UET Reactor Solids Removal in Heat Exchanger Cooling Loops
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Solution Overview
Problem
In heat exchanger systems, suspended solids and minerals precipitate and settle, leading to reduced heat transfer efficiency and blockages due to inadequate water velocity and contamination from ambient air, causing sedimentation and scale formation.
Innovation Solution
A method involving a pump with calculated flow rate and head, a UET Reactor for electro-coagulation, and a solid separator device to maintain critical velocity and remove suspended solids through partial electrolysis and coagulation, ensuring continuous cleaning and preventing sedimentation within the heat exchanger.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If water velocity is reduced by control valves or variable speed drive, then energy consumption is reduced, but suspended solids settle and form sedimentation
Solution Approach 1:
The system performs preliminary action by maintaining a minimum critical velocity in the heat exchanger even during low-flow conditions, and by using electro-coagulation to pre-treat the water before it enters the heat exchanger. This prevents solids from settling in the first place, allowing energy reduction without sacrificing reliability.
Solution Approach 2:
The system changes parameters by introducing electro-coagulation to alter the physical-chemical state of suspended solids, transforming them from stable suspensions into coagulated particles that can be easily removed. This allows the system to operate at lower velocities without sedimentation, as the coagulated particles settle more efficiently in the separator.
2Temperature
If control valves are used to regulate water flow, then temperature control is improved, but suspended solids settle and block pipes
Solution Approach 1:
The system introduces an intermediary treatment process (electro-coagulation reactor) between the pump and the heat exchanger. This intermediary device coagulates suspended solids before they can settle in the heat exchanger or pipes, eliminating the harmful blocking effect while preserving the necessary flow control for temperature regulation.
Solution Approach 2:
The system extracts suspended solids from the water stream using a solid-liquid separator that removes coagulated particles before the water enters the heat exchanger. This extraction prevents solids from causing blockages in the heat exchanger and pipes, allowing control valves to function properly for temperature control without generating harmful sedimentation.
3Temperature
If cooling tower operates with ambient air, then cooling efficiency is improved, but dust and dirt contaminate the water system
Solution Approach 1:
The system converts the harmful effect of dust contamination into a benefit by using electro-coagulation to target and remove not only dust particles but also all suspended solids. The same mechanism that addresses dust also handles other contaminants, transforming the contamination problem into an opportunity for comprehensive water purification that protects the heat exchanger.
4Use of energy by moving object
If water circulation is stagnant, then pump energy consumption is reduced, but solids precipitate and form scale
Solution Approach 1:
The system performs preliminary action by continuously treating water with electro-coagulation and removing solids through the separator, even during low-flow or stagnant conditions. This preliminary maintenance prevents scale formation and keeps the heat exchanger clean, allowing the pump to operate at lower energy consumption without sacrificing heat transfer performance.
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 method effectively maintains the heat exchanger clean by removing suspended solids and preventing sedimentation, ensuring uninterrupted operation and improved heat transfer performance by directing coagulated solids outside the system.
Implementation Method 1
A partial electrolysis reactor, the UET ReactorTM, which reacts with the excess of minerals and creates an electro-coagulation process
Implementation Method 2
A partial electrolysis reactor, the UET ReactorTM, which reacts with the excess of minerals and creates an electro-coagulation process
Implementation Method 3
A solid separator device is equipped with pipes that direct the velocity of the water in a way that coagulated solids will settle in it
Data Source
AI summary
A method for solids removal in heat exchanger systems includes a first water flow path from a heat exchanger to a cooling tower and back to the heat exchanger, including: forming an additional path in parallel with the first path, wherein water flows from the heat exchanger to a UET reactor and back to the heat exchanger, and wherein the UET reactor including means for solids removal from the water using a partial electrolysis process. Optionally, the volumetric flow rate in the additional path is about 5% of the volumetric flow rate in the first water flow path.