Process for enhanced closed-circuit cooling system
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Solution Overview
Problem
Existing closed-circuit cooling liquid systems for gas streams are costly and inefficient due to high power consumption and capital costs, primarily because of the complexity of air coolers and lack of evaporative cooling, which results in excessive energy use and operational expenses.
Innovation Solution
A closed-circuit cooling liquid system is designed with a heat exchanger and air cooler where the cooling liquid temperature increases, then cooled back to its initial temperature using an air cooler with a surface area ratio optimized to reduce energy consumption and capital costs, featuring a pump and conduits for continuous circulation, and optionally using multiple heat exchangers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a closed-circuit cooling liquid system is used to cool gas streams, then water loss is reduced, but power consumption and capital costs increase significantly
Solution Approach 1:
The patent merges the gas cooling function and liquid cooling function into a single heat exchanger unit. The gas stream is cooled by the cooling liquid in the same equipment where the cooling liquid is subsequently cooled by air, eliminating the need for separate cooling systems and reducing overall power consumption while maintaining water conservation benefits
Solution Approach 2:
The heat exchanger serves multiple functions: it cools the gas stream using the cooling liquid, and then cools the cooling liquid itself using air. This multi-functional design reduces the need for additional cooling equipment and lowers capital and operating costs while maintaining the closed-circuit water conservation advantage
2Loss of substance
If a closed-circuit cooling liquid system is used, then water loss is reduced, but capital costs increase due to additional equipment complexity
Solution Approach 1:
The patent combines the gas cooler and liquid cooler into a single integrated heat exchanger unit, reducing the number of separate equipment components. This integration simplifies the overall system configuration while maintaining the closed-circuit water conservation benefits
Solution Approach 2:
The heat exchanger is designed to perform multiple cooling functions simultaneously - cooling the gas stream and cooling the cooling liquid. This multi-functional design eliminates the need for additional specialized equipment, reducing capital costs and simplifying the system
3Loss of substance
If a closed-circuit cooling liquid system is used, then water loss is reduced, but the system footprint and equipment size increase
Solution Approach 1:
The patent merges two cooling functions into one compact heat exchanger unit, reducing the total equipment footprint. By eliminating the need for separate gas cooler and liquid cooler equipment, the system occupies less space while maintaining water conservation advantages
4Temperature
If conventional heat exchanger design is used, then cooling duty is met, but discharge temperature is too low requiring excessive cooling capacity
Solution Approach 1:
The patent changes the design parameters of the heat exchanger, specifically allowing a higher discharge temperature (up to 120°C) from the gas cooling section. This parameter change reduces the temperature differential required in the liquid cooling section, thereby reducing the overall cooling capacity needed and lowering system costs
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 achieves a lower operating power demand and reduced capital costs by optimizing the surface area ratio of the air cooler to the heat exchanger, allowing for higher temperature differences and reduced water loss, corrosion, and fouling, leading to substantial power reductions and cost savings.
Implementation Method 1
a heat exchanger in which a gas stream is cooled against a cooling liquid
Implementation Method 2
at least one air cooler for cooling the cooling liquid after passing through the at least one heat exchanger
Data Source
AI summary
An apparatus and method for cooling a gas stream is provided comprising at least one heat exchanger in which a gas stream is cooled against a cooling liquid, whereby the cooling liquid temperature increases from a first temperature to a second temperature, at least one air cooler for cooling the cooling liquid after passing though the at least one heat exchanger, surface area of the at least one air cooler being designed to decrease temperature of the cooling liquid to the first temperature; a pump; and conduits to form a closed-circuit for the cooling liquid to pass continuously through the at least one heat exchanger and the at least one air cooler. The ratio of surface area of the at least one air cooler to the surface area of the at least one heat exchanger is optionally 12 or lower, and the difference of temperature between the second temperature and first temperature being greater than 15° C.