Open-Sided Liquid Collection Assembly for Cooling Tower Airflow
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Solution Overview
Problem
Conventional industrial cooling towers face issues with air diffusion inefficiency due to non-uniform air flow distribution and maintenance challenges related to large liquid collection basins, which affect thermal performance and increase maintenance costs.
Innovation Solution
A liquid collection assembly with elongated, open-sided surface elements positioned above fans in the tower housing, directing liquid into gutters and allowing uniform air diffusion through the cooling media, reducing pressure drop and enhancing thermal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional large bottom sumps are used to collect falling water, then the system can contain enough liquid to charge the system and allow particles to settle out, but the large volume of liquid increases the weight of the system and increases rooftop loading
Solution Approach 1:
The liquid collection system is segmented into multiple small collection troughs distributed throughout the tower rather than using a single large bottom sump. Each trough collects liquid locally and directs it to gutters, eliminating the need for a large centralized collection basin and reducing overall system weight.
Solution Approach 2:
The collection troughs are positioned at multiple vertical levels within the tower housing, transforming the liquid collection from a single-point bottom collection to a distributed multi-level collection system. This dimensional distribution allows efficient liquid collection without requiring a large bottom sump volume.
2Ease of manufacture
If conventional collection troughs with sloping plate members are used, then liquid can be collected and directed to gutters, but air flow is blocked or limited on wall areas and much of the air is forced to one side of the tower
Solution Approach 1:
The collection troughs are designed with selective properties: they are highly effective at liquid collection where needed, but intentionally open-sided to allow air passage. Each trough's geometry is optimized locally to balance liquid collection efficiency with air flow permeability, rather than using uniform solid construction throughout.
Solution Approach 2:
The collection troughs function as porous structures that allow air to pass through while still effectively collecting liquid. The open-sided design creates a porous-like effect where the trough walls are permeable to air flow but remain effective at intercepting and directing liquid to gutters.
3Ease of manufacture
If the liquid collection assembly is positioned below the fill media, then liquid can be collected and directed to gutters, but the fans may be exposed to environmental elements and liquid
Solution Approach 1:
The liquid collection assembly acts as an intermediary barrier positioned between the fill media and the fans. It collects liquid falling from the fill media and directs it to gutters before the liquid can reach the fans, thereby protecting the fans from liquid exposure while maintaining effective liquid collection.
Solution Approach 2:
The liquid collection function is extracted from the traditional bottom sump location and repositioned to a higher position within the tower housing, directly below the fill media. This extraction allows liquid to be removed from the system at an intermediate point, protecting downstream components (fans) from liquid exposure.
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 improves air-to-liquid mixing efficiency, reduces maintenance costs by protecting fans from environmental elements, and extends their service life, while also simplifying the manufacturing process.
Implementation Method 1
The surface elements are elongated, open sided members that provide one or more planar or curved surfaces on which liquid falls and adheres to due to surface tension
Implementation Method 2
The surface elements are angled so gravity is utilized to carry the liquid down the surface elements and into one of the gutters
Implementation Method 3
The fans force air directly upward in the tower
Implementation Method 4
evaporative cooling media, or liquid cooling coils
Implementation Method 5
evaporative coolers
Data Source
AI summary
An apparatus has a housing with at least one gutter, a body of fill material disposed in the housing, a liquid distribution system disposed in the housing and positioned above the fill material, a fan positioned below the body of fill material for blowing air upward through the fill material, a liquid collection assembly positioned between the fill material and the fan for collecting the liquid gravitating through the fill material. The liquid collection assembly has at least one troughless, open sided surface element angled so gravity is utilized to capture the down flowing liquid to provide a barrier between the fill media and the fan and to carry the liquid down the surface element and into the at least one gutter.