MATERIAL COOLING SYSTEM HAVING A VARIABLE HEAT REJECTION INTERFACE

Abstract

A cooling system for an industrial facility includes a facility that has a thermal energy output and an input, a dry cooler that includes a plurality of blowers, an evaporative cooling tower, a fluid-cooled chiller, a valving system that receives a thermally-charged media from the thermal energy output for delivery to at least one of the dry cooler, the evaporative cooling tower, and the fluid-cooled chiller, and a temperature sensor that is in communication with the valving system via a controller. The temperature sensor measures a current ambient temperature and cooperates with the controller to automatically adjust the valving system to direct the thermally-charged media to one of the dry cooler, the evaporative cooling tower, and the fluid-cooled chiller for rejecting heat from the thermally-charged media to define a thermally-receptive media. The cooling system further includes a return conduit that delivers the thermally-receptive media to the input.

Description

FIELD OF THE DISCLOSURE

The present disclosure generally relates to material cooling systems, and more specifically, a material cooling assembly that includes a valving system that can deliver a thermally-charged media between any one of a number of heat rejecting mechanisms as conditions around a facility change over time.

BACKGROUND OF THE DISCLOSURE

During operation of a manufacturing facility, various heat rejecting mechanisms are utilized for removing excess heat through a thermal exchange system. The thermal exchange system cools a fluid media that is heated in the facility during manufacturing processes and power generation processes. These heat rejecting mechanisms are used to deliver heat from the facility so that the cooling media can be recycled back to the facility for re-use and further heat rejecting capabilities.

SUMMARY OF THE DISCLOSURE

According to one aspect of the present disclosure, a cooling system for an industrial facility includes a facility that has a thermal energy output and an input, a dry cooler that includes a plurality of blowers, an evaporative cooling tower, a fluid-cooled chiller, a valving system that receives a thermally-charged media from the thermal energy output for delivery to at least one of the dry cooler, the evaporative cooling tower, and the fluid-cooled chiller, and a temperature sensor that is in communication with the valving system via a controller. The temperature sensor measures a current ambient temperature and cooperates with the controller to automatically adjust the valving system to direct the thermally-charged media to one of the dry cooler, the evaporative cooling tower, and the fluid-cooled chiller for rejecting heat from the thermally-charged media to define a thermally-receptive media. The cooling system further includes a return conduit that delivers the thermally-receptive media to the input.

According to another aspect of the present disclosure, a cooling system for an industrial facility includes a dry cooler that includes a plurality of blowers, an evaporative cooling tower, a fluid-cooled chiller, a valving system that delivers a thermally-charged media to one of the dry cooler, the evaporative cooling tower, and the fluid-cooled chiller. The valving system is configured to receive the thermally-charged media from an injection molding facility. A temperature sensor is in communication with the valving system via a controller. The temperature sensor measures a current ambient temperature and cooperates with the controller to automatically adjust the valving system to direct the thermally-charged media to one of the dry cooler, the evaporative cooling tower, and the fluid-cooled chiller for rejecting heat from the thermally-charged media to define a thermally-receptive media. A supplemental cooling system extends between the fluid-cooled chiller to the dry cooler and between the fluid-cooled chiller to the evaporative cooling tower. The supplemental cooling system assists the fluid-cooled chiller in rejecting heat from the thermally-charged media.

According to another aspect of the present disclosure, a method for operating a cooling system for a facility includes the steps of delivering a thermally-charged media from a facility to a cooling system, measuring a temperature of ambient air to surround the facility utilizing a temperature sensor, operating a valving system based upon the temperature of the ambient air to deliver the thermally-charged media to one of a dry cooler, an evaporative cooling tower and a fluid-cooled chiller, rejecting heat from the thermally-charged media to define a thermally-receptive media, and returning the thermally-receptive media to the facility.

