High-output atmospheric water generator
11679339 ยท 2023-06-20
Assignee
Inventors
Cpc classification
Y02A20/00
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B01D5/0051
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
An atmospheric water generator (AWG) may be used to extract water from ambient air. A compact screw compressor of the AWG may be used to compress refrigerant, a condenser of the AWG may be used to condense refrigerant, an expansion device, and an evaporator of the AWG may be used to transfer heat from ambient air to refrigerant, causing moisture in the air to condense. The condensed moisture may be collected in a water collection unit.
Claims
1. An apparatus, comprising: a first atmospheric water generation circuit comprising: a first condenser configured to condense refrigerant to a liquid state, the first condenser comprising microchannel coils; a first expansion device having an inlet coupled to an outlet of the first condenser and configured to reduce refrigerant pressure and temperature; a first evaporator having an inlet coupled to an outlet of the first expansion device and configured to condense water from air adjacent to the first evaporator by transferring heat from the air to the refrigerant, the first evaporator comprising microchannel coils; a container configured to collect the water condensed by the first evaporator; a first compact screw compressor having an inlet coupled to an outlet of the first evaporator and an outlet coupled to an inlet of the first condenser configured to compress the refrigerant; a first fan for moving the air though the apparatus; a water treatment system coupled to an output of the container to treat water from the container; a pump for pumping water from the container and through the water treatment system; a water line for passaging water from the water treatment system to an output of the apparatus; a subcooling system coupled between the outlet of the first condenser and the inlet of the first expansion device configured to absorb heat from refrigerant flowing from the first condenser to the first expansion device, wherein the subcooling system comprises a refrigerant circuit separate from the refrigerant circuit of the first atmospheric water generation circuit; and a controller, operable for controlling the first fan, the first evaporator, the first compact screw compressor, and the pump of the first atmospheric water generation circuit and controlling the subcooling system, for producing treated water from the air.
2. The apparatus of claim 1, wherein the first fan comprises a vane-axial fan configured to removed dry air from an area adjacent to the first evaporator and configured to replace the dry air with moist air.
3. The apparatus of claim 2, wherein the vane-axial fan is further configured to cool the condenser.
4. The apparatus of claim 1, wherein the subcooling system comprises a direct expansion plate heat exchanger configured to transfer heat directly between refrigerant flowing from the first condenser to the first expansion device and refrigerant flowing through the subcooling system.
5. The apparatus of claim 1, wherein the subcooling system comprises a heat rejection unit to cool the subcooling system.
6. The apparatus of claim 5, wherein the heat rejection unit comprises an airfoil axial fan.
7. The apparatus of claim 6, wherein airflow of the subcooling system produced by the airfoil axial fan is isolated from the first evaporator.
8. The apparatus of claim 1, further comprising a variable frequency drive (VFD) configured to control one or more motors of the system.
9. The apparatus of claim 1, wherein the water treatment system is coupled to the output of the container to treat water from the container for microbial, particulate, and dissolved mineral content.
10. The apparatus of claim 9, wherein the pump comprises a double diaphragm water condensate pump to pump water from the container through the water treatment system.
11. The apparatus of claim 1, further comprising: a second atmospheric water generation circuit comprising: a second condenser configured to condense refrigerant to a liquid state; a second expansion device having an inlet coupled to an outlet of the second condenser and configured to reduce refrigerant pressure and temperature; a second evaporator having an inlet coupled to an outlet of the second expansion device and configured to condense water from air adjacent to the second evaporator by transferring heat from the air to the refrigerant; and a second compact screw compressor having an inlet coupled to an outlet of the second evaporator and an outlet coupled to an inlet of the second condenser configured to compress the refrigerant, wherein the container collects water from both the first evaporator and the second evaporator.
12. The apparatus of claim 11, wherein: the subcooling circuit is operable to cool the first and the second atmospheric water generation circuit.
13. The apparatus of claim 1, wherein the apparatus further comprises a second expansion device and a second evaporator, wherein the first and second evaporators are coupled in parallel with the first compact screw compressor.
