INDUSTRIAL COOLING SYSTEM TO CONTROL THE WATER TEMPERATURE OF THE PROCESS USING A HYBRID OF AIR-COOLED AND WATER-COOLED PHASES

The invention is an industrial cooling system to control the temperature of the water coming back from the process using a hybrid of air-cooled and water-cooled phases related to the cooling systems, including heat exchangers to reduce and control the temperature of the fluids. This invention is also a hybrid system of air-cooled and water-cooled heat exchangers and heat exchangers immersed in water, and features intelligent control of the fluids entering the process reactors. The invention is a type of cooling tower based on heat exchanges between the hot fluid and ambient air as a cooling fluid and also heat transfer from hot fluid passageways with cooler fluids such as water or cooled air with the help of water. The fluid enters a round trip cycle by entering the tube network and finned tubes of the main heat exchanger.

THE TECHNICAL FIELD OF THE INVENTION

The present invention is related to the cooling systems, including heat exchangers, in order to reduce and control the temperature of fluids. It is also related to the hybrid system of air cooled and water cooled heat exchangers and heat exchangers immersed in water, and also to the intelligent control of fluids entering the process reactors as well as optimum water consumption systems in cooling towers using intelligent control systems as well as hybrid systems of floor exchangers.

THE TECHNICAL PROBLEM OF THE INVENTION

In this industry, and in particular in chemical industries related to energy, controlling the temperature of the process is an incurring challenge. Depending on the location of various industries in latitudinal and longitudinal terms, as well as the altitude above sea level of the location of the desired industries or the relative humidity of the environment, controlling the temperature of the fluids of the process is done in different ways. In most methods, the amount of consumed electricity or water is very high, and causes environmental damage in addition to heightened costs of operation.

PRIOR ARTS

In older methods, conventional exchangers such as air cooled fin tube exchangers or heat exchangers using transmission of temperature from one fluid to another are used. By improving the common techniques in temperature control, both cooling efficiency and the amount of energy consumption, especially the water consumption of cooling systems, have been taken into consideration. In hot and dry zones where available water is limited, water consumption levels can be one of the main challenges of controlling the temperature of the process. For this purpose, the hybridization of different technologies in the process of controlling the temperature of the process-cooling liquid has been taken into consideration by industrialists. Among the cases provided in the field of technology, the following inventions can be mentioned:

A Korean patent No. KR200315236Y1 which is dated Jun. 2, 2003 titled “Hybrid cooling tower” relates to a hybrid cooling tower, comprising of: a casing with an air supply port through which air is introduced and an exhaust port through which air is discharged, forming a heat exchange region therein: a blowing fan for discharging the air introduced through the air supply port to the exhaust port; A first heat exchanger provided in a zone adjacent to the exhaust port in the casing to allow the coolant and the air to face each other and exchange heat; A second heat exchanger provided in a lower region of the first heat exchanger to exchange heat between the cooling water passing through the first heat exchanger and the air introduced from the air supply port; A flow guide member provided in the heat exchange zone and guiding cooling water and air flowing through the first heat exchange part and the second heat exchange part; A sprinkling unit for supplying high-temperature cooling water to the first heat exchange unit and the second heat exchange unit; An eliminator for recovering water droplets scattered through the exhaust port into the casing, and a water collection tank for collecting and discharging the water cooled through the first heat exchange unit and the second heat exchange unit.

A US patent with publication No. US20200158439A1 which is dated Sep. 23, 2015 titled “Hybrid wet/dry cooling tower and improved fill material for cooling tower” provided a hybrid wet/dry cooling tower and novel splash fill material. In one embodiment, the cooling tower includes a wet cooling section having a draft fan above it for drawing air through the wet section to cool liquid traversing the wet section. The cooling tower also includes a dry cooling section disposed laterally adjacent to the wet section and configured to enable the draft fan to draw air through the dry section. In another embodiment, the dry cooling section has one or more added draft fan(s) for drawing air through the dry section with or without the operation of the draft fan disposed above the wet section. In other embodiments, different structures and configurations of plastic splash fill material are described.

A European patent No. EP3289300B1 which is dated May 1, 2019 titled “Hybrid cooling tower” is a hybrid cooling tower comprising of a tower shell being supported by legs above ground level, providing an air intake between ground level and a lower edge of the tower shell, a wet cooled segment arranged inside of the tower shell and having wet cooling cells arranged at a distance from the tower shell and receiving cooling air through the air intake and via first louvers, wet fans arranged on top of the wet cells for inducing upwards humid air exhaust flow; a dry cooled segment being arranged outside of the tower shell above said air intake for wet cells, the dry cooled segment having air coolers being arranged as vertical cooling deltas around the tower shell equipped with second louvers for controlling cooling air inlet, the dry cooled segment being supported by cooling delta legs, the tower shell having inlet openings arranged along the dry cooled segment for the air warmed up by the dry cooled segment.

A Korean patent No. KR101357243B1 which is dated Jan. 28, 2014 titled “Hybrid cooling tower” is a hybrid cooling tower in which the hot feed water generated while cooling the target object is injected into the cooling tower to pass the hot feed water, which is moved before the cooling operation, into the cooling tower. By cooling the collected water to the target object, the cooling water is remarkably cooled, and the recovery rate of the evaporated water discharged from the cooling tower is improved to minimize the loss of cooling water and to release the dried air to the outside where possible. The present invention relates to a hybrid cooling tower capable of maximally suppressing external scattering of white smoke generated in a cooling tower.

A Chinese invention with application No. CN108469187A which is dated May 30, 2018 titled “The air-cooled clammy hybrid cooling tower of thermic load self-balancing” is a kind of air-cooled clammy hybrid cooling tower of thermic load self-balancing provided which belongs to circulating water cooling device technical field. The aqueous vapor liquid cooling system structure design for solving the existing air-cooled clammy hybrid cooling tower is unreasonable. The overall structure is heavy, the actual motion energy consumption is higher. The air-cooled clammy hybrid cooling tower of thermic load is self-balancing, which is characterized in that described cold. But the tower body crossing current cooling zone aqueous vapor liquid cooling system is fitted with water transfer water collection agencies, and water transfer water collection agencies are aqueous vapor liquid cooling. But the system top is fitted with a catch basin equipped with adjustment: the first sparge pipe of water flowing control valve, lower part, catch basin by lower draft tube connects the collecting-tank of cooling tower body bottom or catch basin.

