Cooling Tower Bypass for Plume Abatement and Efficiency
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Cooling towers face challenges in plume abatement and water conservation, with existing solutions requiring complex and costly wet and dry air heat transfer mechanisms, increasing operational costs when not in plume abatement mode, and leading to contaminant concentration issues that affect cooling efficiency.
Innovation Solution
A cooling tower design with a vertical axis, featuring evaporative media, liquid distribution, and heat exchanger modules with bypass flow paths and air current generators to manage air streams and reduce heat content, allowing for efficient heat transfer and plume abatement without significant cost increases, while also incorporating dampers to regulate airflow and maintain thermal performance across varying conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a separate heat exchanger is used to partially cool hot water before it enters the cooling tower, then plume formation is reduced, but the cooling tower efficiency decreases and operational costs increase
Solution Approach 1:
The patent combines the plume abatement function and cooling function into a single integrated cooling tower system. The heat exchanger modules are incorporated within the cooling tower structure itself, allowing hot water to be cooled both for plume reduction and for the primary cooling purpose in one unified system, rather than using separate heat exchangers that would reduce overall efficiency.
Solution Approach 2:
The cooling tower is designed to perform multiple functions simultaneously: it provides primary cooling of hot water through evaporative cooling while also performing plume abatement through the heat exchanger modules. This multi-functionality eliminates the need for separate dedicated plume abatement equipment and maintains overall system efficiency.
2Object-affected harmful factors
If complex wet and dry air heat transfer mechanisms are implemented, then plume abatement is achieved, but device complexity and cost increase
Solution Approach 1:
The cooling tower is divided into distinct functional sections: an evaporative cooling section with fill media for primary cooling, and heat exchanger modules for plume abatement. This segmentation allows each section to perform its specific function efficiently while maintaining overall system simplicity and avoiding the need for complex integrated wet-dry mechanisms.
Solution Approach 2:
The patent uses ambient air as an intermediary medium that serves dual purposes: it provides the evaporative cooling function in the fill section and simultaneously serves as the cooling medium in the heat exchanger modules for plume abatement. This eliminates the need for separate complex mechanisms by using the same ambient air resource for both functions.
3Productivity
If water is continuously circulated through the cooling tower, then cooling efficiency is maintained, but contaminant concentration increases affecting cooling performance
Solution Approach 1:
The system implements a water treatment approach where a portion of the contaminated cooling water is discharged (blowdown) and replaced with fresh water. This prevents excessive contaminant buildup that would otherwise degrade cooling performance, while minimizing water loss through efficient contaminant management.
4Object-affected harmful factors
If a separate heat exchanger is used for plume abatement, then plume reduction is achieved, but additional water is consumed
Solution Approach 1:
The system merges the plume abatement water usage with the primary cooling water circulation system. The same cooling water that would otherwise be discharged is routed through the heat exchanger modules to perform plume abatement, eliminating the need for a separate water supply and reducing overall water consumption.
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 solution enables effective operation in both plume abatement and non-abatement modes with reduced operational costs, improved thermal performance, and minimized contaminant concentration, effectively addressing the challenges of plume reduction and water conservation.
Implementation Method 1
transferring heat from the first air stream into the second air stream
Implementation Method 2
heat is transmitted from the water to the air by both sensible and evaporative heat transfer
Implementation Method 3
ambient air is forced passed the heated water and heat is transmitted from the water to the air
Data Source
AI summary
A cooling tower having an evaporative media along with a liquid distribution system that distributes hot liquid over the evaporative media. The cooling tower includes a pair of heat exchanger modules that each have a first set of passageways in fluid communication with a first flow duct and a second set of passageways in fluid communication with a second flow duct. The heat exchanger module transfers heat from a first air stream into a second air stream. The cooling tower further includes a first bypass flow path that extends between the first heat exchanger module and the second heat exchanger module whereby a bypass door regulates airflow there through.