill block 246, the second fill block 248, and the third fill block 250 may include all technical details, materials, dimensions, and orientations described with respect to the first fill block 146, the second fill block 148, and the third fill block 150, respectively. The fill media 240 may be film fill media with fill blocks arranged in alternating orientations between adjacent layers, as described with respect to the fill media 140. Similar to FIG. 2A, first fill block 246 and the second fill block 248 of the first layer of fill 242 may extend in a first direction D1, while the third fill block 250 of the second layer of fill 244 may extend in a second direction D2. The first direction D1 and the second direction D2 may be aligned forty-five degrees to one-hundred-five degrees apart. In one example, the direct may be aligned ninety degrees apart. In some cases, the first direction D1 and the second direction D2 may be substantially perpendicular to each other, such that the fill sheets in adjacent layers are arranged in alternating orientations.

[0050] The heat exchange system 200 may include a collection basin 252 positioned vertically beneath the fill media 240. The collection basin 252 may be configured to collect water that has passed through the fill media 240 for recirculation to the first water distribution system 222. Frames 254 may be positioned at a lower portion of the heat exchange system 200 to provide structural support for the fill media 240 and the components above.

[0051] FIG. 4B illustrates a cross-sectional view of the heat exchange system 200, showing the internal arrangement of components and the flow paths for air and water through the heat exchange system 200. The flow path of air A and the flow path of water W illustrate the movement of air and water through the various sections of the heat exchange system 200 during operation.

[0052] With continued reference to FIG. 4B, air may enter the heat exchange system 200 through the top inlet 216 in a substantially downward direction. The top inlet 216 may receive air that flows vertically downward through the first waterAttorney Docket No. 00465-0013-00304distribution system 222 and into the coil section containing the coils 226. Air passing through the coil section may exit through the first opening 256 and the second opening 257 positioned between the coils 226 and the water collection unit 228. The first opening 256 may distribute air into the first chamber 258, while the second opening 257 may distribute air into the second chamber 260.

[0053] Simultaneously, air may enter the heat exchange system 200 through the first side inlet 210 positioned on the first wall 202 and through the second side inlet 212 positioned on the second wall 204. The first side inlet 210 may function as a first horizontal air inlet with a laterally-facing opening configured to receive air flowing in a substantially horizontal direction. The second side inlet 212 may function as a second horizontal air inlet with an additional laterally-facing opening configured to receive air flowing in a substantially horizontal direction. The second horizontal air inlet may be horizontally aligned with the first horizontal air inlet, such that both inlets receive air at a common vertical level within the heat exchange system 200. In some examples, the third wall 206 and the fourth wall 208 may include inlets aligned with the first side inlet 210 and the second side inlet 212 that are also configured to receive air flowing in a substantially horizontal direction.

[0054] With continued reference to FIG. 4B, air entering through the first side inlet 210 and the second side inlet 212 may flow upward through the fill media 240 in a counterflow arrangement with respect to water flowing downward through the fill media 240. The fill media 240 may function as a fill section configured to facilitate evaporative cooling. Air flowing upward through the fill media 240 may pass around the troughs of the second water distribution system 233 and continue upward into the first chamber 258 and the second chamber 260.

[0055] Once air has entered the first chamber 258 and the second chamber 260, the first fan system 218 and the second fan system 219 may be configured to discharge air from the heat exchange system 200. The first fan system 218 may include at least one fan configured to create a negative pressure within the first chamber 258 to draw air through the coil section and from the fill media. Similarly, the second fan system 219 may include at least one fan configured to create a negative pressure within the second chamber 260 to draw air through the coil section and the fill media 240. By creating negative pressure within the first chamber 258 and the second chamber 260, the first fan system 218 and the second fan systemAttorney Docket No. 00465-0013-00304219 may draw air through both the coil section and the fill media 240 before discharging the air from the heat exchange system 200.

[0056] With continued reference to FIG. 4B, water may be sprayed from the first water distribution system 222 through the plurality of nozzles 224 onto the coils 226. The flow path of water W through the coil section moves in a downward direction concurrent with the flow path of air A entering through the top inlet 216. As water flows over the exterior surfaces of the coils 226, heat may transfer from the process fluid circulating within the coils 226 to the water film. The water leaving the coils 226 may fall onto the first sloped wall 229a and the second sloped wall 229b of the water collection unit 228. The first sloped wall 229a and the second sloped wall 229b may direct the water inward toward the opening 232, where the water passes through to the second water distribution system 233. The second water distribution system 233 may redistribute the water into the one or more troughs 230 and through the plurality of nozzles 234 onto the fill media 240. The flow path of water W moves downward through the fill media 240 while the flow path of air A moves upward through the fill media 240 in a counterflow arrangement. As the water flows downward through the fill media 240, evaporative cooling may occur, reducing the temperature of the water. The cooled water may be collected in the collection basin 252 positioned beneath the fill media 240 and recirculated through the pipes 220 to the first water distribution system 222.