Another Korean invention with publication No. KR20100035838A which is dated Sep. 29, 2008 titled “Hybrid type cooling tower” relates to a hybrid cooling tower with improved heat exchange efficiency. The Hybrid cooling tower according to an embodiment of the present invention comprises an air chamber, an injection device, a first filler and a second filler. Here, the air chamber forms a body, but a first air inlet is formed on a pair of first side walls facing each other, and a second air inlet is formed on the second side walls connected to each of the first side walls to face each other. The addition is formed through. The injector is provided above the inside of the air chamber so that the cooling water at a high temperature is uniformly sprayed. The first filler is provided horizontally in the interior of the air chamber, and is installed below the injector so that primary heat exchange of the coolant and the air injected from the injector is performed. The second filler is provided on the lower side of the first filler, so that the secondary heat exchange of the incoming air is opposed to each other through the first air inlet and the second air inlet, and the first coolant first heat exchanged in the first filler.

A US invention with publication No. US20100018237A1 which is dated Jul. 28, 2008 titled “Low Water Consumption Cooling Tower for Gasification Plants” is a hybrid cooling tower and a method and system for using the cooling tower. The cooling tower is designed to reduce water consumption and eliminate plume formation. The cooling tower comprises a wet section having a plurality of wet section fans and a dry section having a plurality of dry section fans. The wet section fans are adjustable to operate at an increased rate and a reduced rate, depending upon ambient conditions surrounding the cooling tower. The wet section may comprise at least one shutter door. In operation, typically the wet section fans operate at the increased rate during a summer peak price period and at the reduced rate during a winter peak price period and an off-peak price period. Typically, the dry section fans operate at an increased rate all year. The plurality of nozzles are designed to spray high temperature water through the wet section cooling fill so that heat exchange may occur between the ambient air entering the wet section and the high temperature water.

Another European invention with publication No. EP2498037A2 which is dated Mar. 7, 2011 titled “Hybrid fan cooling tower” is a cooling tower apparatus that extends along a vertical axis. The cooling tower includes a first housing structure having an inlet and a first outlet located at a first position along the vertical axis, wherein the housing structure includes a base and opposing side walls that extend along the vertical axis away from the base. The tower also includes a heat exchanger disposed in the housing structure, where it is positioned adjacent to the first outlet and extends at least partially all the way across it. Finally, the hybrid tower employs an air current generator positioned in a plane normal to the vertical axis and oriented to direct an air stream toward the base and through the heat exchanger and the first outlet.

A Chinese invention with application No. CN107270733A which is dated May 12, 2017 titled “Double hybrid cooling towers of effect” is a kind of pair of hybrid cooling towers of effect, including a cooling tower, tank body, peripheral hardware radiating aluminum pipe and coolant circulation pump. The delivery port of the tank body is connected to one end of the coolant circulation pump, the other end of the coolant circulation pump is connected to the water inlet of peripheral hardware radiating aluminum pipe and the delivery port of the peripheral hardware radiating aluminum pipe is connected with the water inlet of the tank body. The water inlet pipe of the cooling tower is arranged between the coolant circulation pump and peripheral hardware radiating aluminum pipe, and the outlet pipe of the cooling tower is arranged between the delivery port of the peripheral hardware radiating aluminum pipe and the water inlet of the tank body.

Another Chinese invention with Patent No. CN202915744U which is dated May 1, 2013 titled “Hydroelectric hybrid cooling tower” discloses a hydroelectric hybrid cooling tower. The cooling tower comprises a tower body, a blower arranged at the top of a box body, a water turbine arranged in the inner chamber of the tower body and used for driving the blower to rotate, a water distributor and a filler arranged below the water distributor, and is characterized by further comprising a motor, a transmission, an automatic clutch, a hybrid power box, a temperature sensor and a control chip circuit board, wherein the transmission is connected between the motor and the automatic clutch; the automatic clutch is mounted between the transmission and the hybrid power box. The hybrid power box is mounted among the automatic clutch, the power output shaft of the water turbine and the power input shaft of the blower. A temperature sensor is arranged in a water collecting pool of the tower body; and the control chip circuit board is connected with the motor and the temperature sensor respectively. The benefits of the hydroelectric hybrid cooling tower include how the outlet water temperature of the cooling tower can be automatically detected, and when the outlet water temperature exceeds the set value, the motor drives the water turbine to rotate so as to improve the cooling efficiency of the water turbine.

In a German invention with patent No. DE19926665A1 which is dated Apr. 10, 2003 titled “Hybrid cooling tower assembly has a lower wet and an upper dry cooling section with direct air flow heat exchange at the bottom and upwards connecting flow windows/heat exchangers and closure control walls”, a hybrid cooling assembly has a lower wet cooling section where a fluid to be chilled, in a direct heat exchange with coolant air flowing in through openings. An upper dry cooling section has inflow windows and heat exchangers in the verticals over the openings of the lower wet cooling section. They carry the fluid to be chilled while coolant air flows into the hybrid cooling assembly. Control walls, in a plate shape, can close the openings and flow windows at least partially, to set the humidity level of the cool air outflows. At least one drive for the control walls is placed under the influence of a temperature-dependent regulation and control unit. Also on the inside of the control walls are provided cleaning fluid spray nozzles.

Another German invention with publication No. DE102008031219B3 which is dated Jun. 25, 2009 titled “Hybrid cooling tower, has mixing assembly comprising completely open trapezoidal lower surface and open rectangular output side, and openings arranged in trapezoidal side wall of mixing assembly” provided a tower which has a mixing chamber with a truncated pyramid shaped mixing assembly that extends transverse to an ascending airflow. The assembly guides another air flow towards the former airflow, and comprises a completely or predominantly open trapezoidal lower surface and an open rectangular output side. Three openings are arranged in a trapezoidal side wall of the mixing assembly. The mixing assembly is arranged in a chamber wall of the mixing chamber, where two of the openings are arranged directly opposite to each other.

