Heat exchanger apparatus

Abstract

The invention relates to a heat exchanger apparatus comprising at least one metal sheet (10) (e.g. aluminium), and preferably a plurality in a stack. Each metal sheet (10) has a corrugated surface, with fabric covering at least a portion of one surface of the metal sheet to promote evaporation. A wetting agent (e.g. LiCl/Polyvinyl-Alcohol (PVA) solution) is provided in the fabric to promote wetting of the fabric, and also acts as an anti-microbial agent. The fabric preferably covers all of the corrugated surface, and two planar portions are provided above and below the corrugated surface respectively. In use, the heat exchanger apparatus is disposed with a long side vertical and the corrugated surface is disposed on a middle portion, the upper planar portion is contiguous with an air outlet, and/or the lower planar portion is contiguous with an air inlet. In a preferred embodiment, the corrugated surface has in cross-section a profile of a periodic waveform, wherein the peak-to-peak distance is 11.6 mm, the amplitude is 2.5 mm, and corrugations intersect the plane of the heat exchanger apparatus at an angle to that plane of 50 degrees. Also disclosed are a cooling system incorporating the heat exchanger apparatus and methods of operating the cooling system, involving intermittently operating a water supply system for the application of water to the fabric, and/or, recirculating water from a water sump using the water supply system.

Claims

1. A heat exchanger apparatus, comprising: a plurality of metal sheets placed together such that adjacent metal sheets of the plurality of metal sheets define channels to promote air flow; a water supply system; and a controller coupled to the water supply system, wherein each sheet of the plurality of metal sheets includes a corrugated surface having corrugations over a first portion of the metal sheet, fabric covering a second portion of the metal sheet to promote evaporation, the second portion at least overlapping the first portion, a wetting agent in the fabric to promote wetting of the fabric and to act as an anti-microbial agent, and at least some of the corrugations in the corrugated surface having at least one through hole located near an uppermost end of the metal sheet, wherein the plurality of metal sheets has an axis of elongation arranged vertically, the corrugations being parallel with the axis of elongation, wherein the water supply system is configured for supplying water to the fabric of the heat exchanger apparatus for evaporative cooling, and wherein the controller is configured to operate the water supply system for the application of water to the fabric to maintain the fabric in a moist condition.

2. A heat exchanger apparatus according to claim 1, wherein (i) the second portion is overlapping the first portion, or (ii) the first portion is fully contained within the second portion.

3. A heat exchanger apparatus according to claim 2, wherein each of the metal sheets comprises, outside the first portion, a third portion, the third portion being flat.

4. A heat exchanger apparatus according to claim 3, wherein (i) the first portion of each of the metal sheets is disposed on an upper portion of the heat exchanger apparatus and/or is contiguous with an air outlet, and/or (ii) the third portion is disposed on a lower portion thereof and/or is contiguous with an air inlet.

5. A heat exchanger apparatus according to claim 2, wherein each of the metal sheets comprises, outside the first portion, a fourth portion, the fourth portion being flat.

6. A heat exchanger apparatus according to claim 5, wherein the fourth portion is disposed on an uppermost portion of each of the metal sheets and/or is contiguous with an air outlet.

7. A heat exchanger apparatus according to claim 1, wherein the corrugated surface has, in cross-section, a profile of a periodic waveform, and wherein the periodic waveform has a peak-to-peak distance of (i) 10-13 mm, (ii) 11-12 mm or (iii) 11.6 mm, and/or wherein the periodic waveform has an amplitude of (i) 2-3 mm, (ii) 2.2-2.8 mm or (iii) 2.5 mm, and/or wherein corrugations intersect the plane of the heat exchanger apparatus at an angle to that plane of (i) 46-54 degrees, (ii) 48-52 degrees, or (iii) 50 degrees.

8. A heat exchanger apparatus according to claim 1, wherein the fabric is a synthetic moisture-wicking fabric.

9. A heat exchanger apparatus according to claim 1, wherein the fabric is formed of (i) polyester or (ii) textile fabric.

10. A heat exchanger apparatus according to claim 1, wherein the wetting agent comprises a haloid and polyvinyl surfactant.

11. A heat exchanger apparatus according to claim 10, wherein the wetting agent comprises Polyvinyl Pyrollidone (PVP) or Polyvinyl-Alcohol (PVA).