14. The apparatus of claim 1, wherein the compact screw compressor does not require any of an external motor, oil filter, oil reservoir, and oil cooling system to operate.
15. The apparatus of claim 1, wherein the first condenser, first evaporator, first, expansion valve, and first compact screw compressor are each configured to be operationally positioned within a standard shipping container.
16. The apparatus of claim 15, wherein the apparatus is configured to condense water from air following the coupling of one or more fans onto the standard shipping container.
17. The apparatus of claim 1, wherein: the subcooling system comprises a subcooling compressor, a subcooling condenser, a subcooling heat exchanger, a subcooling expansion valve, and a subcooling evaporator; and the controller is operable to control operation of the subcooling compressor, the subcooling condenser, the subcooling expansion valve, and the subcooling evaporator of the subcooling system.
18. The apparatus of claim 1, wherein the controller is operable to control operation of the first expansion device and govern the rate and pressure at which refrigerant is passed to the first evaporator, the first pump, and the first compact screw compressor.
19. The apparatus of claim 1, wherein the apparatus comprises a water production capacity up to or exceeding approximately 10,000 gallons per day.
20. A method for condensing water comprising: compressing refrigerant using a first compact screw compressor; transferring the refrigerant from the first compact screw compressor to a first condenser having microchannel coils; condensing the refrigerant to a liquid state, using the first condenser; transferring the refrigerant from the first condenser to a first expansion device; reducing refrigerant pressure and temperature, using the first expansion device; transferring the refrigerant from the first expansion device to a first evaporator having microchannel coils; condensing water from air adjacent to the first evaporator, using the first evaporator, by transferring heat from the air to the refrigerant; and collecting the condensed water in a container; operating a pump to transfer the collected water through a water treatment system: transferring the refrigerant from the first evaporator to the first compact screw compressor, wherein transferring the refrigerant from the first condenser to the first expansion device comprises absorbing heat from the refrigerant transferred from the first condenser to the first expansion device using a refrigerant circuit of a subcooling heat exchange system; wherein the refrigerant circuit of the subcooling heat exchange system is separate from the refrigerant circuit that transfers refrigerant from the outlet of the first condenser to the inlet of the first expansion device; and controlling with a controller, a first fan, the first evaporator, the first compact screw compressor, the pump, and the subcooling system for producing the treated water from the air.
21. The method of claim 20, further comprising removing dry air from an area adjacent to the first evaporator and replacing the dry air with moist air using a vane-axial fan.
22. The method of claim 20, further comprising: cooling the sub cooling system using a heat rejection unit of the subcooling system.
23. The method of claim 20, further comprising controlling the first compact screw compressor using a variable frequency drive.
24. The method of claim 20, wherein: the operating the pump comprises transferring the collected water through the water treatment system to sterilize, filter, and mineralize the collected water.
25. The method of claim 24, further comprising: compressing refrigerant using a second compact screw compressor; transferring the refrigerant from the second compact screw compressor to a second condenser; condensing refrigerant to a liquid state, using the second condenser; transferring the refrigerant from the second condenser to a second expansion device; reducing refrigerant pressure and temperature, using the second expansion device; transferring the refrigerant from the second expansion device to a second evaporator condensing water from air adjacent to the second evaporator, using the second evaporator, by transferring heat from the air to the refrigerant; and transferring the refrigerant from the second evaporator to the second compact screw compressor, wherein the step of collecting condensed water comprises collecting water condensed by both the first evaporator and the second evaporator in the container.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) For a more complete understanding of the disclosed system and methods, reference is now made to the following descriptions taken in conjunction with the accompanying drawings.
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DETAILED DESCRIPTION
(16) High-output atmospheric water generators may be used to generate a water supply by extracting moisture from ambient air. Refrigerant may be cycled through the AWG to cool air, causing water in the air to condense. Fans may move air through the AWG so that when air is cooled and water is extracted warm, moist, air may be brought in to replace the cool dry air for continued water extraction. High-output atmospheric water generators can produce in excess of 10,000 gallons of water a day.