[0057] The heat exchange system 200 may operate in a dry mode without water circulation when ambient temperatures are sufficiently cold. In dry mode operation, the pump 225 may be deactivated such that water is not circulated from the collection basin 252 to the first water distribution system 222 or the second water distribution system 233. Air may continue to flow through the top inlet 216 and through the first side inlet 210 and the second side inlet 212, passing over the coils 226 and through the fill media 240 to provide cooling to the process fluid circulating within the coils 226. Dry mode operation may be utilized when ambient air temperatures are low enough to provide sufficient cooling capacity without evaporative heat transfer. In some cases, dry mode operation may be employed to prevent water from freezing within the heat exchange system 200 during cold weather conditions.

[0058] FIG. 5 illustrates a front view of the heat exchange system 200, according to one or more embodiments. A cross sectional, overhead view 500 of componentsAttorney Docket No. 00465-0013-00304of the water distribution system 233 is shown (e.g., one or more troughs 230 and the floor 231) is indicated in FIG. 5, showing the internal arrangement of components within the heat exchange system 200.

[0059] With continued reference to FIG. 5, the cross sectional view 500 illustrates the arrangement of the second water distribution system components within the heat exchange system 200. The floor 231 is positioned centrally and is configured to receive water from the water collection unit positioned above. The floor 231 holds collected water and distributes the water outwards into one or more troughs 230, including a first trough 230a and a second trough 230b. The first trough 230a extends from the floor 231 toward the first wall 202, while the second trough 230b extends from the floor 231 toward the second wall 204. The first trough 230a and the second trough 230b may each include a plurality of nozzles configured to spray fluid onto the fill media 240 positioned below. The spacing between the first trough 230a and the second trough 230b provides passages for airflow, allowing air flowing upward through the fill media 240 to navigate around the troughs and continue upward into the first chamber 258 and the second chamber 260 before being discharged by the first fan system 218 and the second fan system 219.

[0060] In one or more embodiments described herein, the heat exchange system may provide concurrent flow of air and spray water over the coils. In such configurations, both the air and the water may flow in the same downward direction through the coil section. The concurrent flow arrangement may result in improved water film coverage around the tubes of the coils. When air and water move in the same direction, the air flow may assist in spreading the water film more uniformly across the exterior surfaces of the coil tubes. The improved water film coverage may enhance heat transfer capacity by maintaining a more consistent wetted surface area on the coils. Additionally, the concurrent flow arrangement may reduce the risk of scale generation on the coil surfaces. Scale formation may occur when minerals in the water precipitate onto surfaces, and improved water film coverage may help prevent localized dry spots where scale deposits may otherwise accumulate.

[0061] In one or more embodiments described herein, the heat exchange system may include one or more sloped walls (e.g., a single sloped wall, or a funnel with two sloped walls facing inwards) within a water collection system that serves a dual function. The water collection system may collect water leaving the coil section and direct the water toward a second water distribution system for redistribution over theAttorney Docket No. 00465-0013-00304fill media. Simultaneously, the funnel structure may direct airflow upward around the coil section toward a fan system. By shaping the water collection system with sloped walls, the heat exchange system may guide the air exiting the fill media along a path that avoids obstruction while also channeling the collected water to the redistribution system below. The second water distribution system may include troughs with a plurality of nozzles, where the troughs extend across the width of the heat exchange system. These troughs and nozzles may redistribute the collected water over the fill media while minimizing blockage of the airflow path from the fill media to the fan system.

[0062] In one or more embodiments described herein, the structural arrangement of the heat exchange system may provide blockage of ultraviolet light to a water basin positioned at the bottom of the heat exchange system. The fill media, water distribution systems, coils, and other internal components positioned above the water basin may prevent direct sunlight from reaching the water collected in the basin. By blocking ultraviolet light from the water basin, the heat exchange system may inhibit algae growth within the recirculated water. Algae growth in evaporative cooling systems may lead to fouling of heat transfer surfaces, clogging of nozzles and distribution systems, and degradation of water quality. The ultraviolet light blockage provided by the standard structural arrangement may reduce the need for additional shading structures or increased chemical treatment to control biological growth in the water basin.

[0063] A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. Accordingly, other implementations are within the scope of the following claims.

