Water-Cooled Condenser Pans to Prevent Coil Corrosion and Scale
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Solution Overview
Problem
Evaporative condensers in refrigeration and air-conditioning systems have a short lifespan due to corrosion from direct water contact and suffer from scale deposition issues that reduce heat transfer efficiency and are difficult to maintain.
Innovation Solution
The evaporative condenser design prevents direct contact between cooling water and refrigeration coils, using water pans with non-stick coatings to collect scale, which can be easily removed, and incorporates a water level control system to manage water supply efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If cooling water is directly sprayed on the evaporative condenser, then cooling efficiency is improved, but the condenser lifespan is reduced due to corrosion
Solution Approach 1:
The patent introduces an intermediary substance (absorbent material such as cellulose, paper, or fabric) that mediates between the cooling water and the condenser surface. This absorbent material absorbs water and transfers cooling effect through evaporation without allowing direct water contact with the condenser, thereby maintaining high cooling efficiency while preventing corrosion and extending lifespan.
2Use of energy by stationary object
If cooling water is used to cool the condenser, then energy consumption is reduced, but scale deposition increases and is difficult to remove
Solution Approach 1:
The absorbent material serves as an intermediary that prevents scale from depositing on the condenser surface. Scale forms on the absorbent material instead, which can be easily removed or replaced without damaging the condenser or requiring complex cleaning procedures.
Solution Approach 2:
The patent treats the absorbent material as a disposable component that can be easily replaced. Rather than attempting to remove scale from the condenser, the entire absorbent material becomes saturated with scale and is simply replaced, significantly reducing maintenance complexity and cost.
3Productivity
If water is continuously supplied to the evaporative condenser, then cooling performance is maintained, but water consumption increases
Solution Approach 1:
The patent incorporates a feedback mechanism through float valves or level sensors that monitor water levels in the condenser or collection pan. When water reaches a certain level, the feedback system automatically stops water supply, preventing over-saturation and reducing unnecessary water consumption while maintaining adequate cooling performance.
Solution Approach 2:
The absorbent material has a finite capacity to absorb water, and the system naturally self-regulates water uptake. Once the absorbent material is saturated, it cannot absorb more water, which automatically limits water consumption without requiring active control mechanisms.
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 extends the lifespan of evaporative condensers, prevents corrosion, and facilitates easy scale removal, enhancing energy efficiency and reducing maintenance challenges.
Implementation Method 1
The water absorbs heat to make water vaporize into the air in a process known as evaporation, which is a natural physical phenomenon where water absorbs heat energy to change water from the liquid phase to vapor phase, resulting in a lower temperature.
Implementation Method 2
cool the hot refrigeration coil by transferring heat from the hot refrigerant to the cooling water
Data Source
AI summary
The refrigeration system of this invention utilizes a water cooled condenser which is made of multiple water pans with refrigeration coil soldered underneath for multi-stages cooling. The water pans are stacked on top of each other with the hottest coil located at the bottom. The bottom water pan dries up water faster than the other water pans since it has the hottest coil soldered underneath. Once the water level of the bottom water pan is low enough to be refilled, the supply water fills in from the top water pan and propagating downward to the water pan down below until it reaches the water pan at the bottom. The water refilling ceases once the bottom water pan is full. The unwanted heat from a refrigeration system is transferred from the refrigerant to the water, and then from the water to the air by evaporation.