A European invention with patent No. EP0968397B1 which is dated Dec. 11, 2002 titled “Hybrid cooling tower” relates to a cooling process in which the hot water to be cooled in one wet cooling section and the other partial quantity in a dry cooling section cooled by air. The hot water can also complete through the dry cooling section and then be led through the wet cooling section. In this invention above trickle furniture, a water distribution system extends over at least the main part of the tower cross-section, and comprises beneath the trickle furniture air inlet openings in the tower wall, further comprising above the water distribution system peripheral dry cooling elements subjected to a transverse flow of cooling air, a fan with a suction action incorporated in the tower outflow opening, and, in the region between the water distribution system, the dry cooling elements, and the fan, air mixing furniture, at least one portion of the water distribution system being disconnect able from the water supply.

A European invention with patent No. EP1314945B1 which is dated Jul. 26, 2006 titled “Arrangement of hybrid cooling towers” is an arrangement of several hybrid cooling towers, each composed of a wet part, comprising water distribution devices for the direct exchange of heat between cooling water and ambient air flowing laterally into the wet part; a dry part arranged above the wet part, comprising heat exchangers for the indirect exchange of heat between cooling water and ambient air flowing laterally into the dry part; and a common mixing chamber for the air leaving the wet part and the dry part. The cooling towers are arranged in two mutually substantially parallel rows, between which there is a clearance, with the width of the clearance, as measured between the mutually facing sides of the wet part, being less than three times the width of the wet part.

Another European invention with patent No. EP1314945B1 which is dated Apr. 10, 2013 titled “Hybrid cooling tower” relates to a hybrid cooling tower of a hybrid cooling system having a mixing chamber with at least one truncated pyramid-like mixing fixture transversely projected into a rising first air flow, which supplies a second air flow to the first air flow and comprises an open trapezoidal lower side and a complete or predominantly open rectangular outlet side, characterized in that at least one roof opening is arranged in a trapezoidal roof area of the mixing fixture, wherein means are provided to open and close the roof opening. The roof openings are at least partly opened at high ambient temperatures (summer mode) and at least partly closed on falling ambient temperatures (winter mode). The rectangularly formed horizontal cross section hybrid cooling tower has in a lower height range lateral inlet openings, via which cooling air enters the hybrid cooling tower.

A Japanese invention with patent No. JP5133601B2 which is dated Jan. 30, 2013 titled “Cooling tower system” is a cooling tower system for cooling water, including a blowing means for sending air used to cool the cooling water; a plurality of cooling means having water tanks for sprinkling the cooling water to be cooled, cooling the sprinkled cooling water with the air sent by the blowing means, and storing the cooled cooling water; the plurality of cooling means are connected in a line from upstream to downstream in the flow of cooling water in the cooling tower system, the cooling means excluding the most upstream cooling means takes cooling water from the water tank of the cooling means connected to the upstream side of the cooling means by using a water intake pump, and the cooling water is supplied by the air sent by the blowing means. Sprinkling water so that the position to be cooled is the same height among the plurality of cooling means, in the air blowing means, the air sent by the air blowing means sequentially passes through the plurality of cooling means from the downstream cooling means to the upstream cooling means in the cooling water flow in the cooling tower system, and blowing air in a direction orthogonal to the direction in which the cooling water sprayed by the cooling means flows, cooling tower system.

A Korean invention with patent No. KR100283743B1 which is dated Feb. 15, 2001 titled “A hybrid type cooling tower” relates to a cooling tower used for cooling water in a refrigeration, air conditioning apparatus or industrial heat exchanger. More specifically, the heat transfer performance is improved by expanding the heat transfer area of the filler, which greatly affects the performance of the cooling tower, to compensate for the shortcomings of conventional cooling towers, and by adopting a new ventilation method, the power and noise used for cooling is reduced. It relates to a hybrid cooling tower that can be reduced in size. At the bottom of the lower tank there is a tank for storing the cooling water, and the second filler is located at a predetermined height and positioned on the upper portion of the lower tank, a chamber which is a space surrounded by the second filler, and an agent installed between the second filler and the chamber to prevent water vapor from flowing into the chamber. The eliminator and louver which surround the periphery of the second filler prevent water from flowing out to outside and suck outside air, and the second filler.

Another Korean invention with patent No. KR100526758B1 which is dated Nov. 9, 2005 titled “Hybrid cooling tower” relates to a hybrid cooling tower, comprising: a casing having an air supply port through which air is introduced and an exhaust port through which air is discharged, and forming a heat exchange region therein; A blowing fan for discharging the air introduced through the air supply port to the exhaust port; A first heat exchanger provided in an area adjacent to the exhaust port in the casing to allow the coolant and the air to face each other and to exchange heat with each other; A second heat exchanger provided in a lower region of the first heat exchanger to exchange heat between the cooling water passing through the first heat exchanger and the air introduced from the air supply port; A flow guide member provided between the first heat exchange part and the second heat exchange part to guide coolant and air flowing through the first heat exchange part and the second heat exchange part; A sprinkling unit for supplying high temperature cooling water to the first heat exchange unit and the second heat exchange unit; An eliminator for recovering water droplets scattered through the exhaust port into the casing; and a water collecting tank for collecting and discharging the cooling water cooled through the first heat exchange unit and the second heat exchange unit.

A US invention with patent No. US3903212A which is dated Sep. 2, 1975 titled “Fan-assisted cooling tower and method of operation” is an apparatus and the method of operating it, for withdrawing waste heat from industrial plants and particularly for condensing steam or other condensable fluids exhausting from condensable fluid driven turbines in a fan-assisted wet, dry or wet and dry air cooled tower wherein the fans are located outside of the tower with the fan shafts positioned in a generally vertical direction so that the entire interior of the tower may be utilized for maximum liquid cooling and the fans are readily accessible but protected from wind destruction. Generally, the object of the invention is to provide a mounting system and arrangement for a fan-assisted natural draft cooling tower wherein the mechanical equipment for the tower fans is in the ambient air. Easily accessible for inspection and maintenance and not subject to the corrosive action of the water or other liquid being cooled.