These and other features, advantages, and objects of the present disclosure will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a schematic diagram illustrating a facility that utilizes an aspect of the heat rejection assembly that incorporates a plurality of cooling mechanisms for extracting thermal energy from a thermally-charged media;

FIG. 2 is a schematic diagram illustrating an aspect of the heat rejecting assembly;

FIG. 3 is a schematic diagram illustrating an aspect of the heat rejecting assembly; and

FIG. 4 is a linear flow diagram illustrating a method for operating a heat rejection assembly.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As exemplified in FIGS. 1-4, reference numeral 10 generally refers to a cooling system that is typically coupled with a facility 12, such as an injection molding facility, a manufacturing facility, a power generating facility, other similar industrial facility. The cooling system 10 is used for recirculating a thermal exchange media 14 between the facility 12 and the cooling system 10. Through this recycling process, thermal energy, typically in the form of heat 16 that is generated within the facility 12, can be delivered to the cooling system 10. The cooling system 10 rejects, or separates, the heat 16 from the thermal exchange media 14. This rejected heat 16 is delivered to a separate location so that the heat 16 is removed from the thermal exchange media 14. This thermal exchange media 14, now having thermal capacity for collecting additional heat 16, is recirculated back to the facility 12 for reuse via one of the delivery conduits 56.

Referring again to FIGS. 1-4, according to various aspects of the device, the cooling system 10 for the facility 12 includes the structure 30 for the facility 12 that includes a thermal energy output 32 and an input 34. The cooling system 10 includes a dry cooler 36 that includes a plurality of blowers 38 or fans. An evaporative cooling tower 40 is also included within the cooling system 10 as well as a fluid-cooled chiller 42. A valving system 44 directs a thermally-charged media 46 from the thermal energy output 32 of the facility 12 to the valving system 44. A temperature sensor 48 that is in communication with the valving system 44 via a controller 50 measures a current ambient temperature 52 surrounding the facility 12 and the cooling system 10. This temperature sensor 48 cooperates with the controller 50 to automatically adjust the valving system 44 to direct the thermally-charged media 46 to one of the dry cooler 36, the evaporative cooling tower 40 and the fluid-cooled chiller 42. Each of these cooling components 54 of the cooling system 10 provides certain benefits over the other cooling components 54 when the ambient temperature 52 is within certain ranges, as will be discussed more fully herein. Additionally, under certain conditions, these cooling components 54 can operate cooperatively to achieve the thermal rejecting functions of the cooling system 10. When the thermally-charged media 46 has moved through the cooling components 54, the heat 16 is extracted and the thermally-charged media 46 is converted into thermally-receptive media 114 that is returned to the facility 12 to continue extracting heat 16 from the machinery operated and processes performed within the facility 12.

Referring again to FIGS. 1-4, the valving system 44 and the temperature sensor 48 operate cooperatively based upon the sensed ambient temperature 52, as measured by the temperature sensor 48. When the ambient temperature 52 is within a predetermined temperature range, the temperature sensor 48 communicates with the valving system 44 to deliver the thermally-charged media 46 to the fluid-cooled chiller 42. When the temperature sensor 48 senses that the ambient temperature 52 is below this predetermined temperature range, the valving system 44 operates to deliver the thermally-charged media 46 to the dry cooler 36. Typically, the dry cooler 36 will include little to no fluid or moisture. Accordingly, where the temperature is particularly low, such as below freezing, the dry cooler 36 can operate in a manner that will not result in freezing or icing of the various components of the dry cooler 36.

Similarly, when the ambient temperature 52 is within the predetermined temperature range, use of the fluid-cooled chiller 42 maintains the fluid within a particular cooling chamber 60. The thermally-charged media 46 is moved through this cooling chamber 60 of the fluid-cooled chiller 42. In this manner, heat 16 can be extracted from the thermally-charged media 46 to a separate media within the cooling chamber 60 of the fluid-cooled chiller 42. Accordingly, each of the fluid-cooled chiller 42 and the dry cooler 36 operate in a manner that minimizes or eliminates the possibility of freezing or icing during operation of the cooling system 10.

Referring again to FIGS. 1-4, when the temperature sensor 48 senses that the ambient temperature 52 is above the predetermined temperature range, the valving system 44 operates to deliver the thermally-charged media 46 to the evaporative cooling tower 40. The evaporative cooling tower 40 utilizes various forms of fluid, typically liquid, that is injected as a mist or water droplets into the cooling tower 40 for causing evaporation within the evaporating space 70 of the cooling tower 40. Evaporative cooling towers 40, because they utilize various forms of liquid in generating the evaporative cooling system 10, tend to freeze at lower temperatures. Accordingly, the valving system 44 delivers the thermally-charged media 46 to the evaporative cooling tower 40 in conditions when it is less likely that icing or other freezing will occur within the evaporative cooling tower 40.