Claims

Attorney Docket No. 00465-0013-00304CLAIMSWhat is claimed is:

1. A heat exchange system, comprising:a first air inlet configured to receive a flow of air moving in a substantially vertical direction;a first water distribution system positioned below the first air inlet;a plurality of coils positioned below the first water distribution system;a water collection system positioned below the plurality of coils;an opening between the plurality of coils and the water collection system, the opening configured to distribute a flow of air to a first chamber, the first chamber extending in a vertical direction that is substantially parallel to the plurality of coils;a second water distribution system positioned below the water collection system;fill media positioned below the second water distribution system; and a second air inlet positioned below the fill media, the second air inlet being configured to receive a flow of air moving in a substantially horizontal direction.

2. The heat exchange system of claim 1, further comprising:a third air inlet positioned on an opposite face of the heat exchange system from the second air inlet, the third air inlet being configured to receive a flow of air moving in a substantially horizontal direction.

3. The heat exchange system of claim 1, further comprising:a collection basin beneath the fill media configured to collect water passing through the fill media.

4. The heat exchange system of claim 3, further comprising:pipes configured to distribute a liquid from the collection basin to the first water distribution system.

5. The heat exchange system of claim 1, further comprising:a fan system fluidly connected downstream of the first chamber, a fan of the fan system having a substantially vertical axis of rotation.Attorney Docket No. 00465-0013-003046. The heat exchange system of claim 1, wherein the water collection system includes a sloped wall configured to direct water from the plurality of coils into the second water distribution system.

7. The heat exchange system of claim 1,wherein the first water distribution system includes a first plurality of nozzles configured to spray fluid and the second water distribution system includes a plurality of nozzles configured to spray fluid.

8. A heat exchange system, comprising:a first air inlet on a first wall of the heat exchange system;a second air inlet on a second wall of the heat exchange system, the second wall being opposite to the first wall, wherein the first air inlet and second air inlet are configured to receive air;fill media positioned vertically above the first air inlet and second air inlet, the fill media extending between the first wall to the second wall;a third air inlet on a third wall of the heat exchange system, the third wall connecting the first wall to the second wall,a coil casing extending below a third wall, wherein the coil casing is fluidly downstream of the third air inlet and includes a plurality of coils;a first chamber located vertically below the third wall, the first chamber extending vertically parallel to the coil casing; anda first opening in the coil casing, the first opening being configured to distribute air from the first air inlet, second air inlet, or third air inlet to the first chamber.

9. The heat exchange system of claim 8, further comprising:a fan system extending vertically upwards from the third wall, the fan system being substantially aligned with and fluidly coupled to the first chamber.

10. The heat exchange system of claim 8, wherein the fill media includes:a first layer of fill; anda second layer of fill vertically above the first layer of fill.Attorney Docket No. 00465-0013-0030411. The heat exchange system of claim 10, wherein the first layer of fill includes a first fill sheet extending in a first direction, wherein the second layer of fill includes a second fill sheet extending in a second direction, wherein the first direction and the second direction are aligned forty-five degrees to one-hundred-five degrees apart.

12. The heat exchange system of claim 11, wherein the first layer of fill includes a first plurality of fill sheets, wherein each fill sheet in the first plurality of fill sheets extend in the first direction.

13. The heat exchange system of claim 11, wherein the second layer of fill includes a second plurality of fill sheets, wherein each fill sheet in the second plurality of fill sheets extend in the second direction.

14. The heat exchange system of claim 8, wherein the fill media is film fill media.

15. A heat exchange system, comprising:a first air inlet with an upward-facing opening configured to receive air flowing in a substantially downward direction;a first spray system positioned beneath the first air inlet and configured to distribute water;a coil section positioned beneath the first spray system, the coil section including a plurality of heat exchange coils;a first horizontal air inlet with a laterally-facing opening configured to receive air flowing in a substantially horizontal direction;a fill section positioned above the first horizontal air inlet, the fill section configured to facilitate evaporative cooling;a second spray system positioned above the fill section and configured to distribute water onto the fill section;a first chamber adjacent to the coil section, the first chamber being configured to receive air passing through the coil section; anda first fan system configured to discharge air from the first chamber.Attorney Docket No. 00465-0013-0030416. The heat exchange system of claim 15, further comprising:a second chamber positioned on an opposite side of the coil section from the first chamber, wherein the coil section is positioned between the first chamber and the second chamber.

17. The heat exchange system of claim 15, further comprising:a water basin positioned vertically beneath the fill section; anda pump system configured to circulate water from the water basin to the first spray system.

18. The heat exchange system of claim 15, wherein the first fan system includes at least one fan configured to create a negative pressure within the first chamber to draw air through the coil section.

19. The heat exchange system of claim 15, wherein the fill section includes a plurality of fill media sheets.

20. The heat exchange system of claim 15, further comprising:a second horizontal air inlet with an additional laterally-facing opening configured to receive air flowing in a substantially horizontal direction, the second horizontal air inlet being horizontally aligned with the first horizontal air inlet.

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