Another US invention with patent No. US3923935A which is dated Dec. 2, 1975 titled “Parallel air path wet-dry water cooling tower” is a parallel air path wet-dry water cooling tower usable in one form for fog abatement and in another form as a dry cooling tower helper where makeup water resources are limited. In both instances though, hot water to be cooled is first directed to finned tube heat exchange structure where air from the ambient atmosphere moving along one path is brought into indirect heat exchange with the hot water to effect partial cooling thereof. The partially cooled water is then directed to an evaporative and thus wet heat exchange structure to further cool the water by bringing the latter into direct contact with a second airstream from the ambient atmosphere moving along a second path. The dry and wet airstreams emanating from the dry and wet heat exchangers respectively are combined prior to returning to the atmosphere. Dampers may be provided in association with one or the other or both of the heat exchange structures to permit selective variation of air flowing along said paths thereof through the heat exchange structures. The relative sizes of the dry and wet heat exchange structures are correlated for most efficient operation to meet a particular fog abatement or water conservation requirement.

Also another US invention with patent No. US4076771A which is dated Feb. 28, 1978 titled “Bottom vented wet-dry water cooling tower” is a cooling tower which has excellent water conservation properties and resistance to recirculation of heated discharge air, and which is designed for minimizing undue low level deflection and spreading of hot moist discharge air with essentially complete elimination of visible fog plumes above the tower. In preferred forms, the tower includes a pair of elevated, two-pass, obliquely disposed heat exchange conduit banks, a plurality of spaced, underlying evaporative cooling sections located between the conduit banks for serially receiving partially cooled water there from, and separate induced draft fans and structure presenting individual air discharge paths for the dry and evaporative sections respectively, in order to pull air currents through each of the latter and separately discharge the resultant dry and moist airstreams upwardly into the atmosphere in a pattern such that the dry air at least partially surrounds the central moist air. Bottom-venting of the tower between the evaporative sections allows prevailing wind currents to flow under the dry section banks and transversely through the tower for venting wind-created negative pressure eddies or vortices on the lee side of the tower which in turn minimizes recirculation of hot discharge air back to the downwind tower air inlets. Moreover, the air discharge pattern of the tower lessens low level deflection and spreading of the central moist air so that unwanted deposition of moisture on adjacent equipment or structures is minimized.

An international invention with publication No. WO2016174481A1 which is filed in WIPO dated May 30, 2015 titled “Cooling tower having a circular or a polygonal shape tower structure” is a cooling tower that has a circular or a polygonal shape tower structure and provides both natural and mechanical drafts. The air cooling tower comprises cooling panels arranged in triangular shape cooling deltas, the cooling deltas being located vertically along a lower circumferential part of the tower structure. The tower structure has a height of at least 2 times that of the cooling deltas for inducing the natural draft, and the mechanical draft is provided by induced draft fans arranged with horizontal axes and along and adjacent the vertical cooling deltas.

Another invention with publication No. WO2016174482A1 which is filed in WIPO dated Apr. 30, 2015 titled “Hybrid cooling tower” is a hybrid cooling tower for a hybrid cooling system; the hybrid cooling tower comprising-a tower shell being supported by tower shell legs above a ground level, providing an air intake between the ground level and a lower edge of the tower shell; a wet cooled segment arranged inside of the tower shell and having wet cooling cells arranged at a distance from the tower shell and receiving cooling air through the air intake and via first louvers; wet fans arranged on top of the wet cells for inducing upwards humid air exhaust flow; a dry cooled segment being arranged outside of the tower shell above said air intake for wet cells, the dry cooled segment having air coolers being arranged as vertical cooling deltas around the tower shell equipped with second louvers for controlling cooling air inlet, the dry cooled segment being supported by cooling delta legs, the tower shell having inlet openings arranged along the dry cooled segment for the air warmed up by the dry cooled segment; and dry fans arranged in at least some of the inlet openings of the tower shell, for inducing mechanical draft for the dry cooled segment and for driving air warmed up by the dry cooled segment into mixture with the humid air exhaust flow.

A Chinese invention with patent No. CN210265008U which is dated Apr. 7, 2020 titled “Water turbine for elbow type hybrid power cooling tower” discloses a water turbine for an elbow type hybrid power cooling tower, which comprises an elbow type water turbine, an auxiliary motor, a speed reducer and a steel plate base, the inner cavity of the elbow type water turbine is provided with an elbow type water turbine output shaft which penetrates through the right end surface of the elbow type water turbine, the right end of the auxiliary motor is connected with an auxiliary motor output shaft, the auxiliary motor output shaft and the elbow type water turbine output shaft are respectively and fixedly connected with a speed reducer through a coupler, the left end of the elbow type water turbine is connected with a water inlet pipe of the water turbine, a fixing beam is arranged in an inner cavity of a water inlet of the water inlet pipe of the water turbine, the fixed beam is rotatably connected with the left end of an output shaft of the elbow type water turbine, the left end of the output shaft of the elbow type water turbine is connected with a water guide ball head, the inner chamber lateral wall of hydraulic turbine inlet tube has the stator through bolt fixedly connected with, the runner has been cup jointed to the one end that the elbow formula hydraulic turbine output shaft is close to the stator.

Another Chinese invention with patent No. CN105066734B which is granted dated Aug. 3, 2018 titled “A kind of Complex-cooling tower” discloses a kind of complex cooling towers, including mainly water tanks, spray pumps, light pipe tube banks, fillers, nozzles, water fenders, finned-tube bundles and air-introduced machines. The outer air of the tower enters from the bottom shutter and passes through the light pipe tube bank, packing section and finned-tube bundle successively from bottom to top after the cooling tower, and the ambient environment is discharged by top air-introduced machine after heat, and high temperature fluid then first flows through and is evaporated cooling into light pipe tube bank after finned-tube bundle is pre-chilled from top to bottom and flows out the cooling tower after being reduced to required temperature. The shutter angle of the depression air inlet is set at four sides of finned-tube bundle lower square box wall surface, and the high-temperature water in cooling fins enter the tube bank again after mixing with the air for entering into and up movement by bottom shutter, raising cooling efficiency while delaying the corrosion of the finned tube. Cooling settings packing section is evaporated; the contact area of air and shower water is increased, extends heat-exchange time, and improves heat exchange efficiency.