Referring again to FIGS. 1-4, the cooling system 10 can include a plurality of separate control valves 80 that can be operated to deliver the thermally-charged media 46 from the thermal energy output 32 of the facility 12 and to one of the cooling components 54 of the cooling system 10. As discussed herein, these cooling components 54 of the cooling system 10 include the dry cooler 36, the evaporative cooling tower 40 and the fluid-cooled chiller 42.

According to the various aspects of the device, these cooling components 54 of the cooling system 10 can be separate components that are separated from one another. In such an aspect of the device, these cooling components 54 can be connected by various material delivery conduits 56 and other similar connections for delivering the thermally-charged media 46 from the facility 12, through one or more components of the cooling system 10, and then back to the facility 12 or to a separate location. It is also contemplated that two or all of the cooling components 54 of the cooling system 10 can be incorporated into a single self-contained assembly that is built within a single structure. This single structure can be manufactured on site, can be manufactured off site or a combination thereof. In such an aspect of the device, the dry cooler 36, the evaporative cooling tower 40 and the fluid-cooled chiller 42 can be manufactured as a unit or integral assembly. Accordingly, the movement of the thermally-charged media 46 can be performed efficiently and within a relatively small area.

According to various aspects of the device, the predetermined temperature range for the cooling system 10 can be between approximately 30° F. and 69° F. These temperatures are typically monitored in a dry bulb setting where the temperature sensor 48 is within the ambient atmosphere or sheltered from precipitation and solar energy. It is contemplated that this predetermined temperature range can vary depending on the elevation and climate in which the facility 12 is located, the design of the facility 12, the thermal exchange requirements and other factors. Accordingly, the predetermined temperature range noted above is an exemplary range of temperatures and is provided as a non-limiting example.

Referring now to FIGS. 1-3, which represent non-limiting aspects of the cooling system 10, thermal energy output 32 can be in the form of a gravity-operated drain from the facility 12. As discussed herein, the thermally-charged media 46 is delivered from the facility 12 via a delivery conduit 56 and into the media flow conduits 90 of the cooling system 10. These media flow conduits 90 can move through an initial filtration system 92 that can include a warm return for collecting the thermally-charged media 46 from the facility 12 as well as a water filter 82 that can include a bypass mechanism 84. The thermally-charged media 46 can then move to a portion of the valving system 44, typically one of the control valves 80. As discussed herein, the one or more control valves 80 of the valving system 44 are operated according to the measurements taken by the temperature sensor 48. Depending upon the ambient temperature 52 surrounding the facility 12 and the cooling system 10, the valves operate to deliver the thermally-charged media 46 to an appropriate cooling mechanism of the heat rejection assembly. Where the ambient temperature 52 is within the predetermined temperature range, a control valve 80 of the valving assembly directs the thermally-charged media 46 to the fluid-cooled chiller 42. The fluid-cooled chiller 42 includes an evaporator 94 and a condenser 96 that operate to reject heat 16 from the thermally-charged media 46 for delivery into a separate area.

According to FIGS. 1-3, the condenser 96 within the fluid-cooled chiller 42 can be coupled with a supplemental thermal exchange system 98 that assists in rejecting heat and thermal energy from the cooling system 10. The supplemental thermal exchange system 98 can operate to move a cooling fluid 110, such as a supplemental thermal exchange media 112, from the fluid-chilled cooler and to one of the evaporative cooling tower 40 and the dry cooler 36 through a supplemental delivery conduit 120. Accordingly, as the heat 16 from a thermally-charged media 46 is delivered to the fluid-cooled chiller 42, this heat 16 is received by the condenser 96 of the fluid-cooled chiller 42 and delivered to one of the other cooling components 54 of the heat rejection assembly, via the cooling fluid 110 that is delivered through the supplemental delivery conduit 120. Depending upon the ambient temperature 52, this cooling fluid 110 can be delivered to the evaporative cooling tower 40 or the dry cooler 36. As discussed herein, where the ambient temperature 52 is above the predetermined temperature range, the cooling fluid 110 is typically delivered to the evaporative cooling tower 40. Alternatively, where the ambient temperature 52 is within or below the predetermined temperature range, the cooling fluid 110 is delivered to the dry cooler 36. This delivery of the cooling fluid 110 is dependent upon the ambient temperature 52 to avoid freezing or icing of the various components of the cooling system 10.

