Multi-stage water distribution system for cross-flow evaporative heat exchanger
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Solution Overview
Problem
Indirect evaporative cooling systems face inefficiencies in distributing water evenly across heat exchanger surfaces, leading to incomplete wetting and reduced evaporative effect, especially in large heat exchangers with varying temperature and humidity conditions, which affects cooling capacity and water consumption.
Innovation Solution
A multi-stage water distribution system with strategically positioned spray nozzles and fans that activate based on outdoor temperature thresholds, ensuring uniform water distribution across sub-heat exchangers, optimizing cooling capacity while minimizing water consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If water is sprayed uniformly across the entire heat exchanger surface, then evaporative cooling effect is improved, but water consumption increases
Solution Approach 1:
The system divides the heat exchanger into multiple zones and applies water spray selectively to specific zones based on their cooling needs. The controller activates only certain nozzles (first nozzle or both first and second nozzles) depending on outdoor temperature conditions, ensuring water is applied where most needed rather than uniformly across the entire surface.
Solution Approach 2:
The water distribution system is segmented into multiple nozzles positioned at different locations on the heat exchanger. This segmentation allows independent control of water application in different zones, enabling the system to optimize water usage by activating only the necessary nozzles under different operating conditions.
2Productivity
If multiple nozzles are activated simultaneously, then cooling performance increases, but water consumption increases
Solution Approach 1:
The system dynamically adjusts the number of active nozzles based on outdoor temperature conditions. The controller activates only the first nozzle when outdoor temperature is below the threshold, and activates both first and second nozzles when outdoor temperature exceeds the threshold, creating a dynamic water distribution strategy that adapts to environmental conditions.
Solution Approach 2:
The system changes the operational parameters (number of active nozzles) based on the outdoor temperature parameter. By monitoring the outdoor temperature against a predetermined threshold, the system adjusts water distribution intensity to match the cooling demand, optimizing both cooling performance and water consumption.
3Temperature
If water spray is applied at high intensity, then evaporative cooling effect is enhanced, but water consumption increases
Solution Approach 1:
The system applies water spray at targeted locations rather than excessive coverage. By activating only the necessary nozzles based on outdoor temperature conditions, the system applies just enough water to achieve the required cooling effect without excessive water usage, maintaining optimal cooling efficiency while conserving water.
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 enhances cooling capacity by selectively wetting critical areas of the heat exchanger, achieving up to 27% increase in cooling performance with reduced water usage, and adapts to varying environmental conditions for efficient energy management.
Implementation Method 1
a thin water film is applied over the heat exchanging surfaces of the heat exchanger typically with a water spray system. By spraying water on the heat exchanger, the water can absorb the heat within the heat exchanger and evaporate it to the outdoor air
Implementation Method 2
Such systems use fans to move cold outside air across an air-to-air heat exchanger, which in turn cools the hot data center air on the inside of the heat exchanger
Data Source
Figure 1~2C
Figure 3A~5
Figure 6~7
AI summary
A heat exchange system includes a first heat exchanger subassembly, a second heat exchanger subassembly, a first nozzle configured to spray fluid at the first heat exchanger subassembly, and a second nozzle configured to spray fluid at the second heat exchanger subassembly. The heat exchange system further includes memory storing controllerexecutable instructions and a controller configured to execute the instructions, which cause the controller to activate the first nozzle when an outdoor temperature is below a threshold temperature, and activate the first nozzle and the second nozzle when the outdoor temperature is above the threshold temperature.