12. A heat exchanger apparatus according to claim 10, wherein the wetting agent comprises a salt compound.

13. A heat exchanger apparatus according to claim 12, wherein the wetting agent is a LiCl/Polyvinyl-Alcohol (PVA) solution.

14. A heat exchanger apparatus according to claim 1, wherein each of the metal sheets is formed of aluminium.

15. A heat exchanger apparatus according to claim 1, wherein all of the corrugations in the corrugated surface of each of the metal sheets have one or more through holes at or near the uppermost end thereof.

16. A heat exchanger apparatus according to claim 1, wherein the water supply system is configured to recirculate water to the heat exchanger apparatus from a water sump.

17. A method of operating a cooling system, the method including: providing a heat exchanger apparatus according to claim 1; and intermittently operating the water supply system using the controller for the application of water to the fabric to maintain the fabric in a moist condition.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Other features of the invention will be apparent from the following description of preferred embodiments shown by way of example only with reference to the accompanying drawings, in which;

(2) FIG. 1 shows a perspective side view of a heat exchanger sheet according to an embodiment of the invention;

(3) FIG. 2 shows a perspective side view of a stack of heat exchanger sheets shown in FIG. 1;

(4) FIG. 3 is a schematic perspective view of four sheets of the apparatus of FIG. 2;

(5) FIG. 4 is a cross section across the heat exchanger sheet shown in FIG. 1; and

(6) FIG. 5 shows steps of a method according to an embodiment of the invention.

DETAILED DESCRIPTION

(7) FIG. 1 shows a perspective side view of a heat exchanger sheet according to an embodiment of the invention, generally designated 10. In FIG. 1 the heat exchanger sheet is shown in its normal orientation in use. The heat exchanger sheet 10 is of series 5005 aluminium. The heat exchanger sheet 10 is corrugated over an upper region 14. The series 5005 aluminium used to form the heat exchanger sheet 10 provides suitable ductility to form the corrugations, and also provides the required thermal conductivity. An upper region 15 of the heat exchanger sheet 10 is planar. A lower region 16 of the heat exchanger sheet 10 is planar. Also shown is that the transition 17 from each of the upper region 15 and the lower region 16 to the corrugations is smooth. The heat exchanger sheet 10 is 360 mm wide, and 1000 mm long. The corrugated region of the heat exchanger sheet 10 is 860 mm in length. The planer region 16 is 115 mm in length, and the planer region 15 is 20 mm in length. As shown in FIG. 1 the heat exchanger sheet 10 is elongate and an axis of elongation 19 thereof is indicated, which is a direction of the heat exchanger sheet 10 with the greatest dimension. In use the axis of elongation 19 is arranged vertically (i.e. substantially vertically). The axis of elongation 19 is also the direction in which the channels run, and is also the direction in which fluid flows as discussed below.

(8) A fabric is glued to one side of the heat exchanger sheet 10 as shown by the dashed outline 12. The fabric is preferably formed of a material exhibiting the following, or substantially similar, properties in a test of the capillary wick effect (i.e. water suction height), when the material is suspended with its lower end in water:

(9) TABLE-US-00001 Wicking height (cm) (a) 1.0 1.5 3.1 3.6 5.2 6.2 (b) 4.9 6.3 9.0 11.0 14.2 16.5

(10) More preferably, the fabric is formed of Coolmax-2 ((b) above), available from Invista. The row (a) above is for craft paper and is included as a control to show the advantages of using Coolmax-2.

(11) The fabric is preferably formed of a material exhibiting the following, or substantially similar, properties in a test of water diffusivity and evaporation rate, when the material is glued to the aluminium sheet, has water drops applied to it and is observed from above:

(12) TABLE-US-00002 Drop Wetted Evaporation diffusion time area (cm.sup.2) time (min) (a) 7′30″ 9′20″ 5.6 57.3 24′10″ 46′40″ (b) 57″ 11′45″ 3.4 64.4 13′12 29′10″

(13) More preferably, the fabric is formed of Coolmax-2 ((b) above), available from Invista. The row (a) above is for craft paper and is included as a control to show the advantages of using Coolmax-2. It will be appreciated that the Coolmax fabric is a polyester material, which is synthetic and generally resistant to degradation, which might be termed a synthetic moisture-wicking fabric, e.g. a woven fabric that is synthetic and moisture-wicking.

