System and methods utilizing fluid coolers and chillers to perform in-series heat rejection and trim cooling
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Solution Overview
Problem
Traditional chillers face inefficiencies in power consumption and operational stability due to high energy demands for cooling and water usage, with air-cooled chillers consuming more power and water-cooled chillers requiring complex water flow control systems and posing risks during transitions between cooling modes.
Innovation Solution
A hybrid cooling apparatus and method that includes a fluid cooler with wet media and a chiller, utilizing free cooling air to fluid and air to refrigerant heat exchangers, along with a modular design for flexible operation and energy management, allowing for adaptive cooling modes based on ambient temperature and fan power usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If air-cooled chillers are used, then cooling capacity is provided, but power consumption is significantly higher
Solution Approach 1:
The cooling system is segmented into multiple independent cooling circuits (first cooling circuit with first chiller, second cooling circuit with second chiller) that can operate independently or in combination. This allows selective operation of chillers based on ambient conditions to optimize power consumption while maintaining required cooling capacity.
Solution Approach 2:
The system dynamically transitions between different operating modes (free cooling mode, first mechanical cooling mode, second mechanical cooling mode) based on ambient temperature and cooling load requirements. This dynamic adaptation allows the system to use the most energy-efficient cooling method available under current conditions.
2Use of energy by moving object
If water-cooled chillers are used, then power consumption is reduced, but water consumption increases significantly
Solution Approach 1:
The system segments cooling functions into free cooling (using ambient air and wet media) and mechanical cooling (using chillers). This allows the system to avoid water-intensive cooling methods when ambient conditions permit free cooling, thereby reducing water consumption while maintaining acceptable power consumption levels.
Solution Approach 2:
Wet media serves as an intermediary between ambient air and the cooling circuit, enabling evaporative cooling that reduces reliance on water-cooled chillers. This intermediary mechanism allows heat rejection to ambient air with minimal water consumption compared to traditional water-cooled chiller systems.
3Use of energy by moving object
If free cooling mode is used, then power consumption is reduced, but operational stability decreases during mode transitions
Solution Approach 1:
The system is divided into independent cooling circuits with dedicated chillers and heat exchangers that can operate independently. This segmentation allows smooth transitions between free cooling and mechanical cooling modes without the instability issues that arise in integrated systems, as each circuit can be controlled and switched independently.
Solution Approach 2:
The system pre-cools condenser water using free cooling apparatus during cooler seasonal operation before transitioning to mechanical cooling mode. This preliminary action ensures that the system is already in a stable thermal state before mode switching, preventing operational instability and lockout conditions during transitions.
4Productivity
If traditional pumping systems are used, then cooling distribution is achieved, but power consumption increases significantly
Solution Approach 1:
The cooling distribution system is segmented into multiple independent cooling circuits, each with its own optimized pumping requirements. This allows for more efficient pump operation in each circuit compared to a single large pumping system, reducing overall power consumption while maintaining adequate cooling distribution to all areas.
Solution Approach 2:
The system utilizes hydraulic principles with wet media and evaporative cooling to reduce reliance on high-power pumping systems. By leveraging natural convection and evaporative effects, the system achieves cooling distribution with lower pumping power requirements compared to traditional forced-circulation systems.
5Power
If chiller compression cycle operates at high ambient temperature, then cooling capacity is maintained, but compressor power increases due to higher compression ratio
Solution Approach 1:
The system dynamically switches between free cooling mode and mechanical cooling mode based on ambient temperature conditions. During high ambient temperature periods when compression ratio and compressor power would be elevated, the system can transition to mechanical cooling mode with optimized operation, or utilize wet media evaporative cooling to reduce the thermal load on compressors, thereby maintaining cooling capacity while managing compressor power consumption.
6Use of energy by moving object
If chiller compression cycle operates at low ambient temperature, then compressor power is reduced, but operational stability decreases due to low compression ratio
Solution Approach 1:
The cooling system is segmented into free cooling apparatus and mechanical cooling chillers that can operate independently. During low ambient temperature conditions, the system can operate in free cooling mode, bypassing the chiller compression cycle entirely and avoiding the operational instability associated with low compression ratios. This segmentation allows the system to achieve both low power consumption and high operational stability during cool weather.
7Reliability
If dual pathway piping is used for critical systems, then system reliability during maintenance is improved, but system cost increases
Solution Approach 1:
The cooling system is segmented into multiple independent cooling circuits with separate chillers and heat exchangers. This segmentation provides inherent redundancy and isolation capabilities, allowing maintenance on one circuit without affecting others, similar to dual pathway piping but achieved through circuit segmentation rather than complex piping configurations. This reduces system cost while maintaining reliability during maintenance.
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 solution significantly reduces power and water consumption, enhances operational stability by optimizing cooling modes, and allows for modular expansion to meet varying cooling demands, thereby improving the efficiency and reliability of cooling systems.
Implementation Method 1
a fluid cooler with wet media
Implementation Method 2
a free cooling air to fluid heat exchanger disposed adjacent to the wet media
Implementation Method 3
an air to refrigerant heat exchanger disposed adjacent to the free cooling air to fluid heat exchanger
Data Source
AI summary
The cooling systems and methods of the present disclosure involve modular fluid coolers and chillers configured for optimal power and water use based on environmental conditions and client requirements. The fluid coolers include wet media, a first fluid circuit for distributing fluid across wet media, an air to fluid heat exchanger, and an air to refrigerant heat exchanger. The chillers, which are fluidly coupled to the fluid coolers via pipe cages, include a second fluid circuit in fluid communication with the air to fluid heat exchanger and a refrigerant circuit in thermal communication with the second fluid circuit and in fluid communication with the air to refrigerant heat exchanger. Pipe cages are coupled together to allow for expansion of the cooling system when additional cooling capacity is needed. The fluid coolers and chillers are configured to selectively operate in wet or dry free cooling mode, partial free cooling mode, or mechanical cooling mode.