Multi-Layer Cooling Tower Fill Segmentation for Heat Exchange
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Solution Overview
Problem
Conventional cooling towers require thick fill material units for effective cooling, leading to high material consumption, increased power usage, uneven heat transfer, and reduced efficiency due to air resistance, making it difficult and costly to improve overall performance.
Innovation Solution
A cooling tower design featuring multiple-layer cooling units arranged in parallel or vertically, with water collection and distribution basins and fill material units, allowing for even water distribution and parallel air flow for enhanced heat exchange, reducing the thickness and power consumption of fill material units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the thickness of the fill material unit is increased to achieve effective cooling performance, then the cooling efficiency is improved, but the material consumption and device complexity increase
Solution Approach 1:
The fill material unit is divided into multiple layers with different structures and functions. The first layer (31) has through holes for water distribution, the second layer (32) has through holes for air flow, and the third layer (33) provides cooling function. This segmentation allows each layer to be optimized independently, achieving effective cooling with reduced overall thickness compared to a single thick fill material unit.
2Productivity
If the thickness of the fill material unit is increased to improve cooling performance, then the heat exchange effectiveness is improved, but the power consumption of the pumping device increases
Solution Approach 1:
The segmented structure with through holes in the first and second layers creates natural water distribution and air flow paths. This reduces the resistance to air flow through the fill material, allowing the fan unit to operate at lower power while maintaining effective heat exchange. The water distribution system also benefits from reduced pressure requirements due to the optimized layer structure.
3Productivity
If the thickness of the fill material unit is increased to achieve uniform cooling, then the cooling performance is improved, but the heat transfer uniformity across the transverse direction deteriorates
Solution Approach 1:
The multiple-layer structure with through holes distributed across different layers ensures uniform water distribution and air flow across the transverse direction. The first layer's through holes distribute water evenly, while the second layer's through holes allow uniform air penetration. This segmented approach prevents the heat transfer non-uniformity that occurs in thick single-layer fill materials where air flow becomes restricted toward the center.
4Productivity
If the thickness of the fill material unit is increased to improve cooling effectiveness, then the heat exchange capability is improved, but the air resistance and device complexity increase
Solution Approach 1:
The fill material unit is segmented into three functional layers, each with specific through hole patterns. This segmentation allows for optimized air flow paths and water distribution without requiring excessive overall thickness. The structured segmentation provides clear functional zones that simplify the design and manufacturing process compared to attempting to achieve the same performance with a monolithic thick structure.
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 design improves cooling efficiency, reduces material and energy consumption, and maintains consistent heat transfer performance across the cooling tower, addressing the limitations of conventional systems.
Implementation Method 1
the ambient air and the water film are arranged to perform heat exchange so that the ambient air will extract heat from the thin water film
Implementation Method 2
The water falling on the fill material unit 16P naturally moves in a top-down manner along the fill material unit 16P and forms a thin water film therein
Data Source
AI summary
A cooling tower includes a tower casing, a pumping device, a water storage tank, at least one cooling assembly and a fan unit. The cooling assembly includes a first multiple-layer cooling unit comprising a first water collection basin, a first fill material unit provided underneath the first water collection basin, and a first water receiving basin provided underneath the first fill material unit and connected to the water storage tank. The second multiple-layer cooling unit includes a second water collection basin connected to the water storage tank, and a second fill material unit provided underneath the second water collection basin. The cooling water in the second water collection basin is arranged to be distributed on the second fill material unit. The water flowing in the second water collection basin is collected in the water storage tank.