(14) The operation to apply the fabric to the aluminium sheet involves grinding of the aluminium surface to abrade it, applying a specific Sikaflex®-291i Marine Adhesive on the rough surface, and spreading the fabric (preferably Coolmax-2 fibre) on the glued surface. It has been found by the inventors that an excellent binding up effect is thus created, leading to the enhanced heat transfer between the dry and wet sides of the sheets 10, and increased water evaporation on the wet surface of the sheets 10. Such an adhesive provides a suitable heat transfer between the aluminium heat exchanger sheet 10 and the fabric 12. In one arrangement for manufacture of the heat exchanger sheet 10, a hotplate (not shown) is preheated to a designated temperature and allowed to stabilise for about 30 minutes, the heat exchanger sheet 10 is then placed on the hotplate for about 5 minutes, the adhesive is then spread over the heat exchanger sheet 10, and then the fabric 12 is put on to the adhesive on top of the heat exchanger sheet 10. Pressure is then applied on the top of the fabric 12 (for example by placing a mass having a suitable profile onto the fabric 12), the hotplate is then allowed to cool until the adhesive is set. Such a way of applying the fabric 12 to the heat exchanger sheet 10 may be termed a hot pressure method.

(15) To complete preparation of the fabric, a wetting agent, preferably a haloid polyvinyl surfactant solution, e.g. LiCl/Polyvinyl-Alcohol water affinity solution, is applied to the fabric. It has been found by the inventors that an enhanced water diffusivity effect is achieved and, over long term operation, the surface had no fouling, corrosion, as well as no bacterial growth. The LiCl/Polyvinyl-Alcohol solutions act as a water affinity solution (i.e. a wetting agent), and also acts as an anti-microbial agent. Alternatively Polyvinyl Pyrollidone (PVP) may be used instead of the Polyvinyl-Alcohol (PVA) wetting agent. Furthermore, the haloid and polyvinyl surfactant solution may alternatively be termed a polymeric wetting agent, which also acts as an anti-microbial agent. In general terms the wetting agent/anti-microbial agent is a mixture of a salt and a wetting agent, for example, a combination of a lithium salt and a wetting agent.

(16) Returning to FIG. 1, in each heat exchanger sheet 10, two rows of through holes 18 are provided at an upper end of the corrugations. In one arrangement, up to four rows of through holes 18 may be provided. The through holes 18 are in a side of each raised portion of each corrugation. As will be described in more detail below, during operation, the intake air is drawn into a heat exchanger apparatus incorporating a stack of the heat exchanger sheets 10. This part of the air travels along dry channels formed by the stack. At the end of the dry channels, the air is divided into two parts: one is delivered to the room space for space cooling while the other is diverted to the adjacent wet channels, via through holes 18.

(17) FIG. 2 shows a perspective side view of a stack of heat exchanger sheets 10 shown in FIG. 1, generally designated 20. In FIG. 2 like features to the arrangements of FIG. 1 are shown with like reference numerals. In FIG. 2 the heat exchanger sheets 10 are placed next to each other so that the aluminium sides of adjacent heat exchanger sheets 10 are facing each other, and so that the fabric sides of adjacent heat exchanger sheets 10 are facing each other. The corrugations of adjacent sheets provide vertical channels such that there are “wet channels” having fabric sides, and “dry channels” having aluminium sides. In this embodiment the gap between two heat exchanger sheets 10 to form a wet or dry channel is at its maximum 5 mm. The vertical channels comprise trapezoid or rhomboid flow channels for the “wet” and “dry” air. The surfaces of the adjacent sheets 10 do not require supporters to form these trapezoid or rhomboid flow channels, which avoids a restriction to the air flow. Such an arrangement of adjacent sheets 10 stops moisture transfer between adjacent channels, and means that only heat transfer can happen between adjacent “wet” or “dry” air channels, also which provides an overall improved operation of the heat exchanger sheets 10.

(18) In FIG. 2 the ambient intake air (either from outside of the room or mixture of outside and inside of the room air, received via an inlet air filter) is shown at 22, the cool product outlet air is shown at 24, and the working air and water discharge are shown at 26. Water is input at the top of each “wet channel”. It will be appreciated that whereas the stack of heat exchanger sheets are shown at 28, in practice the sides would be closed so that air or water does not escape. In practice there might be up to 100 heat exchanger sheets 10 in a stack.

(19) It will be appreciated that the flat regions 15 and 16 of each heat exchanger sheet 10 comprise inlet and outlet regions respectively. Such flat parts of the heat exchanger sheets 10 permit ready air and water distribution within the channels of the stack of heat exchanger sheets 20.

