uhull

JSTDWorkshopMeeTng
Project Overview
Key Technologies for Enhancing Energy
Efficiency
of the Dew Point Air Cooler and its
Manufacturing
EP/M507830/1-TSB42438-290245
ProfessorXudongZhao
UniversityofHull,UK
Xudong.zhao@hull.ac.uk
20thJune2016,London,Uk
International Collaboration
Aim
Todevelopanoveldewpointaircoolerandassociated
manufacturingprocess
–withenhancedenergyefficiencyandindustrial&environmentalsustainability
Op6misa6ontool
Experimental
prototype
Pre-produc6on
line
Workshop
demonstrator
Work Programme
Programme (Work Packages)
3
1 Developmentofthecoolerdesignandoptimizationtool
anddeterminationofitsperformancedata
1.1 Developmentofthecoolerdesign&optimizationtool
1.2 Determinationofthecooler'performancedata
2 Constructionandtestingofa4kWratedcooler,and
identificationofrelevantmanufacturingmachinerytools
2.1 Constructionofthe4kWratedcooler
2.2 Testingofthe4kWratedcoolerunderlabcondition
2.3 Identificationofrelevantmanufacturingmachinery
tools
3 Developmentofamanufacturingprocessandproduction ofa20kWratedcooler
3.1 Developmentofamanufacturingprocesswithafew
newmachinerytools,anenergymanagementsystem, andanautomatedassemblyline
3.2 Productionofa20kWratedcooler
4Installation, real-time measurement, and public demonstrationofthecooler
Year 1
6
9
12
15
Year 2
18 21
24
M1
Responsible/participating
organisations
UHULL
Assisted by Tsinghua
M2
HHULL
Assisted by Sinogreen &
ebmpapst
M3
Sinogreen
Assisted by Tsinghua, ebmpapst,
UHULL
5Projectmanagement
M4
Sinogreen
Assisted by Tsinghua, UHULL,
ebmpapst
UHULL, involving all
6Disseminationandexploitation
Sinogreen, involving all
Innovations
Innova6on1
Corrugatedheatexchangingsurfacethatcanincreaseheattransferareaby
around35%,leadingtothesamepercentageofincreaseinheattransfer
rate.
Corrugatedheatexchanger.vs.flatplateheatexchanger
Innovations
Innova6on2
EliminaTonoftheuseoftheairguidebetweentheadjacentheatexchanging
sheetsthatcanreducetheairflowresistancewithintheflowchannelsby
55%,leadingtosamepercentageofreducToninthefanpower
consumpTonofthecooler.
Innovations
Innova6on3
Asuper-performancefibrematerial(i.e.,coolmax-2)usedasthewetsurface
oftheheatexchangingsheetcansignificantlyimprovethewet-abilityand
waterdiffusivityacrossthesurface,thusenhancingtheheatandmass
transferperformanceoftheheatexchanger.
1.
Coolpass
2.
Coolmax - 1
6.
Bamboocharcoal+
Coolmax®active
7.
Coolpass - 2
3.
Craftpaper
4.
Coolmax - 2
8.
Topcool®
spandex
9.
320D
Supplex®+3M®
5.
Coolmax - 3
10.
228T
Supplex®+3M®
Innovations
Innova6on4
AwateraffinitycoaTngmaterial(LiCl/Polyvinyl-Alcohol)canfurtherenhancethe
plates’wateradsorpToncapacityandthusincreaseitsheattransferrate,and
meanwhile,maintainlongtermperformanceoftheheatexchangerandprevent
negaTveeffects(e.g.fouling&corrosion)tothesupplyairandcoolerbody.
Coa6ngeffec6venessexperiment
Innovations
Innova6on5
WatercirculaTonrunsintermifentlyinordertokeepthewet-surfaceoftheheat
exchangingsheetinsaturaTonstateandmeanwhilepreventawaterfilmformulated
onthesurfacethatwouldrestraintheevaporaTonofwater.
Watersupplyismainlydeliveredbythetapwater,whilecirculaTonpumpisonly
acTvatedwhenthebofomtankisfull,thusminimisingthepumpoperaTonalTmeand
itspowerconsumpTon
Timerelay&magneTc
valve
Numerical Simulation
Asakeypartofthecoolerthenovelirregularheatandmassexchangerhas
been simulated for various operaTng condiTons using the computer cooler
design & opTmizaTon tool and its performance data has been determined.
Both corrugated and flat plate heat and mass exchanger have been
invesTgatedandcomparedtoillustratethebenefittousethecorrugatedheat
andmassexchanger.