When the cooling fluid 110 from the fluid-cooled chiller 42 is delivered to the evaporative cooling tower 40 or the dry cooler 36, the heat 16 delivered by the cooling fluid 110 is rejected into atmosphere or rejected into a separate thermal exchange media 14 for recycling or reuse of the captured heat 16. The cooling fluid 110, which is now at a lower temperature, is returned to the condenser 96 of the fluid-cooled chiller 42 to again receive the rejected heat 16 from the thermally-charged media 46. After leaving the chiller, the now-spent thermally-charged media 46 is converted to thermally-receptive media 114 and is returned to the facility 12 via a fluid pump 116 and the input 34.

Referring again to FIGS. 1-3, where the ambient temperature 52 is below the predetermined temperature range, the various control valves 80 of the valving system 44 direct the thermally-charged media 46 to the dry cooler 36. In this instance, because of the low ambient temperature 52, the dry cooler 36 operates independently to reject heat 16 from the thermally-charged media 46 to atmosphere or to a supplemental thermal exchange media 112 for recycling the captured heat 16. Also, because of the low ambient temperature 52, air surrounding the dry cooler 36 has a large capacity for receiving and dispersing rejected heat 16. In this manner, the dry cooler 36 is able to efficiently and effectively reject heat 16 from thermally-charged media 46 to atmosphere or to the supplemental thermal exchange media 112.

As is exemplified in FIGS. 1-3, where the ambient temperature 52 is above the predetermined temperature range, the various control valves 80 of the valving system 44 direct the thermally-charged media 46 to the evaporative cooling tower 40. Typically, the evaporative cooling tower 40 utilizes various forms of liquid to generate evaporative cooling within an evaporating space 70 within the cooling tower 40. Where the ambient temperature 52 is within these higher ranges, the evaporative cooling tower 40 rejects heat 16 from the thermally-charged media facility 12 and into the fluid within the evaporation space that includes an evaporator fan 130. The evaporator fan 130 causes the heat 16 to combine with the fluid and elevate the temperature of the fluid within the evaporating space 70. This results in the fluid evaporating and dissipating the heat 16. As discussed herein, this rejected and dissipated heat 16 can be delivered to the ambient atmosphere or can be recycled through the use of the supplemental thermal exchange media 112.

As exemplified in FIGS. 2-3, after the thermally-charged media 46 has been cooled and now defines the thermally-receptive media 114, the thermally-receptive media 114 can be delivered, via a fluid pump 116 and a delivery conduit 56, such as a return conduit 58, back to the input 34 for the facility 12. In certain aspects of the device, this thermally-receptive media 114 can also be delivered to the condenser 96 for the fluid-cooled chiller 42 as well as through the dry cooler 36. By moving the thermally-receptive media 114 through the fluid-cooled chiller 42 and the dry cooler 36, various maintenance functions within these components can be achieved during operation of the cooling system 10. These maintenance operations can be used periodically, such as when one or more of the cooling components 54 remain idle over an extended period of time. Typically, when the evaporative cooling tower 40 is utilized, this occurs during the summer months, when ambient temperatures 52 exceed the predetermined temperature range for an extended period of time. Accordingly, to maintain the fluid-cooled chiller 42 and the dry cooler 36 during these warmer months, movement of the thermally-receptive media 114 through these cooling components 54 can operate to perform these maintenance functions.

According to various aspects of the device, the various fluids and fluid media of the cooling system 10 are operated utilizing one or more fluid pumps 116. It is contemplated that each of these fluid pumps 116 includes a primary pump 140 and a secondary pump 142 that operate in combination to ensure continuous operation of the cooling system 10. In each of the fluid pump locations, the primary pump 140 and secondary pump 142 are switched periodically, such as weekly, to ensure proper operation of each of the primary pump 140 and the secondary pump 142. This switching of operation between the primary pump 140 and secondary pump 142 ensures that the fluid pumps 116 are not idle for an extended period of time. This also assists in maintaining and extending the life of the fluid pumps 116 of the cooling system 10. The use of the primary pump 140 and the secondary pump 142 also allows for periodic maintenance of either the primary pump 140 or the secondary pump 142 without causing a shutdown of the entire system.

According to the various aspects of the device, the various cooling components 54 of the cooling system 10 operate cooperatively to efficiently reject heat 16 from a thermally-charged media 46. As described herein, the rejection of heat 16 by the fluid-cooled chiller 42 typically includes either the evaporative cooling tower 40 or the dry cooler 36, depending upon the ambient temperature 52, to complete rejection of heat 16 from the thermally-charged media 46. These processes serve to convert the thermally-charged media 46 that is delivered from the facility 12 to the thermally-receptive media 114 that is delivered back to the facility 12 for continuing the thermal rejection process.