(20) FIG. 3 is a schematic perspective view of four sheets of the apparatus 20 of FIG. 2, generally designated 30. In FIG. 3 like features to the arrangements of FIG. 2 are shown with like reference numerals. In FIG. 3 four heat exchanger sheets 10 are shown with the corrugations omitted for clarity. Surfaces of two of the heat exchanger sheets 10 having fabric on them are shown at 32 (i.e. the fabric 32 is on one side of each sheet 10). Aluminium surfaces of two of the heat exchanger sheets 10 are shown at 34 (i.e. the aluminium surface 34 is one side of each sheet 10). With such an arrangement the fabric 32 of a surface of one sheet 10 faces the fabric 32 of a surface of another sheet 10. Similarly the aluminium surface 34 of one sheet 10 faces the aluminium surface 34 of another sheet 10. Also shown is a water reservoir 36 having a water level 38. The water reservoir is filled from a supply of water 40, which may be tap water. A pump 42 transfers water from the water reservoir 36 along conduit 44 to two water ducts 46 at the top of the two wet channels. Water 46 from the waters ducts 46 wets the fabric 32 on each heat exchanger sheet 10, and the fibres of the fabric with the wetting agent help to spread moisture on the fabric 32 and enlarge the wetted area, which promotes evaporation. A valve device (not shown) may be provided so that the supply of water 30 is shut off when the reservoir water is at a certain level.

(21) The ambient intake air 22 is drawn into a dry channel by a fan (not shown). The intake air is then split into two streams whereby one stream 50 passes into the through holes 18 and the other stream exits as the cool product outlet air 24. The stream 50 then enters the two wet channels as shown at 52 where it causes water to evaporate from the fabric. The stream 50 also absorbs the heat transported from the dry channel and receives the moisture evaporated from the wet channel surface, i.e. the fabric 32. It will be understood that the fabric 32 promotes high evaporation due to the fibres and wetting agent thereof. It will be appreciated that a top of each wet chamber is closed so that the air cannot escape from the top of each wet channel and is forced downwards as shown at 52. The working air and water discharge are shown at 26. Such an arrangement may be termed a counter flow heat exchanger whereby inlet ambient air 22 passes in one direction (i.e. upwards) on one side of a sheet 10, and working air and water 26 pass in another direction (i.e. downwards) on another side of the sheet 10. It will be understood that the inlet ambient air 22 passes upwards in a “dry channel”, and the working air and water 26 pass downwards in a “wet channel”. With such an arrangement each of four corrugated heat exchanger sheets 10 works as a heat transfer plate with an increased heat transfer area. The air discharged at 26 is hot and humid. It will be appreciated that the air 22 travels along the dry channels of the stack where it loses heat and becomes colder due to the established temperature difference between the dry and wet sides of the sheets 10 caused by the water evaporation on the wet surface. In effect the corrugated region provides an increased heat and mass transfer area between the air 22 and the air 26.

(22) The four sheets 10 are only a part of the stack of heat exchanger sheets 10, and the four sheets of FIG. 3 are a small working unit of the apparatus. In practice the four-sheet unit would be repeated several times in a stack of heat exchanger sheets 10. It will also be appreciated that a controller (not shown) is coupled to the water supply system, and is configured for intermittently operating the water supply system for the application of water to the fabric to maintain the fabric in a moist condition. The controller is also configured to recirculate water to the heat exchanger apparatus from the water reservoir 36, which may also be termed a water sump.

(23) FIG. 4 is a cross section across the heat exchanger sheet shown in FIG. 1. As seen in FIG. 4, the corrugated surface has in cross-section a profile of a periodic waveform. Such a waveform may be quasi sinusoidal, triangular or other. An irregular or regular corrugated surface may be used.

(24) The corrugated surface has a horizontal dimension W, in the direction transverse to the direction of extension of corrugations therein, of 300-400 mm, 325-375 mm, or, in a preferred embodiment, 348 mm. In any event, the heat exchanger sheets 10 may have side strips 59, i.e. at the edges of the sheet 10, that are 6 mm wide, thereby facilitating mounting/fixing of the sheets in a stack.