(17) An example atmospheric water generator 200, shown in
(18) The superheated gaseous refrigerant may be received by a condenser 204 which may condense the refrigerant into a saturated or subcooled liquid. The condenser 204 may cool the refrigerant to cause it to condense into a liquid state. The condenser 204 may be a microchannel condenser coil, passing refrigerant through small channels to enable more efficient condensation of the refrigerant.
(19) The subcooled liquid refrigerant may be passed from the condenser 204 to an expansion device 206. The expansion device 206 may further cool the refrigerant by reducing pressure on the refrigerant. The expansion device 206 may, for example, be an expansion valve or a capillary tube. The expansion device 206 may include one or more independent acting microcontrollers to control operation of the expansion device 206 and govern the rate and pressure at which refrigerant is passed to the evaporator 208. Due to the decreased pressure, the refrigerant output from the expansion device 206 may be a mixture of liquid and vapor.
(20) The refrigerant may be passed from the expansion device 206 to the evaporator 208. Evaporator 208 may allow heat from air adjacent to evaporator 208 to be transferred to the refrigerant inside, thereby reducing the temperature of the air. The reduction of temperature of the air may cause water to condense. The evaporator may for example be a microchannel evaporator coil. Similar to microchannel condenser coils, microchannel evaporator coils pass refrigerant through small channels to enable more efficient heat transfer from the air to the refrigerant. The heat transfer from the air to the refrigerant may cause the remaining liquid refrigerant to vaporize. The vapor refrigerant may then be passed back to compressor 202 to continue the cycle.
(21) Water condensed by the evaporator 208 may be collected in a water collection unit 210 for accumulation and pump feed. Water collection unit 210 may, for example, be made of stainless steel. Water treatment system 216 may include a bacteria control system, particulate filtration, and mineralization to purify water pumped from water collection unit 210. When water is needed, pump 214 may operate to transfer water from water collection unit 210 through the water treatment system 216. Pump 214 may, for example, be a food-safe, run-dry, self-priming, double diaphragm, water condensate pump. Water treatment system 216 may treat water so that the water is fit for human consumption. After passing through water treatment system 216, the water may pass through water line 222 to an output of the AWG 200. The water treatment system 216 may not be included, may be internal to each AWG module, or may be external with multiple AWG modules sharing a single water treatment system 216. For example, the water line 222 may be coupled to bulk use or a water treatment skid for drinking water.
(22) Air may be moved through the AWG 200 using fan 220. Fan 220 may be a vane-axial fan. Although a single fan is shown, multiple fans may be used to move air through the AWG 200. For example, the fan 220 may move warm moist air into the unit through electrostatic air filter 218. The warm, moist air may then be channeled around evaporator 208 which may cool the air, causing moisture in the air to be condensed into water collection unit 210. Fan 220 may then move the cool dry air around the condenser, where the air may absorb heat from the refrigerant in the condenser, causing the refrigerant to condense more efficiently. The warmed air may then be expelled from the AWG 200 by fan 220. Airflow in the AWG 200 may be designed, using vane-axial fan 220, to produce partial airflow through a controlled portion of the AWG 200 around the evaporator 208 with a bypass stream allowing partial airflow bypassing the evaporator 208. The two partial streams may combine for full airflow cooling condenser 204 and expulsion from the AWG 200. The use of a bypass airstream can help to minimize water entrainment in air that is expelled from the AWG by the fan 220.
(23) Motors of the AWG 200 may be controlled by controller 224. Controller 224 may include a variable frequency drive (VFD) or a plurality of VFDs. Controller 224 may control fan 220, expansion device 206, pump 214, and compact screw compressor 202. The use of variable frequency drives by controller 224 to drive components may allow the compressor 202, fan 220, and pump 214 to run continuously and ramp up/down in speed when started or stopped. Variable frequency drives can thus smooth power consumption and reduce overall peak power demand.