Referring now to FIGS. 1-5, having described various aspects of the cooling system 10, a method 400 is disclosed for operating a cooling system 10 in conjunction with the facility 12. According to the method 400, step 402 includes delivering a thermally-charged media 46 from the facility 12. Step 404 includes measuring the ambient temperature 52 surrounding the facility 12 utilizing a temperature sensor 48. Step 406 includes operating the valving system 44, based upon the sensed temperature, to deliver the thermally-charged media 46 to one of the dry cooler 36, the evaporative cooling tower 40 and the fluid-cooled chiller 42. Step 408 of the method 400 includes rejecting heat 16 from the thermally-charged media 46 that is delivered back to the facility 12. As discussed herein, the conversion of the thermally-charged media 46 to the thermally-receptive media 114 is accomplished through the heat rejection functions of the dry cooler 36, the evaporative cooling tower 40 and the fluid-cooled chiller 42. Additionally, as described herein, these components can operate in combination to fulfill these heat rejection functions, depending upon the ambient temperature 52. Step 410 includes retuning the thermally-receptive media 114 to the facility 12 to continue the heat rejection process. Accordingly, the media that defines the thermally-charged media 46 and the thermally-receptive media 114 is continuously recirculated through the cooling system 10 and the facility 12. This thermal exchange media 14, as well as the secondary thermal exchange media 14, can be in the form of air, water, glycol, a refrigerant, combinations thereof, and other similar media that is able to efficiently receive and reject heat 16.

As described herein, the valving system 44 utilizes a controller 50 and cooperates with the controller 50 to operate the various control valves 80 of the valving system 44. It is contemplated that the controller 50 can be incorporated within the one or more control valves 80 of the valving system 44. It is also contemplated that the cooling system 10 can include a central controller 50 that operates the various control valves 80 of the valving system 44 as well as the motors, blowers 38 and fluid pumps 116 of the dry cooler 36, the evaporative cooling tower 40 and the fluid-cooled chiller 42.

These cooling components 54 can be sized and configured based upon the amount of heat 16 being rejected from a particular facility 12. By way of example, and not limitation, the dry cooler 36 can include one or more blowers 38. Typically, the dry cooler 36 includes a plurality of blowers 38 that can be used for moving a media, typically ambient air, across flow conduits 90 containing the thermally-charged media 46. These blowers 38 operate to reject heat 16 from the thermally-charged media 46 to atmosphere. Additionally, the evaporative cooling tower 40 can be sized to accommodate a particular cooling capacity. The number of evaporative cooling towers 40 can also be adjusted depending on the heat-rejecting needs of the facility 12. Additionally, the fluid-cooled chiller 42 can include a single chiller or multiple chillers that can operate in combination.

Degrees F.		Degrees F.	Chillers Electrical Usage
Measures at	HRS/	Measured @	Cond.	KW Hrs	EQUIPMENT OPERATING
Wet Bulb	YEAR	Dry Bulb	Temp.	(540 Ton)	*cooling tower	WATER
65	0	100/104	72	0.46	A - for chiller condensers	water evaporated
62	18	95/99	68	0.407		1% flow
61	129	90/94	68	0.407	1,756 total operating hr/yr	540 ton @ 3 gal/ton × 1% = 16.2 gpm
60	252	85/89	67	0.407		16.2 gpm × 1756 hr/yr × 60
58	347	80/84	65	0.407
56	444	75/79	63	0.407		1,706,832 gallons/year
54	566	70/74	61	0.407		540 ton × 1756 hrs/yr ×
						.427 kw hr = 404,898 kw/yr
52	634	65/69			* dry cooler
49	619	60/64			B - for chiller condensers	0
46	601	55/59				water evaporated
43	672	50/54
39	712	45/49			5,680 total operating hours per year
36	777	40/44
32	849	35/39
29	816	* 30/34
24	601	25/29			C - dry cooler to supply
					chilled water (water
					cooled chiller off)
20	385	20/24				0
16	201	15/19				water evaporated
11	82	10/14
6	36	5/9			1,321 total operating hours per year
2	11	0/4
−3	3	−5/−1
−8	1	−10/−6
−13	1	−15/−11
Total Hours=	8757				Total water evaporated = 1,706,832 gallon/year

