Cooling Tower Virtual Equalization Tank for Multi-Source Water Management
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Solution Overview
Problem
Current cooling tower systems face challenges in detecting and responding to changes in process conditions due to infrequent on-site chemical analysis, leading to reactionary rather than predictive adjustments in cooling water chemistry, and require large capital expenditures for equalization tanks to manage multiple make-up water sources effectively.
Innovation Solution
A cooling tower system with multiple make-up water inlet streams, sensors (such as conductivity and flow sensors), and a controller that creates a virtual make-up stream based on real-time data from these sensors, allowing for real-time adjustments in chemical dosing and blowdown operations without the need for an equalization tank, enabling predictive control of corrosion and scale inhibition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple make-up water sources are used in a cooling tower system, then water supply reliability and operational flexibility are improved, but system complexity increases and requires large equalization tanks for effective management
Solution Approach 1:
The patent creates a virtual equalization tank by using sensors to monitor water quality parameters (conductivity, flow rate, temperature) from multiple make-up water sources and calculating a virtual composite water quality profile. This virtual representation allows the control system to manage multiple sources without requiring a physical equalization tank, thus maintaining reliability while reducing system complexity and capital expenditure
Solution Approach 2:
The patent replaces the mechanical equalization tank with an electronic control system that uses sensors and a controller to monitor and adjust water quality in real-time. The controller calculates the virtual composite water quality by combining data from multiple make-up water sources, substituting the need for large physical storage and mixing infrastructure with intelligent software-based water quality management
2Quantity of substance
If on-site chemical analysis is performed infrequently, then operational costs are reduced, but the ability to detect and respond to changes in process conditions deteriorates
Solution Approach 1:
The patent implements continuous monitoring of water quality parameters using sensors that constantly measure conductivity, flow rate, and temperature of make-up water sources. This continuous data collection provides real-time information about process conditions, enabling the system to detect and respond to changes immediately without the delays inherent in periodic manual sampling and analysis
Solution Approach 2:
The patent establishes a feedback loop where sensor data from multiple make-up water sources is continuously fed to the controller, which compares actual water quality against target parameters and automatically adjusts chemical dosing and water blending ratios. This closed-loop feedback system maintains optimal cooling water chemistry while reducing the need for expensive on-site chemical analysis
3Speed
If reactive adjustments to cooling water chemistry are made, then response time is reduced, but the ability to prevent undesirable conditions deteriorates
Solution Approach 1:
The patent uses the virtual equalization tank and continuous monitoring system to predict future water quality conditions by analyzing trends in make-up water parameters. The controller proactively adjusts chemical dosing and water blending ratios before undesirable conditions develop, preventing scale formation, corrosion, or fouling rather than merely responding after problems occur
Solution Approach 2:
The patent implements a dynamic control system that continuously adapts water quality management based on real-time sensor data. The controller dynamically adjusts chemical dosing rates, blowdown rates, and make-up water blending ratios in response to changing process conditions, transitioning from static periodic adjustments to continuous adaptive control that both responds quickly and prevents problems proactively
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
This solution enables real-time monitoring and adjustment of cooling water chemistry, reducing fouling risks and maintaining optimal thermal transfer efficiency without the need for large equalization tanks, thereby improving operational efficiency and reducing capital expenditures.
Implementation Method 1
at least one sensor monitoring water in each of the make-up water inlet streams; and a controller operably connected to the at least one sensor
Implementation Method 2
the at least one sensor is a flow sensor
Implementation Method 3
Cooling towers are used to remove absorbed heat from a circulating water coolant by evaporating a portion of the coolant in the cooling tower
Data Source
AI summary
A cooling tower system is disclosed. The cooling system includes a cooling tower; at least two make-up water inlet streams configured to supply water to the cooling tower; a blowdown stream configured to remove water from the cooling tower; at least one sensor monitoring water in each of the make-up water inlet streams; and a controller operably connected to the at least one sensor.