Evaporative Cooling Tower Chemistry Control via Softener Feedback
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Solution Overview
Problem
Evaporative cooling systems face challenges in maintaining desired chemical ranges due to increasing total dissolved solids, leading to lime scale formation and water scarcity issues, with existing water softeners prone to mechanical failures and requiring regular salt replenishment.
Innovation Solution
A multi-function total dissolved solids controller (MFTDS) system that includes a water volume sensor, dissolved solids sensor, bleed valve, and softener sensor to monitor and automatically adjust the total dissolved solids levels, integrating with a water softener mechanism to detect regeneration needs and maintain optimal water chemistry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If water softener is used to replace calcium and magnesium ions with sodium ions, then the level of dissolved solids allowable in the evaporative cooling system is raised, but the water softener requires regular replenishment of solid salt and is prone to mechanical failure
Solution Approach 1:
The system uses a brine sensor to detect the conductivity of water in the brine reservoir, providing feedback about the softener's operational status. This feedback mechanism allows the system to monitor whether the softener is functioning properly and to detect when salt replenishment is needed, thereby maintaining reliability while allowing high dissolved solids levels.
Solution Approach 2:
The system automatically monitors and manages the water softener operation through the brine sensor and controller, reducing the need for manual intervention. The softener system serves itself by automatically detecting when regeneration is needed and managing the salt replenishment process, thereby improving reliability while maintaining high dissolved solids tolerance.
2Object-affected harmful factors
If water is bled off and replaced with fresh water to maintain dissolved solids levels, then lime scale formation is prevented, but water waste increases
Solution Approach 1:
The system changes the chemical parameter of the water by using a water softener to replace calcium and magnesium ions with sodium ions. This parameter change allows the system to tolerate much higher levels of dissolved solids without forming lime scale, thereby eliminating the need for frequent water bleeding while still preventing scale formation.
3Loss of substance
If the total dissolved solids setting is raised to conserve water, then water consumption is reduced, but the risk of lime scale precipitation increases
Solution Approach 1:
The water softener acts as an intermediary between the evaporative cooling system and the dissolved solids in the water. By introducing this intermediary component that exchanges calcium and magnesium ions for sodium ions, the system can operate at high dissolved solids levels without the harmful effect of lime scale precipitation, thus conserving water while maintaining system integrity.
4Reliability
If brine sensor is added to detect softener performance, then automatic reset of dissolved solids settings is enabled, but device complexity increases
Solution Approach 1:
The brine sensor serves multiple functions: it detects the conductivity of water in the brine reservoir, monitors softener operational status, and provides feedback for automatic control decisions. This multi-functionality justifies the added component by providing comprehensive monitoring and control capabilities that improve reliability without requiring separate dedicated systems.
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 MFTDS system effectively maintains optimal total dissolved solids levels, reducing lime scale formation and water waste, while ensuring continuous operation of evaporative cooling systems by monitoring water softener performance and automatically adjusting settings, thus conserving water and protecting heat exchange equipment.
Implementation Method 1
the art of cation resin water softening is well established and in wide use. The replacement of calcium and magnesium ions with sodium ions via water softening considerably raises the level of dissolved solids allowable in an evaporative cooling system
Implementation Method 2
the dissolved solids sensor monitors the total dissolved solids in the cooling system via the electrical conductivity of the water
Implementation Method 3
Water in a re-circulating system absorbs heat from somewhere in a facility, building or a process, and then expels that latent heat, as to the atmosphere... this allows the water both to contact the cooler air and to transfer or release some of its heat energy by means of evaporation
Implementation Method 4
a water volume sensor reading the water volume added to the evaporative cooling system. This water volume sensor is, in one embodiment, attached to a water meter which issues a contact closure signal when a set volume of water has passed through
Data Source
AI summary
The automatic reset of an evaporative cooling water dissolved solids set point based on detection of water softener performance is provided. A controller has a sensor, or is given an input signal, which confirms that the softener is operating properly. Positive confirmation of water softener performance allows the controller to maintain a user specified high total dissolved solids set point in the evaporative cooling water. Should a failure of the softener be detected, the controller then maintains a user specified lower total dissolved solids set point.