Another Chinese invention with patent No. CN204438841U which is dated Jul. 1, 2015 titled “There is the high temperature closed cooling tower of pre-cooler” discloses a kind of high temperature closed cooling tower with a pre-cooler, comprising a cooling column body. A spray arm is provided within described cooling column body, connected with the feeding spraying pump by the first main pipeline, first group of serpentine coil and heat radiation filler screen pack is provided with below described spray arm, the bottom of described cooling column body is water tank, is provided with second group of serpentine coil in described water tank, and described second group of serpentine coil is connected with first group of serpentine coil by the second main pipeline. The utility model arranges the first group of serpentine coil and second group of serpentine coil; the described second group of serpentine coil is arranged in the water tank and carries out water logging heat exchange, and realizes pre-cooled well in the high temperature closed cooling tower inside. First group of serpentine coil is entered again after making high temperature fluid pre-cooled, thus avoiding overheated high-temperature water to make shower water at first group of serpentine coil surface flash even. This solves the problem that airtight cooling tower high temperature fluid cannot cool in the easy fouling of coil pipe outer surface.

A US invention with publication No. US20140298834A1 which is dated Apr. 3, 2013 titled “Method and system for hybrid cooling systems” provides systems and methods for a hybrid cooling system that includes a load center with an inlet and outlet. The system also includes a condenser with an inlet and outlet. The load center outlet is fluidically coupled to the condenser inlet. The system further includes a cooling tower that has a cooling tower inlet and a cooling tower outlet. The condenser outlet is fluidically coupled to the cooling tower inlet. The system includes an evaporator with an inlet and outlet. The cooling tower outlet is fluidically coupled to the evaporator inlet, and the evaporator outlet is fluidically coupled to the load center inlet.

DESCRIPTION OF THE INVENTION

The presented invention is a type of cooling tower based on heat exchange between the hot fluid and ambient air as a cooling fluid and also heat transfer from hot fluid passageways to cooler fluids such as water or air cooled with the help of water.

In this invention, the fluid enters a round trip cycle by entering the tube network and fin tubes of the main heat exchanger (FIG. 1, part 1). The heat in the hot fluid is transferred to the heat transfer tubes, which can generally be made of copper, steel or other metals with high heat transfer coefficient, and with the help of the fin tubes on the main heat exchanger tubes, the cooling process is done. The placement of axial fans (FIG. 1, part 2) in the upper part of the fin tubes of the main heat exchanger ensures, if necessary, that by turning on each of the fans and adding these fans to the air flow system from the lower part of the heat exchanger to the upper part is increased and the collision of passing air with fin tubes of the heat exchanger causes heat transfer from the passage of the fluid and the body of the tubes to the passing air. If there is a need to increase the cooling efficiency the following fans are also turned on and help to increase the air flow rate.

If the heat exchange does not make the required reduction in the temperature of the passing fluid, in the lower part of the heat exchanger, a set of water spraying nozzles (FIG. 1, part 3) in a zoned manner can spray water and enter the fine particles of water to the air passing through the heat exchanger section due to the upward air flow created by the axial fans, which causes the cooling efficiency to increase due to the increase in the relative humidity of the passing air and also the reduction of the temperature of the air fluid, and in total the temperature of passing fluid shows a further reduction. The spray nozzles in each of the water spray zones have the possibility of adding small particles of water to the cooling air, just like the fans on the heat exchanger system, the water spray nozzles can also enter the cooling cycle and by increasing the number of nozzles, a greater temperature reduction will be observed in the device system. The existence of a separate network of tubes equipped with a surface heat exchange system in the lower part of the heat exchanger system makes it possible to use as many spray nozzles on the cooling water coil as possible if heat exchange is needed or by directly pouring water on this coil, the heat exchange between the hot fluid and the cooling water is done in the form of evaporation. This coil (FIG. 1, part 4) is connected in series to the main tubes of the cooling system. After passing through the main circuit, the hot fluid continues to pass through this network of tubes. The air flow created by the axial fans of the evaporation and cooling process on these tubes also continues the heat exchange of the cooling water with the said coil, and increases the cooling rate as well as increasing the cooling capacity of the system. In the lower part of the device, there is a basin (FIG. 1, part 5) for collecting sprayed water, which allows the water to be drawn down and collected in this basin. The existence of a third network of tubes (FIG. 1, part 6) of the heat exchange system in the lower basin of the mentioned tower will increase the cooling efficiency and subsequently decrease the temperature of the passing fluid.

Each of the elements in the said cooling tower is equipped with an electric valve to control the passage or non-passage of cooling water (FIG. 1, part 7). The presence of thermal sensors, including thermocouples in the processing fluid path as well as the passing air path, provides the possibility that by adjusting the temperature of the cooled processing fluid output on the electronic controller system, the entry of each fan into the circuit, starting the process of the spraying water and humidification of the passing air, entering the water spraying system on the auxiliary cooling coil or passing the fluid flow through the network of cooling pipes on the bottom of the lower basin, respectively and according to the need to increase the cooling efficiency enters the system or exits the system. The intelligent entry or exit of each element into the circuit minimizes the energy consumption. Also, water spraying in this device is non-continuous and only when the temperature needs to decrease further, water spraying enters the circuit as a non-permanent auxiliary factor. This important point minimizes the amount of water consumption and has much less consumption compared to the existing technologies that use water continuously for the cooling process. In the same conditions of the mentioned invention, with the consumption of generally one tenth of the water consumption of the wet cooling tower, which will have the ability to cool the passing fluid to the same operating temperature as the previous examples of technology. In other words, it can be considered that the present invention is a four-stage hybrid cooling tower device that is based on:

1. Heat exchange of the hot fluid inside the closed cycle with the ambient air, as the first stage of cooling;

2. Heat exchange between the hot fluid inside the closed cycle with the cooled air by humidification method (adiabatic) as the second stage of cooling;

3. Heat exchange between the hot fluid inside the closed cycle with the surface evaporation of water from the outer wall of the tubes, as the third stage of cooling;

4. Heat exchange between the hot fluid inside the closed cycle and the water inside the basin in contact with the outer wall of the submerged pipes in the basin

First Stage of Cooling

In this invention, the fluid initially enters the fin tube bundle. By entering the fluid to the fin tube bundle, it enters a circulation cycle (FIG. 3, part 1). The heat is transferred from the hot fluid to the tubes, and with the help of the existing fins on the tubes, the process of cooling the fluid and transferring heat to the air is done. The presence of axial fans (FIG. 3, part 2) in the upper part of the fin tube bundle ensures, if necessary, that by turning on each of the fans and adding these fans to the system, the flow rate of air passing from the lower part of the heat exchanger to the upper part to be increased and the contact of passing air with fin tubes of the heat exchanger causes heat transfer from the body of the tubes to the passing air. If the ambient air temperature increases, the following fans are also turned on and help to increase the air flow rate.

Second Stage of Cooling

If the heat exchange does not make the required reduction in the temperature of the passing fluid, in the lower part of the fin tube bundle, there is a set of water spraying nozzles (FIG. 3, part 3) in a zoned manner that can proceed to spray the water on filling packing (FIG. 3, part 4) and the packing level of each zone becomes wet. The upward air induced by the fans passes over the wet packing and the relative humidity of the air increases in contact with the water surface and the air temperature decreases.

By increasing the temperature of ambient air, the water spraying network of the next zones will start spraying water on the filling packing of that zone and cause a larger volume of air to cool down and heat exchange will increase between the surface of the finned tubes and the air. Therefore, by increasing the number of water spraying nozzles, the more temperature reduction happens in the system of the device.

Third Stage of Cooling

If the ambient air continues to increase in such a way that the cooling of the second stage does not cool enough the hot fluid inside the closed cycle, the spraying network of the fourth zone is activated and makes the surface of the evaporative bundle wet. By activating the spraying nozzles of this zone, the outer surface tubes of this network become wet and therefore the surface evaporation of water occurs on the tubes. Calculations related to heat transfer in thin film surface evaporation show that the heat transfer coefficient increases significantly. With the help of this feature, the desired temperature reduction in the hot fluid is achieved.

This bundle is connected to the finned tube bundle in series. The hot fluid will pass from this bundle of tubes after passing through the main circuit. Heat exchange due to the flow of wet and cool air created by fans and water spraying system in the zone of the main heat exchanger, along with the heat exchange caused by the process of surface evaporation from the wet pipes in the zone of the third stage tube network increase the amount of cooling and rise the cooling capacity of the system.

Fourth Stage of Cooling

In the lower part of the device, there is a water storage basin (FIG. 3, part 5) which makes it possible for the cycle water to drip down again and collect in this basin. The existence of the third bundle of tubes (FIG. 3, part 6) of the heat exchange system in the basement of the mentioned tower will increase the efficiency of cooling and furthermore reduce the temperature of passing fluid.

The significant feature of this network of tubes is that the heat transfer from hot fluid to the basin water prevents the basin water from freezing in the cold time of the day (Anti freezing).

Each of the existing water spraying networks in the cooling package is equipped with an automatic electric valve to control water spraying on different zones of the machine. Also, each of the electromotors of the fans on the device can be turned off and on or remotely controlled. By using these control facilities, the cooling device is controlled in different climatic conditions so that the required heat exchange capacity of the device is provided with the lowest amount of water and energy consumption.

The presence of temperature sensors, including thermocouples in the fluid path as well as the passing air path makes it possible to regulate the temperature of the outgoing cooled fluid on the electronic controller system and the entry of each of the fans into the circuit, starting the process of spraying water and humidifying the passing air, entrance of the water spraying system on the evaporative bundle or the passage of the flow of the fluid through the antifreeze bundle of the water storage basin and by different climatic conditions enters to the system or exit from it. The intelligent entry or exit of each of the elements into the circuit minimizes the amount of water and energy consumption. Also, the water spraying in this device is not continuous and it is activated only when the ambient air is warmer and the previous cooling stage of the device is not required for cooling by the process, and the water spraying enters the circuit as a non-permanent auxiliary factor. This important thing will minimize the amount of water consumption and consume much less water than the existing technologies which are using water continuously for the cooling process.

The device works in different climatic conditions as follows:

The finned tube bundle of the device at temperatures lower than T0 is responsible for providing the heat exchange capacity of the entire device. In this condition, the amount of water consumption for cooling is zero and the device works completely dry without water consumption.

By increasing the air temperature until T1, the electric automatic valve opens on the water spraying network of adiabatic zone 1 and this zone becomes wet. So about one third of the passing air from the device becomes wet and cool (FIG. 7, part 1). In the air mixing chamber, this cool air mixes with the passing air of other zones and an air with monotonous temperature lower than T0 enters the finned tube bundle. Under these conditions, the finned tube bundle is again able to make the required amount of hot fluid cool.

By increasing the air temperature until T2, the electric automatic valve opens on the water spraying network of adiabatic zone 2 and further to adiabatic zone 1, zone 2 becomes wet too. So about two thirds of the passing air from the device becomes wet and cool. In the air mixing chamber, this cool air mixes with passing air of other zones and air with monotonous temperature lower than T0 enters the finned tube bundle. Under these conditions, the finned tube bundle is again able to make the required amount of hot fluid cool.

By increasing the air temperature until T3, the electric automatic valve opens on the water spraying network of adiabatic zone 3 and further to adiabatic zone 1 and 2, the zone 3 becomes wet too. So the whole passing air from the device becomes wet and cool. In the air mixing chamber, this cool air mixes with passing air of other zones and an air with monotonous temperature lower than T0 enters the finned tube bundle. Under this condition, the finned tube bundle again is able to make the hot fluid cool in the required amount. Generally the increase in the number of adiabatic zones causes a reduction in the consumption of water and an increase in the consumption of energy.

