ORC Cooling System for Heat-Generating Devices
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Solution Overview
Problem
Existing cooling systems for heat-generating devices require electrical or mechanical energy to extract thermal energy from process fluids, which is inefficient, and they lack emergency running capabilities and modular flexibility.
Innovation Solution
A thermodynamic cycle device, such as an Organic Rankine Cycle (ORC) system, is integrated to convert heat into mechanical and/or electrical energy, with additional heat exchangers for backup cooling and modular design to ensure continuous operation and efficient energy use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a conventional air cooler with electrically or mechanically driven fans is used to cool the process fluid, then the cooling function is achieved, but electrical or mechanical energy is consumed to extract thermal energy from the process
Solution Approach 1:
The patent converts the waste heat from the process fluid, which was previously a useless byproduct requiring energy-intensive active cooling, into a useful resource that drives the thermodynamic cycle device to generate mechanical and/or electrical energy. The heat that needed to be removed is now the driving force for energy production, transforming a harmful thermal load into a beneficial energy source.
Solution Approach 2:
The system uses the process fluid's own heat content to drive the cooling process indirectly. The thermodynamic cycle device utilizes the thermal energy from the process fluid to generate power, which can then be used to operate auxiliary cooling equipment or other system components, making the system partially self-sufficient and reducing external energy requirements.
2Loss of energy
If a thermodynamic cycle device is integrated to convert heat into mechanical and/or electrical energy, then energy efficiency is improved and useful power is generated, but the device complexity increases
Solution Approach 1:
The heat exchanger serves multiple functions: it cools the process fluid by removing thermal energy and simultaneously heats the working medium of the thermodynamic cycle device to generate power. This multi-functionality reduces the need for separate heating and cooling equipment, thereby reducing overall system complexity despite the addition of the thermodynamic cycle components.
Solution Approach 2:
The patent merges the cooling function and power generation function into a single integrated system. The thermodynamic cycle device is coupled with the process fluid cooling system, combining what would traditionally be separate operations into one unified arrangement, which simplifies system architecture and reduces the number of independent components required.
3Temperature
If additional heat exchangers are added to maintain target temperature with the thermodynamic cycle device, then the target temperature of the process to be cooled is maintained, but the device complexity increases
Solution Approach 1:
The heat exchanger is designed to perform multiple functions simultaneously: cooling the process fluid to the target temperature and heating the working medium for power generation. This multi-functionality eliminates the need for additional separate heat exchangers that would otherwise be required for heating operations, maintaining temperature control without proportionally increasing system complexity.
4Loss of energy
If the thermodynamic cycle device is used for cooling, then useful mechanical and/or electrical energy is generated, but the reliability of the cooling system decreases due to potential failure of the cycle device
Solution Approach 1:
The system incorporates backup cooling arrangements that are activated when the thermodynamic cycle device fails or is shut down. This prior cushioning ensures that the process cooling function is maintained through alternative means, preventing complete system failure and ensuring continuous operational reliability despite the vulnerability of the integrated thermodynamic cycle.
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 ORC system enhances energy efficiency by generating useful power while maintaining target temperatures, provides emergency running capabilities, and allows for modular expansion of cooling capacity without increasing maintenance or complexity.
Implementation Method 1
an evaporator (20) with an inlet (21) for supplying the process fluid to be cooled from the outlet (11) of the heat-generating device (10) and with an outlet (22) for discharging the cooled process fluid to the inlet (12) of the heat-generating device (10), wherein the evaporator (20) is designed to evaporate a working medium of the thermodynamic cycle device using heat from the process fluid
Implementation Method 2
evaporate a working medium of the thermodynamic cycle device using heat from the process fluid
Implementation Method 3
an expansion machine (30) for expanding the evaporated working medium and for generating mechanical and/or electrical energy
Implementation Method 4
a condenser (50) for condensing the expanded working medium
Implementation Method 5
a pump (60) for transporting the condensed working medium to the evaporator (20)
Data Source
Figure 1~2A
Figure 2B~2C
Figure 3~4
AI summary
The invention relates to a system for cooling a process fluid of a heat-generating device, comprising: an outlet of the heat-generating device (10), wherein the outlet (11) is provided for discharging process fluid to be cooled from the heat-generating device; an inlet (12) of the heat-generating device, wherein the inlet is provided for supplying cooled process fluid to the heat-generating device; and a thermodynamic cycle device, in particular an ORC device, wherein the thermodynamic cycle device comprises: an evaporator (20) with an inlet for supplying the process fluid to be cooled from the outlet of the heat-generating device and with an outlet for discharging the cooled process fluid to the inlet of the heat-generating device, wherein the evaporator is configured for evaporating a working medium of the thermodynamic cycle device by means of heat from the process fluid;an expansion machine (30) for expanding the evaporated working medium and for generating mechanical and/or electrical energy; a condenser (50) for liquefying the expanded working medium, in particular an air-cooled condenser; and a pump (60) for pumping the liquefied working medium to the evaporator.