Cooling Tower Liquid Collection Assembly Airflow Uniformity
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Solution Overview
Problem
Conventional industrial cooling towers face inefficiencies due to uneven air distribution, high maintenance costs from sedimentation and liquid disposal issues, and pressure drops across collection systems, which affect thermal performance and increase operational expenses.
Innovation Solution
A liquid collection assembly is positioned above fans in the cooling tower housing, featuring troughs and diverter plates that direct and diffuse air, reducing pressure drops and enhancing airflow uniformity, while the damper plate's design prevents freezing and ensures efficient liquid collection and recirculation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If collection troughs are closely spaced to reduce water falling past them, then water protection is improved, but pressure drops increase and air flow efficiency deteriorates
Solution Approach 1:
The patent introduces a third vertical dimension by positioning collection troughs at different heights (first trough at higher elevation, second trough at lower elevation). This vertical stacking allows adequate horizontal spacing between troughs to maintain air flow efficiency while still providing comprehensive water collection protection through the cascading arrangement.
2Strength
If transverse support members are used to support collection troughs, then structural support is improved, but air dispersion is blocked and lateral air flow is prevented
Solution Approach 1:
The patent segments the support structure into vertical support members positioned at the ends of troughs rather than continuous transverse supports. This segmentation creates open spaces between and beneath the troughs, allowing air to disperse laterally and vertically while the vertical supports at trough ends provide sufficient structural support.
3Object-affected harmful factors
If dampers are positioned at the bottom of collection troughs to block water, then water protection is improved, but freezing susceptibility increases and damper reliability deteriorates
Solution Approach 1:
The patent repositions the damper from the bottom of the trough to the upper end of the trough, utilizing the vertical dimension. This elevation places the damper above the freezing zone while still allowing it to effectively control water flow into the trough, thereby maintaining reliability in cold environments.
4Quantity of substance
If large volume liquid basins are used to charge the system, then liquid capacity is improved, but system weight increases and rooftop loading capacity is exceeded
Solution Approach 1:
The patent extracts the liquid collection function from a large permanent basin and redistributes it across multiple smaller collection troughs positioned throughout the tower. This allows the system to maintain adequate liquid capacity for charging and operation while significantly reducing the weight concentration and overall footprint, making the system suitable for rooftop installation.
5Quantity of substance
If large basins are used for liquid collection, then liquid capacity is improved, but maintenance complexity increases due to sedimentation and confined space cleaning requirements
Solution Approach 1:
The patent segments the liquid collection system into multiple smaller troughs distributed throughout the tower rather than one large basin. This segmentation reduces sedimentation accumulation in each trough, eliminates confined space entry requirements for maintenance, and allows easier access and cleaning of individual troughs while maintaining total liquid capacity.
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 improves air-to-liquid mixing, reduces pressure drops, and enhances thermal performance, making the cooling tower more efficient and cost-effective by minimizing maintenance and operational costs.
Implementation Method 1
collects the liquid flowing through the fill or heat transfer coils and directs the same to an internal gutter, from which the liquid may be removed and recirculated
Implementation Method 2
provide a uniform path for rising air, to capture the down flowing liquid
Implementation Method 3
counterflow towers wherein water or other liquid falls or is sprayed downward in the tower counter to air moving upwardly in the tower
Implementation Method 4
evaporative coolers, fluid coolers or closed loop cooling towers, evaporative condensers
Data Source
AI summary
A liquid collection assembly positionable between a fill material and a fan of a cooling tower for collecting liquid gravitating through the fill material while allowing air to pass up to the fill material. The liquid collection assembly includes a plurality of trough assemblies supported in a spaced apart, vertically overlapping relationship to provide a uniform path for rising air, to capture the down flowing liquid, to provide a barrier between the liquid distribution system and the fan, and to carry the liquid into the at least one gutter. The trough assemblies are supported by a first end plate and a second end plate through which trough assemblies extend.