(25) The corrugations are chosen to be of a particular dimension to promote air flow. Thus, in terms of the aforementioned periodic waveform, it may have a peak-to-peak distance T (i.e. wavelength) of 10-13 mm, 11-12 mm, or in a preferred embodiment 11.6 mm. In addition, the periodic waveform may have an amplitude 2 A of 4-6 mm, 4.5-5.5 mm or, in a preferred embodiment, 5 mm. Thus, in this embodiment the corrugations are 2.5 mm deep and 5.8 mm wide from the plane of the sheet 10. It has been found by the inventors that corrugations of these dimensions produce channels that are particularly effective in enhancing heat exchanger efficiency. FIG. 4 also shows that the corrugations intersect the plane of the heat exchanger apparatus at an angle to that plane of 50 degrees, and the angle may be between 46-54 degrees, or in a preferred embodiment 48-52 degrees.

(26) It will be understood from FIG. 4 that the plane of the heat exchanger sheet 10 is shown at 57, and that the flat regions 15, 16 are coplanar with the plane 57. Such an arrangement facilitates the water distributor and the inlet/outlet of the air flow through the stack of heat exchanger sheets 10.

(27) FIG. 5 shows steps of a method according to an embodiment of the invention, generally designated 60. It will be appreciated that the steps may be performed in a different order, and may not necessarily be performed in the order shown in FIG. 5.

(28) Initially, at step 62, a plurality of heat exchanger sheets 10 are provided; this may involve tens or hundreds of heat exchanger sheets 10. Then, the heat exchanger sheets 10 are formed into a stack or heat exchanger apparatus at step 64. As part of a cooling system as hereinbefore described, a water supply system (including sump, conduits etc.) is provided, at step 66. Thereafter, the cooling system is operated at 68.

(29) As part of the latter step, the method 60 may comprise the step 70 and/or the step 72. Step 70 comprises receiving water from the stack into the water sump and recirculating water back to the stack from the water sump. It has been found by the inventors that with this small amount of water supply, the water can be directly provided from a water tap, while the circulation pump need only be activated when the bottom water tank is full. This can significantly reduce the operational time of the pump and thus, minimise its power consumption.

(30) Step 72 comprises intermittently operating the water supply system for the application of water to the fabric. It has further been found by the inventors that water supply towards the wet surfaces of the heat exchanging sheets 10 should not be run continuously; instead, it should be run intermittently, for example for 20 seconds during each ten minutes of operation. This method can create a saturated wet surface over the operational period, while preventing the formation of a water film above the wet surface, which can cause a negative effect upon the water evaporation.

(31) Combination of the above features has led to an increase in the cooling system's energy efficiency (COP) by around 80 to 100%, which means that the new heat exchanger apparatus can achieve around 40 to 50% savings in energy use compared to the existing best performance dew point (evaporative) cooling technology with the same amount of cooling output. This will contribute to global energy savings and carbon reduction targets.

(32) The above description describes the heat exchanger sheet 10 being corrugated over an upper region 14 thereof, the lower portion 16 being substantially flat and the portion 15 above the upper region 14 also being substantially flat. In an alternative arrangement the heat exchanger sheet 10 may be corrugated over substantially the entire surface thereof. It will be understood that the area of the corrugated region 14 relative to the area of the heat exchanger sheet 10, or the area of the flat regions 15, 16 may depend on the configuration of the heat exchanger apparatus, and the skilled person will know the requirements for determining the area of the corrugated region 14 and/or flat regions 15, 16.

(33) In the foregoing description various portions of the heat exchanger sheet 10 are shown, for example, the portion 14 with corrugations, the portion 12 with fabric, the lower portion 16 that is flat, and the upper portion 15 that is flat. It will be understood that the area of the portions 12, 14, 15, 16 relative to one another and/or to relative to the area of the heat exchanger sheet 10 may depend on the configuration of the heat exchanger apparatus, and the skilled person will know the requirements for determining the area of the portions 12, 14, 15, 16. In one arrangement the corrugated surface comprises corrugations over a first portion 14 of the one surface of the heat exchanger sheet 10, and the fabric covers at least a second portion 21 (see FIG. 1) of the one surface, such that the second portion 21 at least overlaps the first portion 14. It will be appreciated that the second portion 21 shown in FIG. 2 is for illustrative purposes only, and the amount of overlap between the first portion 14 and the second portion 21 may be larger than shown. In another arrangement the corrugated surface comprises corrugations over a first portion 14 of the one surface of the heat exchanger sheet 10, and the fabric covers at least a second portion 12 of the one surface, the first portion 14 being fully contained within the second portion 12 (see FIG. 1).