(24) Variable frequency drives can also be manually adjusted to optimize motor speed for each component of the AWG 200. Controller 224 may include a programmable logic controller (PLC). The PLC may include a color touchscreen interface for programming operational sequencing of the AWG 200 including ramping functions for the motor drives, such as variable frequency drives, pumpdown sequences, and maintenance and tuning modes for the AWG 200. Controller 224 may monitor a variety of process variables of the AWG 200, such as coil face temperatures in the condenser 204 and evaporator 208. If controller 224 detects operation outside of predetermined operating ranges, such as predetermined temperature ranges, it may take action to safeguard equipment and personnel, such as by shutting down the AWG 200. Controller 224 may also connect to the internet to allow remote access and telemetry of the AWG 200 and to provide notifications regarding system status and maintenance. The controller 224 may also control a plurality of step-motor electric expansion valves (not shown) to control the flow of refrigerant in the system. For example, through the step-motor electric expansion valves, the controller 224 may control main operation of the AWG refrigerant circuit while allowing manual adjustment of the operation of speeds of the fan 220, compressor 202, and pump 214 to tune the system during startup or to trim control during operation. In some embodiments, fan 220 may be driven by a direct drive motor with speed control.
(25) In some embodiments, two or more AWG refrigerant circuits may be coupled in parallel to increase water output. For example, an AWG circuit similar or identical to the AWG refrigerant circuit of
(26) An AWG may be packaged as a AWG module for easy shipping and installation. An example AWG module 300 is shown in
(27) The AWG module may be assembled at the operation site. An example assembled AWG module 400 is shown in
(28) Microchannel condenser coils can enhance the efficiency and water production of an AWG. An example two-row series-flow microchannel condenser coil 500 is shown in
(29) Microchannel evaporator coils can also enhance the efficiency and water production of an AWG. An example two-row parallel-fed microchannel evaporator coil 600 is shown in
(30) An example perspective view 700 of a microchannel coil is shown in
(31) A subcooling system may be used to further cool refrigerant of an AWG system, such as the AWG shown in
(32) An example subcooling system 900 is shown in
(33) A subcooling system may include one or more subcooling plate heat exchanges to facilitate exchange of heat between refrigerant of an AWG refrigerant circuit and refrigerant of the subcooling system. An example plate heat exchanger 1000 is shown in
(34) An AWG may also include a heat rejection unit (HRU) to cool the subcooling system. For example, the HRU may include one or more microchannel coil condensers for condensing refrigerant and passing the heat from the refrigerant to ambient air. The air flow through the HRU may be isolated from the air flow of an AWG refrigerant circuit. An example HRU 1100 is shown in
(35) The HRU 1200 may include multiple condensers 1202A-B coupled to cool refrigerant from refrigerant line 1204. Airfoil axial fans 1302, 1304, illustrated in the top-down view of an example HRU 1300 in
(36) An example method 1400 of extracting water from ambient air using an AWG is shown in
(37) The schematic flow chart diagram of
(38) If implemented in firmware and/or software, functions described above may be stored as one or more instructions or code on a computer-readable medium. Examples include non-transitory computer-readable media encoded with a data structure and computer-readable media encoded with a computer program. Computer-readable media includes physical computer storage media. A storage medium may be any available medium that can be accessed by a computer. By way of example, and not limitation, such computer-readable media can comprise random access memory (RAM), read-only memory (ROM), electrically-erasable programmable read-only memory (EEPROM), compact disc read-only memory (CD-ROM) or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to store desired program code in the form of instructions or data structures and that can be accessed by a computer. Disk and disc includes compact discs (CD), laser discs, optical discs, digital versatile discs (DVD), floppy disks and Blu-ray discs. Generally, disks reproduce data magnetically, and discs reproduce data optically. Combinations of the above should also be included within the scope of computer-readable media.
(39) In addition to storage on computer readable medium, instructions and/or data may be provided as signals on transmission media included in a communication apparatus. For example, a communication apparatus may include a transceiver having signals indicative of instructions and data. The instructions and data are configured to cause one or more processors to implement the functions outlined in the claims.
(40) Although the present disclosure and certain representative advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the disclosure as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the present disclosure, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.