Modular adiabatic pre-cooling cassette with method of retrofit for horizontal air-cooled commercial refrigeration condensers
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Solution Overview
Problem
Existing horizontal air-cooled condensers in commercial refrigeration systems have limited energy efficiency and require costly retrofits for evaporative pre-cooling, due to their horizontal configuration and variability in design, making it difficult to integrate evaporative pre-coolers effectively.
Innovation Solution
A modular evaporative pre-cooler cassette system with a vertical evaporative media configuration, integrated air plenum, and adjustable bypass design is retrofitted onto existing horizontal air-cooled condensers using metal struts and threaded rods, allowing flexible installation and utilizing existing fans to pre-cool air before it passes through the condenser coil, with water and air flow sensing for efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a factory installed evaporative pre-cooler is added to a vertical air-cooled condenser, then energy efficiency is improved, but device complexity and installation cost increase
Solution Approach 1:
The evaporative pre-cooling system is divided into separate modular cassettes that can be independently installed on each condenser unit. Each cassette contains the evaporative media, water distribution system, and support structure as an integrated module, allowing for simplified installation and maintenance while achieving energy efficiency improvements without requiring complete system redesign
Solution Approach 2:
The evaporative pre-cooler cassette is designed to be installed within or adjacent to the existing condenser structure, nesting the new component within the footprint of the existing equipment. This approach adds functionality while minimizing space requirements and reducing the perceived complexity by utilizing the existing structural envelope
2Use of energy by moving object
If an evaporative pre-cooler is retrofitted to an existing horizontal air-cooled condenser, then energy efficiency is improved, but installation difficulty increases due to horizontal configuration
Solution Approach 1:
Instead of attempting to install traditional vertical evaporative media horizontally, the invention inverts the approach by creating self-supporting modular cassettes that contain pre-assembled vertical evaporative media bundles. These bundles are designed to be installed in horizontal orientation while maintaining the vertical flow path of air through the media, effectively solving the orientation mismatch problem between existing horizontal condensers and traditional vertical evaporative coolers
Solution Approach 2:
The evaporative media is configured with adjustable parameters including bundle spacing, orientation angles, and support structures that can be modified during installation to match specific horizontal condenser geometries. This adaptability allows the same cassette design to be installed on various horizontal condenser configurations without requiring custom engineering for each application
3Temperature
If evaporative media is installed in vertical configuration on horizontal condenser, then pre-cooling effectiveness is improved, but structural support complexity increases
Solution Approach 1:
Self-supporting structural bundles are introduced as intermediary elements between the horizontal condenser surface and the vertical evaporative media. These bundles act as independent load-bearing structures that carry the weight of the evaporative media and channel air flow, eliminating the need for complex external support frameworks while maintaining the vertical configuration necessary for effective pre-cooling
4Ease of manufacture
If existing condenser fans are used to pull air through evaporative cassette, then system cost is reduced, but air flow control difficulty increases
Solution Approach 1:
The system incorporates adjustable air flow control mechanisms including variable speed fan motors and adjustable air inlet/outlet openings that allow dynamic optimization of air flow rates. These controls enable the system to adapt to varying ambient conditions and load requirements, maintaining effective pre-cooling while using the existing fan infrastructure, thereby balancing cost savings with operational flexibility
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 significantly increases the energy efficiency of the refrigeration system, reduces maintenance and water consumption, and extends the service life of components, while providing a cost-effective and reusable retrofit method that balances energy savings with water usage.
Implementation Method 1
modular evaporative pre-cooler cassette system with a vertical evaporative media configuration
Implementation Method 2
Modular adiabatic pre-cooling cassette with method of retrofit for horizontal air-cooled commercial refrigeration condensers
Data Source
AI summary
According to another aspect, the present disclosure relates to a system for modular adiabatic evaporative pre-cooling of a horizontal air-cooled commericial refrigeration condenser. The system includes an evaporative media with an air permeable construction. The evaporative media has a water absorbable construction. The system also has a water supply port for supplying the volume of water. The system also has a water distributer for distributing the volume of water supplied from the water supply port. The water distributer distributes the volume of water to the evaporative media. The system also includes a water drain port for draining the volume of water distributed to the evaporative media.