This invention relates to the dissipation of degraded thermal energy to ambient air.
Cooling and thermal energy dissipation are universal tasks in industry. Common heat rejection processes include steam condensation in thermoelectric power plants, refrigerant condensation in air-conditioning and refrigeration equipment, and process cooling during chemical manufacturing. In the case of power plants and refrigeration systems, it is desired to dissipate thermal energy at the lowest possible temperature and as close as possible to the operating environment for optimum energy efficiency.
Where the local environment has a suitable low-temperature sink, e.g., a river, sea, or lake, cooling water can be extracted directly. However, few of these opportunities for once-through cooling are expected to be available in the future because of competition for water sources and recognition of their impact on the environment. In the absence of a suitable coolant source, the only common thermal sink available at all locations is ambient air. Both sensible and latent heat transfer are currently used to reject heat to the air. In sensible cooling, air is used directly as the coolant, and it is used to cool one side of the process heat exchanger. For latent cooling, liquid water is used as the coolant, and it is then itself cooled by partial evaporation in a cooling tower. The thermal energy is transferred to the ambient air in the form of evaporated water vapor, with minimal temperature rise of the air.
These technologies are used routinely in industry, but each one has distinct drawbacks. In the sensible cooling case, air is an inferior coolant compared to liquids, and the resulting efficiency of air-cooled processes can be poor. The air-side heat-transfer coefficient is invariably much lower than liquid-cooled heat exchangers or condensation processes and, therefore, requires a large heat exchange surface area for good performance. In addition to larger surface area requirements, air-cooled heat exchangers approach the ambient dry-bulb temperature, which can vary 30° to 40° F. over the course of a day and can hinder cooling capacity during the hottest hours of the day. Air-cooled system design is typically a compromise between process efficiency and heat exchanger cost. Choosing the lowest initial cost option can have negative energy consumption implications for the life of the system.
With latent heat dissipation, the cooling efficiency is much higher, and the heat rejection temperature is more consistent throughout the course of a day since a wet cooling tower will approach the ambient dew point temperature instead of the oscillatory dry-bulb temperature. The key drawback of this approach is the associated water consumption, which in many areas is becoming a limiting resource. Obtaining sufficient water rights for wet cooling system operation delays plant permitting, limits site selection, and creates a highly visible vulnerability for opponents of new development.
Improvements have been proposed to these basic cooling systems. A significant effort has gone into hybrid cooling concepts that augment air-cooled condensers with evaporative cooling during the hottest parts of the day. These systems can use less water compared to complete latent cooling, but the performance benefit is directly related to the amount of water-based augmentation, so these systems do not solve the underlying issue of water consumption. Despite the fact that meeting the cooling needs of industrial processes is a fundamental engineering task, significant improvements are still desired, primarily the elimination of water consumption while simultaneously maintaining high-efficiency cooling at reasonable cost.
In summary, there is a need for improved heat dissipation technology relative to current methods. Sensible cooling with air is costly because of the vast heat exchange surface area required and because its heat-transfer performance is handicapped during the hottest ambient temperatures. Latent or evaporative cooling has preferred cooling performance, but it consumes large quantities of water which is a limited resource in some locations.
A heat dissipation system apparatus and method of operation using hygroscopic working fluid.
The heat dissipation system described herein circulates a hygroscopic working fluid to transfer heat from a process requiring cooling directly to the ambient air. The hygroscopic fluid is in liquid phase at conditions in which it is at thermal and vapor pressure equilibrium with the expected local ambient conditions. The fluid is composed of a solution of a hygroscopic substance and water. In one embodiment, the hygroscopic substance itself should have a very low vapor pressure compared to water in order to prevent significant loss of the hygroscopic component during cycle operation. The hygroscopic component can be a pure substance or a mixture of substances selected from compounds known to attract moisture vapor and form liquid solutions with water that have reduced water vapor pressures. The hygroscopic component includes all materials currently employed for desiccation operations or dehumidifying operations including hygroscopic inorganic salts, such as LiCl, LiBr, CaCl2, ZnCl2; hygroscopic organic compounds, such as ethylene glycol, propylene glycol, triethylene glycol; or inorganic acids, such as H2SO4 and the like.
Thermal energy is removed from the process in a suitable heat exchanger having one side thereof, the flow of process fluid, and on the other side thereof, the flow of hygroscopic working fluid coolant. This heat exchanger can take the form of any well-known heat exchange device, including shell-and-tube heat exchangers, plate-and-frame heat exchangers, or falling-film heat exchangers. The process fluid being cooled includes a single-phase fluid, liquid, or gas or can be a fluid undergoing phase change, e.g., condensation of a vapor into a liquid. Consequently, the thermal load presented by the process fluid can be sensible, i.e., with a temperature change, or latent which is isothermal. Flowing through the other side of the heat exchange device, the hygroscopic working fluid coolant can remove heat sensibly, such as in a sealed device with no vapor space, or it can provide a combination of sensible and latent heat removal if partial evaporation of the moisture in solution is allowed, such as in the film side of a falling-film heat exchanger.
