Modular Fluid Cooler and Chiller Layout for Stable Free Cooling
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Solution Overview
Problem
Current chiller systems face inefficiencies in power consumption, water usage, and operational stability due to reliance on traditional cooling methods, which are costly and complex, especially in varying environmental conditions, and often require risky transitions between free cooling and mechanical cooling modes.
Innovation Solution
A cooling apparatus and method utilizing a fluid cooler with wet media and a chiller that includes a refrigerant circuit, featuring a modular design with multiple operational modes based on ambient temperature and humidity, allowing for efficient transition between free cooling and mechanical cooling, and incorporating a master controller for optimized operation and energy management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If water-cooled chillers are used to reduce power consumption, then power efficiency is improved, but water consumption increases significantly
Solution Approach 1:
The patent combines air-cooled and water-cooled cooling systems into a hybrid configuration where air coolers and water coolers work together in series. The air cooler pre-cools the ambient air before it reaches the water cooler, reducing the temperature differential the water cooler must handle and thereby reducing water consumption while maintaining power efficiency.
Solution Approach 2:
The hybrid cooling system serves multiple functions: it provides power-efficient cooling when water is available, reduces water consumption by utilizing air cooling, and can operate in different modes (free cooling, mechanical cooling, hybrid) depending on environmental conditions. This multi-functionality allows the system to optimize between power and water usage dynamically.
2Use of energy by moving object
If free cooling apparatus is added to reduce power use, then power efficiency is improved, but system complexity increases due to water flow control systems and swing over valves
Solution Approach 1:
The patent extracts the complex water flow control systems and swing over valves from the free cooling apparatus and replaces them with a simplified hybrid configuration. The air cooler and water cooler are connected in series with straightforward fluid communication, eliminating the need for complicated control mechanisms while maintaining the power-saving benefits of free cooling.
Solution Approach 2:
The patent introduces an intermediary air cooling stage between the ambient environment and the water cooling system. This air cooler acts as a buffer that pre-cools the fluid, allowing the water cooler to operate more efficiently without requiring complex control systems to manage direct free cooling transitions.
3Productivity
If traditional pumping systems are used to support chillers, then cooling capacity is maintained, but power consumption increases significantly
Solution Approach 1:
The patent merges the pumping functions of both air-cooled and water-cooled systems into a single integrated pumping system. This unified approach eliminates redundant pumping capacity, reduces overall power consumption, while maintaining the required cooling capacity through optimized fluid flow management across both cooling stages.
4Productivity
If chiller compression cycle operates under high ambient temperature, then cooling demand is met, but compression ratio increases and compressor power increases
Solution Approach 1:
The patent applies preliminary cooling action by using the air cooler to pre-cool the fluid before it enters the water cooler and chiller system. This preliminary action reduces the ambient temperature effect on the compression cycle, lowering the compression ratio and compressor power requirements while still meeting the cooling demand.
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 significant reductions in power and water consumption, improved operational stability, and flexible adaptation to environmental conditions, enhancing the reliability and efficiency of cooling systems in various applications.
Implementation Method 1
a free cooling air to fluid heat exchanger disposed adjacent to the 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
Implementation Method 4
a refrigerant circuit, which includes a compressor
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.