A modular pre-cooling system
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Solution Overview
Problem
Existing evaporative cooling systems for air-cooled systems face issues such as pressure loss, corrosion, and high maintenance costs due to water evaporation and contamination, which reduce energy efficiency and require frequent filter replacements, especially when ambient temperatures exceed ISO design conditions.
Innovation Solution
A modular pre-cooling system with a rotating mesh mechanism, nozzles for controlled water spray, and a psychrometric analysis-based control unit that minimizes water usage, prevents water leakage, and uses a drift eliminator to manage pressure loss and contamination, while incorporating a dual-mesh structure for dust filtration and corrosion protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If direct evaporative cooling is applied using pads, then cooling efficiency is improved, but pressure loss increases and corrosion damage occurs
Solution Approach 1:
The system divides the evaporative cooling process into separate functional components: a drift eliminator section that prevents water particle detachment, a mesh structure that distributes water evenly, and a corrosion protection layer that isolates metal surfaces from corrosive environments. This segmentation allows each component to address specific issues independently while maintaining overall cooling efficiency.
Solution Approach 2:
The patent introduces an intermediary corrosion protection layer (such as protective coatings or sacrificial anodes) between the water/air environment and the metal components (condensers, serpentines, turbine blades). This intermediary prevents direct contact between corrosive elements and metal surfaces, eliminating the battery effect and sludge formation while allowing evaporative cooling to proceed uninterrupted.
2Object-affected harmful factors
If additional drift eliminator is added to eliminate water particle detachment, then corrosion protection is improved, but pressure loss increases and energy efficiency decreases
Solution Approach 1:
The patent employs thin-film mesh structures and flexible water distribution layers that provide effective drift elimination and water distribution without creating significant flow resistance. These thin films allow air to pass through with minimal pressure drop while still capturing water particles and distributing cooling water evenly across the heat exchange surfaces.
Solution Approach 2:
The system optimizes the physical parameters of the drift eliminator and mesh structure (such as pore size, thickness, and material properties) to achieve the minimum necessary pressure loss. By carefully controlling these parameters, the system maintains effective corrosion protection while minimizing the impact on air flow and energy consumption.
3Ease of operation
If modular design is implemented for easy installation, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The system is divided into standardized modular units (drift eliminator sections, mesh assemblies, corrosion protection modules) that can be independently manufactured, installed, and maintained. Each module is designed with standardized connection interfaces, simplifying assembly and reducing installation complexity despite the overall system's functional sophistication.
Solution Approach 2:
The modular components are designed to perform multiple functions within a single integrated structure. For example, the mesh structure simultaneously serves as a water distribution medium, a drift elimination barrier, and a structural support element. This multi-functionality reduces the number of separate components needed, thereby reducing overall system complexity while maintaining ease of installation and maintenance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system achieves maximum energy efficiency, reduces maintenance needs, and extends filter life by optimizing water use and preventing corrosion, thereby enhancing the operational efficiency and sustainability of air-cooled systems in high-temperature environments.
Implementation Method 1
water flow from the top of a pad filled with cavities is ensured, during the continuous movement of the mentioned water in the pad, hot air passes through the cavities in the pad and contacts with the water and thus cooling the air with the water is achieved
Implementation Method 2
humidification-based (evaporative-adiabatic) modular cooling system
Implementation Method 3
When the water comes into contact with air, it takes heat from the air to cool the air and thus increases the amount of water vapor in the air
Data Source
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AI summary
The invention is a modular pre-cooling system (10) which can be applied externally to the ambient suction air of the dry type refrigerant and central cooling systems required for comfort or process cooling of natural gas and geothermal power plants without disturbing the original structure of the system or units, comprising a transmission element (14) to provide water flow, and a nozzle (13) to spray the water coming from the said transmission element (14), wherein; it comprises, a mesh mechanism (11) which is rotated by an actuation element (15) and which provides a movable or fixed surface to which water is sprayed by the said nozzle (13), and at least one drift eliminator (17).