If the air temperature continues to rise, it is no longer possible to obtain cool air with a temperature lower than T0 by adiabatic method, or the volume of air required to pass through the device is calculated so high that the amount of water required to cool this volume of air will be very large. In this situation, the automatic electric valve on the spraying network of zone 4 is open and the surface of the evaporative bundle is wet, and the surface evaporation of the thin film occurs on the surface of the evaporative bundle. The heat exchange resulting from the surface evaporation of the thin film in this bundle provides a small part of the temperature reduction of the hot fluid. This amount of temperature reduction makes the finned tube bundle able to provide the rest of the required temperature reduction of the hot fluid.

Cooling systems that do not have an evaporative bundle are not able to provide heat transfer in very hot climatic conditions. Also, these systems are not able to cool the hot fluid close to the wet bulb temperature. By adding the evaporative bundle, the cooling system is able to meet the consumer's demand and perform under these conditions, providing the required cooling.

The final part of the heat exchange takes place in the antifreeze bundle. In a situation where the ambient air temperature becomes very cold and there is a possibility of freezing the water in the basin, the warm fluid passes through the antifreeze bundle and prevents the freezing of water in the basin. The required heat transfer to prevent freezing of the storage water basin provides part of the reduction in the temperature of the hot fluid and reduces the cooling load of the finned tube bundle and in the same ratio will result in a reduction in the energy consumption of the device.

Axial Fan

The required air flow is provided by the fan installed on the device. According to the structure and relatively high static pressure required by the device, this fan must be of axial type and also must be installed at the outlet or inlet of the device. Since the installation of the fan in the air intake causes the device to occupy a larger zone (Footprint Zone), it is recommended to use an induced fan at the outlet. The number and size of the fan is determined according to the dimensions of the device and the amount of air required by the device. The material of the fan can be steel, aluminum or plastic (FRP).

Required drives for the fans and pumps of the hybrid cooling device are provided by the electromotors.

Fan Stack

The air coming out of the device is hot and it should not be possible for it to re-enter the device through the air intake. The fan stack helps in this matter and causes hot air to be thrown to a higher distance. Another function of the fan stack is to increase the flow of air through the device in a natural way (natural draft).

Finned Tube Bundle

The finned tube bundle is the main heat exchanger of the device and it is in service during the whole time of operation of the cooling device. This bundle consists of inlet header box, outlet header box and tubes whose outer surface is covered with aluminum fins and provides the required heat exchange duty.

Drift Eliminator

By spraying water on adiabatic packing with adiabatic water spraying networks, there is the possibility for the water droplets to exist in passing air. Since these drops have no effect on reducing the water temperature of the closed cycle, it is considered as the water waste and reduces the efficiency of the device. Installing a drift eliminator before the finned tube bundle prevents water droplets from escaping out of the device. The water droplets stick to the mist eliminator wall and may evaporate and cause a slight decrease in the temperature of the air entering the finned tube bundle, or may fall down in the form of larger droplets and enter the adiabatic packing. The mist eliminator is usually made of plastic.

Adiabatic Zone 1 Water Spray Cycle

In order to reduce and optimize the water consumption of the device, the air temperature range in which the device performs in adiabatic mode is divided into three almost equal ranges. As the air temperature increases, the device enters the adiabatic operating mode from the dry operating mode. The adiabatic zone 1 water spray network has a control valve at the entrance, a tube network and a sufficient number of spray nozzles. Upon entering the first adiabatic mode, the control system of the device orders the opening of the control valve of this network and sprays water on the adiabatic packing relevant to this zone. In this way, the adiabatic packing surfaces of this zone get wet and one third of the air passing through the device gets wet and cooled. Reducing the temperature of this amount of air and mixing it in the mixing chamber causes the cool air to enter monotonously into the finned tube bundle.

Adiabatic Zone 2 Water Spray Cycle

If the air temperature continues to increase and the amount of air temperature reduction during the operation of the adiabatic zone 1 spraying cycle is not enough, the adiabatic zone 2 water spraying cycle is activated and causes the temperature of the air entering the finned tube bundle to decrease. The activation and deactivation of this cycle is similar to the adiabatic zone 1 cycle.

Adiabatic Zone 3 Water Spray Cycle

If the air temperature continues to increase and the amount of air temperature reduction during the operation of the adiabatic zone 2 spraying cycle is not enough, the adiabatic zone 3 water spraying cycle is activated and causes a decrease in the temperature of the air entering the finned tube bundle. The activation and deactivation of this cycle is similar to the adiabatic zone 1 cycle.

Evaporator Zone Water Spray Cycle

When the control system of the device detects that the evaporating bundle section enters the service, the control valve installed at the entrance of the water spraying cycle of this zone is opened and the surface of the evaporating bundle is wet by activating the spray nozzles of this zone and surface evaporation of this zone starts. When the control system of the device detects that there is no need for the evaporation bundle to be active anymore, the command to close the control valve of this network and stop spraying water is issued.

Air Mixing Chamber

After the air exits the adiabatic packing area and the air temperature in direct contact with the water is reduced, it is necessary to make the air temperature uniform and steady by passing through the mixing chamber in order to exchange heat in the finned tube bundle. Sizing this chamber less than the required amount will cause incomplete air mixing, and sizing it more than the required amount will cause an unnecessary increase in the height and weight of the device.

Adiabatic Packing

In order to reduce the air temperature with the moisturizing method, it is required that the contact time of air with water is calculated correctly; otherwise the adiabatic is not performed completely and the temperature of the air entering the device is not reduced to the required amount and there will be a disturbance in the operation of the device. In order to ensure sufficient contact time, the appropriate type and volume of the packing should be calculated and selected. If the contact time is less than the appropriate amount, the temperature of the incoming air will not decrease sufficiently, and if it is more than the appropriate amount, the air pressure will drop too much and the energy consumption of the device will increase.

