Cooling Unit Condensate Atomization for Drainage-Free Operation
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Solution Overview
Problem
Existing condensate removal systems in cooling units, particularly in data centers, face challenges with installation complexity and reduced portability due to the need for drainage systems, which incur additional costs and limit system mobility.
Innovation Solution
A system comprising a drain pan, condensate pump, water tank, plunger pump, and atomizing nozzles that collect and atomize condensate within the exhaust air ducts of the cooling unit, eliminating the need for drainage pipes by using a strainer to filter particulates and switches to manage water levels, with the plunger pump pressurizing water to 40-60 bar for effective condensate removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a gravity drainage system or drain pump system is used to remove condensate, then condensate can be effectively removed from the cooling unit, but the system requires drainage pipes and additional installation complexity
Solution Approach 1:
The patent extracts the drainage function from the traditional external drainage pipe system and relocates it to an internal condensate recycling system. The condensate is collected in a drain pan, pumped through a filter, and reused to cool the condenser, eliminating the need for external drainage infrastructure.
Solution Approach 2:
The system makes the condensate serve a useful function by recycling it to cool the condenser coils. This self-service approach transforms waste condensate into a valuable cooling resource, eliminating the need for external drainage systems while maintaining effective heat rejection.
2Reliability
If traditional drainage systems are installed in data centers, then condensate can be removed, but system portability is reduced and additional costs are incurred
Solution Approach 1:
The patent removes the requirement for external drainage pipes and infrastructure by implementing a self-contained condensate recycling system. The condensed water is captured, filtered, and reused within the cooling unit itself, making the system portable and adaptable to various locations including data centers.
Solution Approach 2:
The condensate serves multiple functions: it is first collected from the evaporator, then used to cool the condenser, and any excess is discharged. This multi-functional approach eliminates the need for dedicated drainage infrastructure while maintaining effective operation.
3Reliability
If condensate is discharged externally, then condensate removal is achieved, but water is wasted and environmental concerns arise
Solution Approach 1:
Instead of discarding condensate through external drainage, the system recovers and reuses it to cool the condenser coils. This recovery process maximizes water utilization and eliminates waste, with only minimal discharge of filtered water after it has served its cooling purpose.
Solution Approach 2:
The condensate serves the system's own cooling needs by circulating through the condenser coils, where it absorbs heat from the refrigerant. This self-service function transforms waste water into a valuable thermal management resource.
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 efficient condensate removal without the need for drainage pipes, enhancing system portability and reducing installation complexity while maintaining effective cooling unit operation, particularly suited for data centers.
Implementation Method 1
The at least one atomizing nozzle is configured to atomize water from the plunger pump
Implementation Method 2
The plunger pump may be configured to pressurize the water to 40 to 60 bar
Implementation Method 3
a condensate pump configured to pump condensate from the drain pan
Implementation Method 4
The system further may include a strainer in fluid communication with the condensate pump and the water tank to remove particulate matter from the condensate prior to entering the water tank
Implementation Method 5
When a cooling coil's evaporator temperature or inlet chilled water temperature is lower than a dew point of return air, condensate forms on fins of the cooling coil
Implementation Method 6
When a cooling coil's evaporator temperature or inlet chilled water temperature is lower than a dew point of return air, condensate forms on fins of the cooling coil
Data Source
Figure 1~2
Figure 3A
Figure 3B
AI summary
A system for removing condensate from a cooling unit (10) includes a drain pan (44) to collect condensate generated by the cooling unit (10), a condensate pump (52) configured to pump condensate from the drain pan (44), and a water tank (54) in fluid communication with the condensate pump (52). The water tank (54) is configured to store condensate in the form of water delivered to the water tank (54) by the condensate pump (52). The system further includes a plunger pump (60) in fluid communication with the water tank (54). The plunger pump (60) is configured to pump water from the water tank (54). The system further includes at least one atomizing nozzle (62) in fluid communication with the plunger pump (60). The at least one atomizing nozzle (62) is configured to atomize water from the plunger pump (60).