Referring again to FIGS. 1-4, the exemplary cooling system 10 provided herein utilizes certain amount of electricity for operating the various mechanical and electrical components of the cooling system 10. An exemplary cooling tower 40 may include a plurality of blowers and fluid pumps 116 for delivering the various cooling fluids within and around the cooling tower 40. As discussed herein, it is also contemplated that the other components of the cooling system 10 can supplement the cooling tower 40 and certain conditions. In such an aspect of the device, the dry cooler 36 and the fluid-cooled chiller 42 can assist in rejecting heat 16 from the thermally-charged media 46 to create the thermally-receptive media 114 to the facility 12. As described herein, the thermally-charged media 46 is delivered to the evaporative cooling tower 40 when ambient temperature 52 is above the predetermined temperature range. As stated another way, when the ambient temperature 52 is warmer, the thermally-charged media 46 is delivered to the evaporative cooling tower 40 for rejecting heat 16 from the thermally-charged media 46.

Referring again to FIGS. 1-4, according to the exemplary cooling system 10 provided above, the fluid-cooled chiller 42 is utilized for rejecting heat 16 from the thermally-charged media 46 when the ambient temperature 52 is within the predetermined temperature range. As described herein, this predetermined temperature range can vary depending upon several factors. Such factors can include, but are not limited to, humidity, altitude, annual precipitation, monthly precipitation, and other similar conditions that can affect humidity levels, temperature, and other atmospheric conditions. As with the evaporative cooling tower 40, the fluid-cooled chiller 42 can be supplemented through the use of the evaporative cooling tower 40 and the dry cooler 36 to provide additional heat-rejecting capabilities for converting the thermally-charged media 46 to the thermally-receptive media 114. The electrical components of the cooling system 10 are again operated and utilized a certain load of electrical power. Various fans, vents, chillers, and other similar components can utilize electrical power for use during operation of the cooling system 10.

The dry cooler 36 is utilized when the ambient temperature 52 is below the predetermined temperature range. Typically, in this condition, it may not be necessary for the fluid-cooled chiller 42 to operate in these lower temperatures. Accordingly, the cooled-ambient air may be sufficient for extracting or rejecting heat 16 from the thermally-charged media 46 for creating the thermally-receptive media 114 that is returned to the facility 12.

It is contemplated that in conditions where the evaporative cooling tower 40 and/or the dry cooler 36 are supplementing the fluid-cooled chiller 42 for rejecting heat 16 that most electricity will be utilized during use of the cooling system 10. Because the dry cooler 36 operates in the lowest temperature ranges, this aspect of the device may utilize the least amount of electricity as the other components of the cooling system 10 may not be needed for rejecting heat 16 from the thermally-charged media 46. Again, the amount of electricity used can vary depending upon certain atmospheric and environmental conditions that can bear on humidity levels, temperature and other environmental factors that relate to the location where the facility 12 is located.

With respect to the exemplary device described above, the annual electrical load drawn by the cooling system 10 can be within a range of approximately 1.5 million kilowatts per year to 2.25 million kilowatts per year.

Utilizing the cooling system 10, a facility 12 can operate various processes and reject heat 16 generated through these processes at any time of year regardless of the ambient temperature 52 and other environmental conditions and factors. These environmental factors and conditions can include, but are not limited to, geographic location, climate, altitude, humidity, barometric pressure and other environmental conditions. Accordingly, use of fluid, typically water, can be maximized for use at certain times of the year and under certain particular conditions depending on the cost and availability of water. It is contemplated that where water is scarce, such as during a drought or where most water is frozen, the fluid-cooled chiller 42 and the dry cooler 36 can operate in combination to achieve at least a portion of the thermal exchange function for the cooling system 10.

It is to be understood that variations and modifications can be made on the aforementioned structure without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.

Claims

1. A cooling system for an industrial facility, the cooling system comprising: a facility having a thermal energy output and an input;a dry cooler that includes a plurality of blowers;an evaporative cooling tower;a fluid-cooled chiller;a valving system that receives a thermally-charged media from the thermal energy output for delivery to at least one of the dry cooler, the evaporative cooling tower, and the fluid-cooled chiller;a temperature sensor in communication with the valving system via a controller, wherein the temperature sensor measures a current ambient temperature and cooperates with the controller to automatically adjust the valving system to direct the thermally-charged media to one of the dry cooler, the evaporative cooling tower, and the fluid-cooled chiller for rejecting heat from the thermally-charged media to define a thermally-receptive media; anda return conduit that delivers the thermally-receptive media to the input.