After thermal energy has been transferred from the process fluid to the hygroscopic working fluid, the hygroscopic fluid is circulated to an air-contacting device where it is exposed directly to ambient air for heat dissipation. The contacting device is constructed in such a way as to generate a large amount of interfacial surface area between the solution and air. Any well-known method may be used to generate the interfacial area, such as by including a direct spray of the liquid into the air, a flow of solution distributed over random packing's, or a falling film of liquid solution clown a structured surface. Flow of the air and solution streams can be conducted in the most advantageous way for a particular situation, such as countercurrent where the solution may be flowing down by gravity and the air is flowing up, cross-flow where the flow of solution is in an orthogonal direction to airflow, cocurrent where the solution and air travel in the same direction, or any combination of these flow types.
Heat- and mass-transfer processes inside the air contactor are enhanced by convective movement of air through the contactor. Convective flow may be achieved by several different means or a combination of such different means. The first means for convective airflow is through natural convection mechanisms such as by the buoyancy difference between warmed air inside the contactor and the cooler and the surrounding ambient air. This effect would naturally circulate convective airflow through a suitably designed chamber in which the air is being heated by the warmed solution. Another means for convective airflow includes the forced flow of air generated by a fan or blower. A further convective airflow means includes inducing airflow using momentum transfer from a jet of solution pumped out at sufficient mass flow rate and velocity.
Inside the air contactor, an interrelated process of heat and mass transfer occurs between the hygroscopic solution and the airflow that ultimately results in the transfer of thermal energy from the solution to the air. When the air and solution are in contact, they will exchange moisture mass and thermal energy in order to approach equilibrium, which for a desiccant liquid and its surrounding atmosphere requires a match of temperature and water vapor pressure. Since the solution's vapor pressure is partially dependent on temperature, the condition is often reached where the solution has rapidly reached its equivalent dew point temperature by primarily latent heat transfer (to match the ambient vapor pressure), and then further evaporation or condensation is limited by the slower process of sensible heat transfer between the air and solution (to match the ambient temperature). The induced mass transfer required to equilibrate vapor pressure is an added gradient that enhances sensible heat transfer.
The net amount of heat and mass transfer within the air contactor is dependent on the specific design of the air contactor and the inlet conditions of the hygroscopic solution and the ambient air. However, the possible outcomes as solution passes through the contactor include situations where the solution can experience a net loss of moisture (a portion of the thermal energy contained in the solution is released as latent heat during moisture evaporation; this increases the humidity content of the airflow), the solution can experience a net gain in moisture content (such occurs when the vapor pressure in the air is higher than in the solution, and moisture is absorbed by the solution having the latent heat of absorption released into the solution and being transferred sensibly to the air), and the solution is in a steady state where no net moisture change occurs (any evaporation being counterbalanced by an equivalent amount of reabsorption, or vice versa). Even in this last instance where there is no net moisture change, the counterbalancing processes of evaporation and reabsorption still have the potential to enhance sensible heat transfer by altering the working fluid temperature and, thus, the sensible heat transfer gradient.
After passing through the air contactor, the solution has released thermal energy to the ambient air either through sensible heat transfer alone or by a combination of sensible and latent heat transfer (along with any concomitant moisture content change). The solution is then collected in a reservoir, the size of which will be selected to offer the best dynamic performance of the overall cooling system for a given environmental location and thermal load profile. It can be appreciated that the reservoir can alter the time constant of the cooling system in response to dynamic changes in environmental conditions. For example, moisture absorption in the ambient atmosphere will be most encouraged during the night and early morning hours, typically when diurnal temperatures are at a minimum, and an excess of moisture may be collected. On the other extreme, moisture evaporation in the ambient atmosphere will be most prevalent during the afternoon when diurnal temperatures have peaked, and there could be a net loss of solution moisture content. Therefore, for a continuously operating system in the ambient atmosphere, the reservoir and its method of operation can be selected so as to optimize the storage of excess moisture gained during the night so that it can be evaporated during the next afternoon, to maintain cooling capacity.
The reservoir itself can be a single mixed tank where the average properties of the solution are maintained. The reservoir also includes a stratified tank or a series of separate tanks intended to preserve the distribution of water collection throughout a diurnal cycle so collected water can be metered out to provide maximum benefit.
The present heat dissipation system includes the use of a hygroscopic working fluid to remove thermal energy from a process stream and dissipate it to the atmosphere by direct contact of the working fluid and ambient air. This enables several features that are highly beneficial for heat dissipation systems, including 1) using the working fluid to couple the concentrated heat-transfer flux in the process heat exchanger to the lower-density heat-transfer flux of ambient air heat dissipation, 2) allowing for large interfacial surface areas between the working fluid and ambient air, 3) enhancing working fluid-air heat-transfer rates with simultaneous mass transfer, and 4) moderating daily temperature fluctuations by cyclically absorbing and releasing moisture vapor from and to the air.
