Modular Heat Exchanger Wetting for Cooling Capacity Control
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Solution Overview
Problem
Industrial refrigeration systems require high energy due to their design, and existing methods to improve heat transfer efficiency, such as using materials with good thermal conductivity, are uneconomical, while wetting devices offer a more cost-effective approach but can lead to sudden increases in power consumption and corrosion issues.
Innovation Solution
A heat exchanger with independently controllable wetting devices that allow for selective and sequential wetting of modules, reducing energy consumption and extending the service life by optimizing cooling capacity and regulating the wetting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If wetting devices are used to improve heat transfer efficiency, then cooling capacity is increased, but power consumption increases suddenly and corrosion issues occur
Solution Approach 1:
The heat exchanger is divided into multiple independently controllable modules (first module, second module, third module, etc.), each with its own wetting device. This segmentation allows selective activation of wetting devices in specific modules based on cooling demands, avoiding simultaneous activation across all modules and thus preventing sudden power consumption spikes while maintaining the ability to enhance cooling capacity where needed.
Solution Approach 2:
The system implements dynamic control of wetting devices through individual actuators for each module, allowing the wetting process to be adjusted in real-time based on operational conditions. This dynamic approach enables optimization of cooling capacity while managing power consumption by activating wetting only when and where required, rather than continuously or simultaneously across all modules.
2Productivity
If wetting devices are used to improve heat transfer efficiency, then cooling capacity is increased, but corrosion of heat exchanger components occurs
Solution Approach 1:
By segmenting the heat exchanger into multiple modules with independent wetting control, the system limits the exposure area to water at any given time. This reduces the overall surface area susceptible to corrosion compared to full-system wetting, thereby extending the service life of components while still achieving enhanced cooling capacity in active modules.
Solution Approach 2:
The wetting process is implemented periodically and selectively rather than continuously across all modules. By activating wetting devices in a sequential or demand-based manner, the system reduces cumulative exposure time of components to water, thereby mitigating corrosion effects while maintaining cooling efficiency when wetting is applied.
3Productivity
If materials with good thermal conductivity are used for fins or tubes, then heat transfer efficiency is improved, but material costs increase significantly
Solution Approach 1:
Instead of using expensive high-conductivity materials throughout the entire heat exchanger, the invention applies wetting enhancement locally to specific modules or zones where it is most needed. This localized approach achieves improved heat transfer efficiency in critical areas without incurring the high material costs of replacing entire heat exchanger components with premium materials.
Solution Approach 2:
The system changes the operational parameters of the heat exchanger by introducing a wetting mechanism that temporarily alters the thermal properties of selected modules. This allows the system to achieve heat transfer efficiency comparable to high-conductivity materials through controlled wetting, avoiding the need to invest in expensive materials while maintaining manufacturing economy.
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 increases the efficiency of the heat exchanger by allowing precise temperature control and reducing the consumption of the third medium, such as water, while extending the service life of the wetting devices and preventing corrosion, with up to 95% savings in the third medium and improved regulation precision.
Implementation Method 1
a third fluid medium can be sprayed into the second fluid medium or onto the heat exchanger or the closed channel system
Implementation Method 2
By means of the first and second wetting devices, which are in particular spray devices, the second fluid medium or the heat exchanger or the closed channel system is wetted with a third fluid medium
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The exchanger (1) has a module (2) and other modules (12, 22, 32, 42, 52, 62, 72) for heat exchange between heat medium and air. Wetting devices (4, 14, 24, 34, 44, 54, 64, 74) e.g. spraying devices, for the respective modules, are wetted with water. One of the wetting devices is operated independent of the wetting device for the other modules. Blocking elements (5, 15, 25, 35, 45, 55, 65, 75) are provided for the wetting devices. A control system detects service life of the blocking elements, so that the blocking elements are shifted based on service life data. An independent claim is also included for a method for wetting a heat exchanger.