2. The cooling system of claim 1, wherein the valving system operates to deliver the thermally-charged media to the fluid-cooled chiller when the ambient temperature is within a predetermined temperature range.

3. The cooling system of claim 2, wherein the valving system operates to deliver the thermally-charged media to the dry cooler when the ambient temperature is below the predetermined temperature range.

4. The cooling system of claim 3, wherein the valving system operates to deliver the thermally-charged media to the evaporative cooling tower when the ambient temperature is above the predetermined temperature range.

5. The cooling system of claim 4, wherein the predetermined temperature range is between approximately 30 degrees Fahrenheit at dry bulb and approximately 70 degrees Fahrenheit at dry bulb.

6. The cooling system of claim 1, wherein the controller is incorporated within the valving system.

7. The cooling system of claim 1, wherein the valving system, the dry cooler, the evaporative cooling tower, and the fluid-cooled chiller are incorporated within a self-contained assembly.

8. The cooling system of claim 1, wherein the thermally-charged media is delivered from the thermal energy output to the valving system via a gravity-operated drain.

9. The cooling system of claim 1, wherein the return conduit includes a process pump that directs the thermally-receptive media to the input.

10. The cooling system of claim 1, further comprising a filtration system that is positions between the thermal energy output and the valving system.

11. The cooling system of claim 1, further comprising a supplemental delivery conduit having a cooling fluid that extends from the fluid-cooled chiller to the dry cooler and the evaporative cooling tower.

12. The cooling system of claim 11, wherein the dry cooler and the evaporative cooling tower provide a supplemental thermal exchange system that supports the fluid-cooled chiller.

13. A cooling system for an industrial facility, the cooling system comprising: a dry cooler that includes a plurality of blowers;an evaporative cooling tower;a fluid-cooled chiller;a valving system that delivers a thermally-charged media to one of the dry cooler, the evaporative cooling tower, and the fluid-cooled chiller, wherein the valving system is configured to receive the thermally-charged media from an injection molding facility;a temperature sensor in communication with the valving system via a controller, wherein the temperature sensor measures a current ambient temperature and cooperates with the controller to automatically adjust the valving system to direct the thermally-charged media to one of the dry cooler, the evaporative cooling tower, and the fluid-cooled chiller for rejecting heat from the thermally-charged media to define a thermally-receptive media; anda supplemental cooling system that extends between the fluid-cooled chiller to the dry cooler and between the fluid-cooled chiller to the evaporative cooling tower, the supplemental cooling system assisting the fluid-cooled chiller in rejecting heat from the thermally-charged media.

14. The cooling system of claim 13, wherein: the valving system operates to deliver the thermally-charged media to the fluid-cooled chiller when the current ambient temperature is within a predetermined temperature range;the valving system operates to deliver the thermally-charged media to the dry cooler when the current ambient temperature is below the predetermined temperature range; andthe valving system operates to deliver the thermally-charged media to the evaporative cooling tower when the current ambient temperature is above the predetermined temperature range.

15. The cooling system of claim 14, wherein the predetermined temperature range is between approximately 30 degrees Fahrenheit at dry bulb and approximately 70 degrees Fahrenheit at dry bulb.

16. The cooling system of claim 13, wherein the valving system, the dry cooler, the evaporative cooling tower, and the fluid-cooled chiller are incorporated within a self-contained assembly.

17. The cooling system of claim 13, wherein a filtration system is positioned upstream of the valving system.

18. The cooling system of claim 13, wherein the controller is incorporated within the valving system.

19. A method for operating a cooling system for a facility, the method including steps of: delivering a thermally-charged media from a facility to a cooling system;measuring a temperature of ambient air surrounding the facility utilizing a temperature sensor;operating a valving system based upon the temperature of the ambient air to deliver the thermally-charged media to one of a dry cooler, an evaporative cooling tower and a fluid-cooled chiller;rejecting heat from the thermally-charged media to define a thermally-receptive media; andreturning the thermally-receptive media to the facility.

20. The method of claim 19, wherein the step of operating the valving system includes: operating the valving system to deliver the thermally-charged media to the fluid-cooled chiller when the temperature of the ambient air is within a predetermined temperature range;operating the valving system to deliver the thermally-charged media to the dry cooler when the temperature of the ambient air is below the predetermined temperature range; andoperating the valving system to deliver the thermally-charged media to the evaporative cooling tower when the temperature of the ambient air is above the predetermined temperature range.