Evaporating Bundle

This bundle performs the second stage in the operation of cooling the processing water in the closed cycle. If the operation of the device in adiabatic mode does not achieve sufficient cooling load, the load will be provided by the evaporating bundle. The evaporating bundle is only used in the condition of maximum ambient air temperature, so it is in service for a short period of time per year and is possible to bypass automatically or manually for a long period of time, although this is not recommended. This section has an independent water spraying network and the start and end of its operation is determined by the control system. Generally, the provision of the cooling load through evaporation leads to higher water consumption than the adiabatic method; however, the hybrid cooling device that is the subject of this invention is designed in such a way that the cooling load resulting from the evaporation bundle reduces the water and electricity consumption of the whole device (compared to providing the same cooling load by the adiabatic part of the device). Since this bundle is in direct contact with the evaporating water, it is subject to severe corrosion; in order to prevent this, it must be covered with a suitable coating such as galvanized or stainless steel. The phenomenon of thin film surface evaporation causes a significant increase in the heat transfer coefficient from the outer wall of the bundle, and in this way, the heat transfer surface of the evaporative bundle can be greatly reduced; on the other hand, the linear velocity of the closed cycle water inside increases. The bundle increases both the drop in water pressure and the erosion of the inner surface of the evaporation bundle tubes. Therefore, the bundle should be designed in such a way that in addition to providing the required cooling load, internal erosion and external corrosion are prevented.

Intake Air Uniformity Chamber

Between the air intake section and the adiabatic packing and evaporation bundle sections, there is an intake air uniformity chamber. This space causes the incoming air to enter the next sections with upward uniform linear velocity. Failure to create such uniformity in the air flow will reduce the efficiency of the device and increase water and energy consumption.

Air Intake

Regardless of under what conditions and in what mode the device works, air flow is always needed. The required air is sucked from the opening located on the walls and enters the device. The dimensions, location and design of this valve are very important in guiding the air flow and drop in air pressure inside the device; improper design of this part will reduce the efficiency and increase the power consumption of the device. Openings must have the ability for a filter to be installed to remove dust from the air before it enters the device.

Water Storage Basin

This basin is installed to store the water required for the open cycle of the device. The water used in all parts of the device is poured into this basin. The volume of water stored in this basin should be selected in such a way that in case of cutoff the make-up water, it will supply the water consumed by the device for a suitable period of time without disrupting the device's performance. The body of the basin can be made of steel or fiberglass. Considering that the make-up water has hardness and salts and the water inside the basin is consumed through evaporation, the hardness of the water inside the basin is always increasing and it is necessary to monitor and control the hardness of this water. If the hardness of the water exceeds the permissible limit, the hardness measuring devices installed on the basin send a signal to the control system, which opens the blow down device, and part of water in the basin is discharged and replaced by make-up water. The design of the basin should be such that the water which is falling from its upper parts does not increase the level of noise in the device. The basin can be designed as a single section or multiple sections. In case of a multi-part design, the water in all parts must be connected so that the passage of water flow between the parts is possible.

This part of the device has two main functions. The main function of the bundle is to prevent the water in the storage basin from freezing in cold weather. When the ambient air has a lower temperature than that of freezing water, there is a possibility of freezing in the water inside the basin. Under these conditions, all or part of the closed cycle hot water enters this bundle, and by transferring heat from the hot water to the basin water, it prevents freezing. The side effects of the bundle include increasing the efficiency of the device, since part of the cooling load of the whole device is carried out by this part and it reduces the cooling load of other parts of the device. Considering that the transfer of heat in other parts of the device requires energy consumption, providing the cooling load by the antifreeze bundle reduces energy consumption. This bundle performs the third stage of the water cooling operation of the closed cycle process.

Control Panel

The device has a specially-made control panel that includes all the control measures of the device. Considering that the device is pre-made (Skid Mounted) and should be able to be installed and set up quickly and easily, the control system of the device should meet all functional needs. The control system is designed in such a way that in the absence of any controlling infrastructure in the factory, it can guide and control the device in the best way possible. Although this panel is designed to control a cooling device, its structure can be controlled synchronously with adjacent and parallel hybrid cooling devices, and the operational sequence of each of the hybrid cooling devices and components and the main parts of them can be easily adjusted and programmed by the device operator.

Power Panel

The main power cable is connected to the main electrical panel and is distributed to all the electrical equipment of the device. In order to exchange signals, this panel is also connected to the control board.

Cover Casing

Considering that open cycle air and water flow in the device and the movement path of these two fluids is very important, the outer cover plays a very important role in the device's performance. In addition to separating the internal environment from the external environment of the device to guide air and water fluids, the outer cover also accounts for the appearance of the device and should be designed in such a way that is appealing.

Main Structure

All parts of the device are held by the main structure. The main structure has several columns and each of these columns must be placed on the foundation so that the total weight of the device is transferred to the foundation.

Internal Supports

All parts and equipment of the device are supported by internal supports. Supports are connected to the device body and chassis with the help of screws and welding.

Open Cycle Circulation Pump

The water required for adiabatic sprinkler networks and evaporation bundles is provided by an open cycle water pump. The inlet of this pump is connected to the water storage basin and transfers the water from the basin to the water spraying networks. This pump can be centrifugal.

DESCRIPTION OF DRAWINGS

FIG. 1 shows the side view of the device.

FIG. 2 includes the following sections:

FIG. 3 which shows the side view of the device.

FIG. 4 which shows the upper view of the heat exchanger.

FIG. 5 which shows the side view of the water nozzle.

FIG. 6 which shows the exploded view of the device.

FIG. 7 which shows the view of different zones of water spray.

FIG. 8 which shows the amount of water consumption in different zones.

FIG. 9 which shows the amount of consumption in the adiabatic zones.

FIG. 10 which shows the amount of saved water in the mentioned device.

FIG. 11 which shows the amount of water consumption in different zones.

FIG. 12 which shows the amount of water consumption in the adiabatic zones.

FIG. 13 which shows the amount of saved water in different months and by percentage.

FIG. 14 which shows the amount of saved water in different months of the year by cubic meter.