System and methods utilizing fluid coolers and chillers to perform in-sertes 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 risks in transitioning between free cooling and mechanical cooling modes, and reliance on complex control systems and pumping systems that consume significant power.
Innovation Solution
A cooling apparatus and method featuring a fluid cooler with wet media and a chiller that includes a refrigerant circuit, using micro-channel heat exchangers and a modular design with a master controller to dynamically adjust cooling modes based on ambient temperatures and load demands, optimizing the use of free cooling, partial free cooling, and mechanical cooling modes to reduce energy and water consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If water-cooled chillers are used to improve power efficiency, then power consumption is reduced, but water consumption increases significantly
Solution Approach 1:
The patent combines air-cooled and water-cooled cooling paths into a single hybrid system that can operate in different modes. The system merges the advantages of both air-cooled (low water consumption) and water-cooled (high power efficiency) chillers by allowing dynamic switching between free cooling, partial free cooling, and mechanical cooling modes based on ambient conditions and cooling demands.
Solution Approach 2:
The system dynamically adjusts its operating mode based on real-time ambient temperature conditions and cooling load requirements. The controller automatically transitions between free cooling mode (when ambient conditions are favorable), partial free cooling mode (during transition periods), and mechanical cooling mode (when full cooling capacity is needed), optimizing both power and water consumption throughout the day.
2Use of energy by moving object
If free cooling mode is used to reduce power consumption, then power efficiency improves, but operational stability deteriorates due to risks during mode transitions
Solution Approach 1:
The system performs preliminary actions by pre-cooling the refrigerant and adjusting system parameters before transitioning between operating modes. The controller monitors ambient conditions and proactively prepares the system for mode changes, ensuring smooth transitions from free cooling to mechanical cooling and vice versa, thereby maintaining operational stability throughout the transition process.
Solution Approach 2:
The system continuously monitors ambient temperature, cooling load, and system operating parameters, using this feedback to dynamically adjust the operating mode. The controller receives real-time data from sensors and automatically adjusts the cooling strategy to maintain stable operation during transitions, preventing the lockout issues that plague traditional systems.
3Ease of operation
If traditional pumping systems are used to maintain fluid flow, then cooling distribution is ensured, but power consumption increases significantly
Solution Approach 1:
The system employs self-service mechanisms where the refrigerant circulation is driven primarily by pressure differentials created during phase change and density differences, rather than relying heavily on powered pumps. The hybrid cooling design allows the system to utilize natural convection and pressure-driven flow in free cooling mode, significantly reducing the power consumption of pumping systems while maintaining adequate cooling distribution.
4Productivity
If chiller capacity is increased to meet peak cooling demands, then cooling productivity improves, but power consumption and cost increase
Solution Approach 1:
The system applies partial free cooling action by utilizing ambient air cooling to the extent possible based on ambient conditions, and only activating the mechanical refrigeration cycle when absolutely necessary to meet the cooling load. This partial action approach allows the system to achieve adequate cooling productivity during peak demands while minimizing power consumption by relying on free cooling during favorable ambient conditions.
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 minimizing risks during mode transitions, and allows for modular expansion to meet varying cooling demands, thereby improving the efficiency and reliability of cooling systems.
Implementation Method 1
fluid cooler with wet media
Implementation Method 2
micro-channel heat exchangers
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.