Softened Makeup Water Control for Cooling Systems
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Solution Overview
Problem
Existing cooling systems face challenges in managing mineral concentration, leading to fouling and increased water consumption due to the need for frequent blowdown, which is costly and environmentally impactful, especially when outdoor installations of water softening equipment complicate and increase installation and maintenance costs.
Innovation Solution
An apparatus and method that includes an open recirculating cooling system with a blowdown system, unsoftened and softened makeup water sources, and a controller that proportionally adds softened makeup water based on cycles of concentration and conductivity levels, simplifying indoor installation and reducing water usage by optimizing mineral management within the system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If outdoor installation of water softening equipment is used, then water consumption is reduced, but installation and maintenance costs increase
Solution Approach 1:
The water softening equipment is extracted from the outdoor environment and relocated indoors, specifically positioned in or near the chiller room. This extraction eliminates the need for outdoor softener installation while maintaining the water consumption benefits, thereby reducing installation and maintenance complexity.
Solution Approach 2:
A proportional control system acts as an intermediary between the softened water source and the cooling system. This controller monitors cycles of concentration and conductivity levels, automatically regulating the addition of softened water to optimize mineral management without requiring complex outdoor installation infrastructure.
2Reliability
If frequent blowdown is performed to prevent fouling, then system reliability is maintained, but water consumption increases
Solution Approach 1:
Water softening is performed preliminarily on the makeup water before it enters the cooling system. By pre-removing hardness minerals from the makeup water source, the system can operate at higher cycles of concentration without experiencing rapid fouling, thereby reducing the frequency of blowdown operations and conserving water.
Solution Approach 2:
The system incorporates conductivity sensors that provide feedback on water quality conditions. This feedback mechanism allows the proportional control system to monitor cycles of concentration in real-time and automatically adjust the addition of softened water, optimizing the balance between preventing fouling and minimizing water consumption.
3Loss of substance
If cycles of concentration are increased to reduce blowdown, then water consumption is reduced, but mineral concentration limits are approached
Solution Approach 1:
The system changes the chemical parameters of the makeup water by applying softening treatment, which removes hardness minerals and alters the mineral composition. This parameter change allows the cooling system to operate at higher cycles of concentration without reaching saturation limits, as the softened water has reduced mineral content that would otherwise contribute to scaling and fouling.
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 solution reduces installation costs, minimizes water consumption, and enhances system reliability by allowing for more efficient cycles of concentration, thereby reducing the need for frequent blowdown and minimizing waste water, while ensuring safe operation by preventing over-purification.
Implementation Method 1
A water softener removes the hardness from water, usually by means of ion exchange
Implementation Method 2
use of a conductivity sensor that monitors low conductivity as a function of system control
Data Source
AI summary
An apparatus introduces partially-purified, softened makeup water into an open recirculating cooling system by injecting proportionated softened makeup water into a secondary side system (such as for filtering the system water) and connected to its primary recirculating system. Proportional unsoftened makeup water is introduced through the secondary side system lines. In particular, the present apparatus and method includes controlling proportional additions (via batch or continuously) of softened and unsoftened makeup water based on cycles of concentration of the system water, and based on characteristics (e.g. conductivity) of the unsoftened makeup water. For example, the present innovation allows the water softener equipment to be placed inside the building where components are easier to install, service, and maintain, while still resulting in optimal control for purposes of minimizing total makeup water required. This results in a more environmentally friendly system with less water usage and installation/maintenance savings.