Referring to drawing
After absorbing thermal energy in process heat exchanger 4, the hygroscopic working fluid is routed to distribution nozzles 7 where it is exposed in a countercurrent fashion to air flowing through air contactor 8. Ambient airflow through the air contactor in drawing
In air contactor 8, both thermal energy and moisture are exchanged between the hygroscopic working fluid and the airflow, but because of the moisture retention characteristics of the hygroscopic solution, complete evaporation of the working fluid is prevented.
If the heat dissipation system 10 is operated continuously with unchanging ambient air temperature, ambient humidity, and a constant thermal load in process heat exchanger 4, a steady-state temperature and concentration profile will be achieved in air contactor 8. Under these conditions, the net moisture content of stored working fluid 1 will remain unchanged. That is not to say that no moisture is exchanged between distributed working fluid 12 and the airflow in air contactor 8, but it is an indication that any moisture evaporated from working fluid 12 is reabsorbed from the ambient airflow before the solution is returned to reservoir 2.
However, prior to reaching the aforementioned steady-state condition and during times of changing ambient conditions, heat dissipation system 10 may operate with a net loss or gain of moisture content in working fluid 1. When operating with a net loss of working fluid moisture, the equivalent component of latent thermal energy contributes to the overall cooling capacity of the heat dissipation system 10. In this case, the additional cooling capacity is embodied by the increased moisture vapor content of airflow 11 exiting air contactor 8.
Conversely, when operating with a net gain of working fluid moisture content, the equivalent component of latent thermal energy must be absorbed by the working fluid and dissipated to the airflow by sensible heat transfer. In this case, the overall cooling capacity of the system is diminished by the additional latent thermal energy released to the working fluid. Airflow 11 exiting air contactor 8 will now have a reduced moisture content compared to inlet ambient air 9.
Another embodiment of heat dissipation system 10 illustrated in drawing
With the operation of the heat dissipation system 10 described herein and the effects of net moisture change set forth, the performance characteristics of cyclic operation can be appreciated. Illustrated in drawing
Illustrated in drawing
The latent component of heat transfer illustrated in drawing
The net cooling capacity of the heat dissipation system 10 is illustrated in drawing
The cost of this boost to daytime heat transfer comes at night when the absorbed latent energy, region E3, is released into the working fluid and must be dissipated to the airflow. During this time, the total system cooling capacity is reduced by an equal amount from its potential value, region E4. However, this can be accommodated in practice since the nighttime ambient temperature is low and overall heat transfer is still acceptable. For a steam power plant, the demand for peak power production is also typically at a minimum at night.
Regarding air contactor configuration, direct contact of the working fluid and surrounding air allows the creation of significant surface area with fewer material and resource inputs than are typically required for vacuum-sealed air-cooled condensers or radiators. The solution-air interfacial area can be generated by any means commonly employed in industry, e.g., spray contactor, wetted packed bed (with regular or random packings), or a falling-film contactor.
Air contactor 8, illustrated in drawing
Illustrated in drawing
Illustrated in drawing
As working fluid 30 flows over the surface of tube 29, heat is transferred from process fluid 28 through the tube wall and into the working fluid film by conduction. As the film is heated, its moisture vapor pressure rises and may rise to the point that evaporation takes place to surrounding airflow 31, thereby dissipating thermal energy to the airflow. Falling-film heat transfer is well known in the art as an efficient means to achieve high heat-transfer rates with low differential temperatures. One preferred application for the falling-film heat exchanger is when process fluid 28 is undergoing a phase change from vapor to liquid, as in a steam condenser, where temperatures are isothermal and heat flux can be high.
A further embodiment of the heat dissipation system 10 is illustrated in drawing
In the embodiment illustrated in drawing
A further embodiment of the heat dissipation system 10 is illustrated in drawing
During high-ambient-humidity conditions when the net moisture content of reservoir solution 1 is increasing, the air at outlet 39 will have a lower moisture vapor content than ambient air 9 entering air contactor 8. Therefore, some advantage will be gained by exposing film-cooled process heat exchanger 32 to this lower-humidity airstream from outlet 39 rather than the higher-humidity ambient air. The lower-humidity air will encourage evaporation and latent heat transfer in film-cooled process heat exchanger 32, and it will allow for lower film temperatures because of the lower dew point associated with the lower-humidity air. The embodiment illustrated in drawing
A further embodiment of the heat dissipation system 10 is illustrated in drawing
The foregoing discussion discloses and describes merely exemplary embodiments of the present invention. One skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims, that various changes, modifications, and variations can be made therein without departing from the spirit and scope of the invention as defined in the following claims.
This application claims priority of U.S. Provisional Patent Application Ser. No. 61/345,864 filed May 18, 2010, which is incorporated herein in its entirety by reference.
This invention was made with government support under Cooperative Agreement No. DE-FC26-08NT43291 entitled “EERC-DOE Joint Program on Research and Development for Fossil Energy-Related Resources,” awarded by the U.S. Department of Energy (DOE). The government has certain rights in the invention.
Number | Date | Country | |
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61345864 | May 2010 | US |