Phase-Change Condenser Design for High-Capacity Supercomputer Cooling
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Solution Overview
Problem
Current condensers, such as shell-and-tube-exchange heaters and finned tube heat exchangers, fail to meet the high refrigerating capacity requirements of supercomputers due to inefficient heat exchange processes and large temperature differences, limiting their effectiveness in data centers.
Innovation Solution
A high-efficiency phase-change condenser design featuring a condenser box with a snakelike condensing coil, where a portion is immersed in liquid refrigerant and another portion is in the gas-phase region, enhancing heat exchange efficiency by allowing vapor bubbles to be cooled directly by liquid and further by the condensing coil, thereby increasing the heat exchange area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional air cooling or conventional liquid cooling (shell-and-tube-exchange heaters, finned tube heat exchangers) is used, then the cooling system is simple in structure, but the heat exchange efficiency is low and the refrigerating capacity is insufficient for supercomputers
Solution Approach 1:
The patent utilizes phase change of refrigerant between liquid and gas states to enhance heat exchange efficiency. The refrigerant evaporates at the evaporator to absorb heat from the cooling object, then condenses at the condenser to release heat, leveraging the latent heat of vaporization and condensation for high-capacity cooling suitable for supercomputers
Solution Approach 2:
The cooling system is divided into distinct functional modules: evaporator, condenser, expansion valve, and refrigerant circulation path. This segmentation allows each component to be optimized for its specific function while maintaining overall system efficiency and enabling independent maintenance of individual components
2Productivity
If indirect contact cooling (air cooling) is used, then the system structure is simple, but the heat exchange efficiency is low due to large temperature difference and thermal resistance
Solution Approach 1:
The patent employs liquid refrigerant circulation instead of air cooling, utilizing the superior thermal conductivity and specific heat capacity of liquids. The refrigerant directly contacts heat sources through the evaporator and exchanges heat efficiently with the environment through the condenser, eliminating the thermal resistance issues of air cooling
Solution Approach 2:
By utilizing phase change of the refrigerant (evaporation and condensation), the system achieves high heat exchange efficiency. The latent heat absorbed during evaporation and released during condensation enables effective heat transfer with minimal temperature difference, reducing thermal resistance losses
3Productivity
If conventional heat exchangers are used, then the device is simple to manufacture, but the heat exchange area is insufficient and refrigerating capacity cannot meet supercomputer requirements
Solution Approach 1:
The system leverages phase change of refrigerant to maximize heat exchange capacity within limited space. The evaporator and condenser are designed to facilitate efficient phase transitions, allowing large amounts of heat to be transferred through relatively small heat exchange areas due to the high latent heat of the refrigerant
Solution Approach 2:
The patent optimizes the spatial arrangement of heat exchange components, utilizing three-dimensional space efficiently. The evaporator and condenser are positioned and configured to maximize heat exchange surface area within the available volume, and the refrigerant circulation path is designed to ensure thorough heat exchange throughout the system
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 significantly improves heat exchange efficiency within a limited space, achieving higher refrigeration capacity and efficiency by breaking vapor bubbles into smaller areas for direct cooling and utilizing both liquid and gas-phase cooling mechanisms.
Implementation Method 1
in the gas-phase region, refrigerant vapor bubbles are liquified by the condensing coil
Implementation Method 2
completely condense liquid-phase and gas-phase saturated refrigerants by the condensing coil
Implementation Method 3
most of the vapor bubbles will be directly cooled by liquid, heat exchange efficiency between the vapor and the liquid is higher
Implementation Method 4
Evaporative cooling is, based on thermology principle, to take away heat by latent heat of vaporization when the refrigerant is boiling
Data Source
AI summary
The application relates to a high-efficiency phase-change condenser for a supercomputer, including a condenser box body, a refrigerant input pipe, a refrigerant output pipe and a condensing coil; a liquid refrigerant accommodated in the condenser box body, and a gas-phase region existing between a liquid level of the liquid refrigerant and a top of the condenser box body; one portion of the condensing coil immersed into the liquid refrigerant, and the other portion of the condensing coil located in the gas-phase region above the liquid level of the liquid refrigerant; and in the gas-phase region, refrigerant vapor bubbles are liquified by the condensing coil. Liquid-phase and gas-phase saturated refrigerants can be completely condensed by the condensing coil in a limited condenser space, thereby improving heat exchange efficiency of the condenser.