Evaporative Condenser Wetting to Prevent Scale and Thermal Resistance
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Solution Overview
Problem
Conventional evaporative condensing systems face inefficiencies due to maintenance issues, scale formation, and thermal resistance caused by recirculated water, which reduces heat transfer efficiency and requires frequent cleaning or replacement of heat exchanger surfaces.
Innovation Solution
An evaporative condensing apparatus with a superhydrophilic heat exchanger surface and a controlled water distribution system that maintains a thin water film, preventing scale buildup and thermal resistance, while an air delivery system minimizes airflow when not needed, reducing noise and maintaining the heat exchanger's efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If recirculated water is used in evaporative condensing systems, then water consumption is reduced, but scale formation and thermal resistance increase, reducing heat transfer efficiency
Solution Approach 1:
The patent changes the chemical composition parameters of the water by adding corrosion inhibitors, scale inhibitors, and biocides to the recirculated water. This modifies the water's properties to prevent scale formation and corrosion while maintaining its cooling capability, thus resolving the contradiction between water conservation and heat transfer efficiency
Solution Approach 2:
The system uses automatic circulation pumps and control mechanisms that allow the cooling water to continuously circulate and self-regulate through the heat exchanger. The water automatically picks up heat from the refrigerant and dissipates it through evaporation, maintaining efficient heat transfer without manual intervention while minimizing water loss
2Productivity
If recirculated water is used in evaporative condensing systems, then cooling efficiency is maintained, but maintenance frequency and cleaning requirements increase
Solution Approach 1:
The system incorporates automatic filtration mechanisms and chemical treatment that enable the cooling water to self-clean and self-regulate. Filters automatically trap particulates, and chemical additives prevent biofilm formation, reducing the need for manual cleaning and maintenance while sustaining cooling efficiency
Solution Approach 2:
The system uses sensors and control mechanisms that monitor water quality, temperature, and flow rates. When parameters deviate from optimal ranges, the system automatically adjusts pump speeds, valve positions, or chemical dosing to restore efficiency, thereby reducing maintenance intervention frequency
3Temperature
If water is sprayed on heat exchanger surface, then evaporative cooling is achieved, but dissolved solids concentrate and precipitate as scale
Solution Approach 1:
The patent converts the potentially harmful concentration of dissolved solids into a beneficial process by using scale inhibitors that bind to precipitating minerals, keeping them in solution. The water that would otherwise form scale is instead maintained in a stable, non-scaling state that continues to provide evaporative cooling
Solution Approach 2:
The system modifies the chemical parameters of the water by adding scale inhibitors and pH adjusters that prevent mineral precipitation. This changes the water's chemistry to maintain solubility of dissolved solids even at high concentrations, preventing scale formation on heat exchanger surfaces
4Ease of operation
If absorptive material is used on heat exchanger, then water distribution is improved, but thermal resistance increases and heat transfer efficiency decreases
Solution Approach 1:
The patent removes the absorptive material layer from the heat exchanger surface, eliminating the thermal resistance barrier it created. Instead, the system uses direct water spray or film application onto the metal heat exchanger surface, achieving both good water distribution and efficient heat transfer through the metal's high thermal conductivity
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 system achieves efficient heat transfer with reduced water consumption, lower cycles of concentration, and minimized scale formation, leading to lower maintenance needs and improved performance compared to traditional evaporative cooling methods.
Implementation Method 1
Water is evaporated on the surface of the heat exchanger containing the medium to be cooled. A large amount of water is sprayed on the heat exchanger surface, and ambient air is also forced over the heat exchanger containing fluid to be cooled. A very small portion of the water (about 1%) evaporates in the air, taking heat from the fluid inside the heat exchanger.
Implementation Method 2
An evaporative condensing apparatus with a superhydrophilic heat exchanger surface and a controlled water distribution system that maintains a thin water film
Data Source
AI summary
The current invention provides an evaporative condensing system using an evaporative condenser heat exchanger having an outer surface. The heat exchanger has a superhydrophilic surface. A compressor is configured to circulate a working fluid through the heat exchanger. A water distribution system is adapted to deposit a controlled amount of water on the heat exchanger to absorb heat from the heat exchanger by evaporation of water from the heat exchanger. A collector is located below the heat exchanger to receive excess water from the heat exchanger and direct excess water to a drain and an air delivery system is provided to direct air over the heat exchanger. The water distribution system supplies water to the heat exchanger in sufficient quantity that the water wets the heat exchanger, keeps the heat exchanger wet along its length, and excess water remains to carry dissolved solids to the collector.