Fluidised Bed Cooling Tower Compact Design
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Solution Overview
Problem
Conventional cooling towers are bulky and unable to achieve approach temperatures below 10° F (5.6° C), limiting their efficiency in industrial applications.
Innovation Solution
A cooling tower design incorporating a fluidised bed of non-spherical packing elements with controlled tumbling rate, achieved by adjusting gas velocity and liquid-to-gas ratio, to enhance surface area contact between gas and liquid, allowing for approach temperatures below 10° F.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional cooling tower design is used, then the structure is simple and easy to manufacture, but the cooling tower is bulky and occupies valuable space
Solution Approach 1:
The patent applies fluidised bed technology where packing elements are suspended and tumbled by upward gas flow, transforming the static packing structure into a dynamic system. This dynamic state increases the effective heat transfer surface area and improves cooling efficiency, allowing for a more compact tower design while maintaining or enhancing performance
Solution Approach 2:
The patent changes the operational parameters by controlling gas velocity and liquid-to-gas ratio to achieve optimal tumbling rates of the packing elements. This parameter optimization enables the fluidised bed to operate at maximum efficiency, reducing the required tower volume while achieving the desired cooling effect
2Temperature
If conventional cooling tower design is used, then the structure is simple, but the approach temperature cannot be reduced below 10° F., limiting efficiency
Solution Approach 1:
The fluidised bed creates dynamic contact between gas and liquid through tumbling packing elements, significantly enhancing heat transfer coefficients. This dynamic interaction allows the system to achieve approach temperatures below 10° F. by maximizing the effectiveness of the gas-liquid contact process
Solution Approach 2:
The patent incorporates control means that monitors and adjusts gas velocity and liquid-to-gas ratio to maintain optimal tumbling rates. This feedback control ensures the fluidised bed operates at peak efficiency, consistently achieving low approach temperatures while adapting to varying operational conditions
3Area of moving object
If fluidised bed of packing elements is used, then the surface area for heat transfer is increased, but the device complexity and control requirements increase
Solution Approach 1:
The fluidised bed system is designed to self-regulate to some extent, where the upward gas flow automatically suspends and tumbles the packing elements without additional mechanical components. The system uses the process fluids themselves (gas and liquid flows) to create the tumbling action, eliminating the need for external motors or actuators to agitate the packing
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 design results in a more compact, cost-effective cooling tower that occupies less space, achieving efficient cooling with reduced energy consumption and preventing fouling, suitable for various industrial applications.
Implementation Method 1
a fluidised bed of packing elements on the support member
Implementation Method 2
the tumbling rate is controlled by a combination of controlled gas velocity and liquid to gas ratio creating turbulent mixing and tumbling of packing elements
Implementation Method 3
for cooling a liquid with a gas
Implementation Method 4
the liquid passes downwardly towards the fluidised bed
Implementation Method 5
a fan for blowing the gas upwardly through the fluidised bed
Implementation Method 6
pump means for pumping the liquid to the liquid spraying means
Data Source
AI summary
A cooling tower (2) for cooling a liquid (4) with a gas (6), which cooling tower (2) comprises: (i) a vessel (8) for receiving the gas (6) passing upwardly and the liquid (4) passing downwardly, with the liquid (4) being hotter than the gas (6); (ii) a gas outlet (4) which is at a top portion (16) of the vessel (8) and which is for allowing the gas (6) to pass out of the vessel (8), (iii) a support member (20) which is positioned across a bottom portion (22) of the vessel (8): (iv) a plurality of apertures (24) which are in the support member (20) and through which the gas (6) and the liquid (4) are able to pass; (v) a fluidised bed (26) of packing elements (28) on the support member (20); (vi) liquid emitting means (30) which is positioned in the vessel (8) above the fluidised bed (26), and which is for emitting alas liquid (4) to be cooled such the liquid (4) passes downwardly towards the fluidised bed (26); (vii) pump means (32) for pumping the liquid to the liquid emitting means (30); and (viii) a fan (34) for blowing the pas upwardly through the fluidised bed (26), and the cooling tower (2) being such that it includes (ix) control means (31) for controlling (a) the velocity of the gas through die vessel (8), and (b) the liquid to gas ratio in the vessel (8), whereby the fluidised bed (26) is caused to operate at a tumbling rate which when combined with selected pre-fluidised packing height causes an approach temperature of below 10° F. (5.6° C.); (x) wherein the tumbling rate is controlled by a combination of controlled gas velocity and liquid to gas ratio creating turbulent mixing and tumbling of packing elements (28) in the fluidised bed (26); (xi) and wherein the pre-fluidised height of the fluidised bed (26) is from 0.15-1.0 m.