Numerical Simulation
Compared to the conventional flat-plate heat exchanger, the irregular/
guideless heat exchanger can achieve:
• 
32-37% higher cooling capacity, dew-point and wet-bulb
effectiveness at a range of geometrical and operational conditions.
• 
29.7%-33.3% higher COP
• 
55.8% to 56.2% lower air flow resistance
Prototype Design
FollowingthecompleTon
ofthecomputer-based
coolerdesign&
opTmizaTontoolandthe
airflowresistanceCFD
analysisandfanselecTon/
control,thefinaldesignof
the4kWprototypesystem
hasbeencompleted.
Twofansinparallelare
usedforboththesupply
andexhaustpaths.Both
locaTonscanusepart
numberR3G225-RE07-03.
Wet Surface Materials Testing
10setsofmaterialstested
1.Coolpass
2.
Coolmax-1
6.
Bamboocharcoal+
Coolmax®acTve
7.
Coolpass-2
3.
Crajpaper
4.
Coolmax-2
8.
Topcool®
spandex
9.
320D
Supplex®+3M®
5.
Coolmax-3
10.
228T
Supplex®+3M®
Wet Surface Materials Testing
Wickheighttes6ng
Wet Surface Materials Testing
Moisturediffusivityandevapora6ontes6ng
SampleNo.
1
3
4
6
9
10
Dripdiffusion time
1drop
10drops
52”
3’30”
7’30”
9’20”
57”
11’45”
51”
4’28”
1’15”
4’10”
1’25”
6’15”
Wettedarea/cm2
1drop
10drops
3.1
24.3
5.6
57.3
3.4
64.4
3.5
37.5
17.1
126.6
19.8
152.3
Evaporationtime/min
1drop
10drops
19’30”
38’50”
24’10”
46’40”
13’12”
29’10”
14’45”
40’50”
12’30”
26’20”
15’15”
24’10”
Wet Surface Materials Testing
Adhesiveperformancetes6ng
SampleNo.
1
4
9
10
Dripdiffusion time/s
1drop
10drops
3’20”
12’50”
2’45”
4’10”
-
Wettedarea/cm2
1drop
10drops
3.1
20.2
6.1
59.3
-
Evaporationtime/min
1drop
10drops
25’30”
41’20”
14’14”
35’10”
-
Heat Exchanger Materials
Corrugatedsheetmanufacturingprocess-materials
RawCoolmax®fabric
Twosidesappearanceofthefabric
1.Fibrematerialselec6on
2.Sikaflex®-291iMarineAdhesive&Sealant
3.Aluminiumsheets
Heat Exchanger Fabrication
Corrugatedsheetmanufacturing–punchingandpressingprocess
Punchingmouldmountedontothe
punchmachine
Heatexchangingsheetstobepunched
Completedheatexchangingsheet–wetside Completedheatexchangingsheet–dryside
Dew Point Air Cooler Fabrication
Heatexchangerassembly
Waterdistributor
Controlelements
Dew Point Air Cooler Fabrication
Heatexchangerassembly
Waterdistributor
Controlelements
Completed Cooler Prototype
4kWexperimentalprototype
Workingprinciplediagram
Prototypeinsidephoto
Test Rigs
TestriginChina
TestriginUK
Test Results
CoolingperformancecomparedtoCoolerado®M30
LocaTon
Working
air flow
(m3/hr)
intake
product
Product Intake Air
Cooling
working
temperature
Air Flow
Flow
capacity
temperature
temperature
air ra=o
drop(℃)
wet-bulb(℃)
(m3/hr) (m3/hr)
(kW)
(℃)
(℃)
Coolerado®M30
1207.0 1530.0 2737.0
0.441
37.8
21.1
Projectprototype
600.1
747.7 1347.8
0.445
37.8
21.1
Projectprototype*
429.3
748.8 1178.1
0.364
37.8
21.1
*ProjectprototypeatopTmumworkingairraTo.(DatabasedonPreliminarytesTngresults.)
Coolerado®
M30
Project
prototype
Project
prototype*
120%
100%
93.0%
101.8%
8.3
4.2
4.8
93.0%
101.8%
113.8%
52.5
50
37.4
40
60%
30
40%
20
20%
10
0%
Project
prototype
18.4
37.4
52.5
60
113.8%
80%
Coolerado®
M30
wet-bulb
effec6veness
COPcomparison
COP
17.0
WetbulbeffecTveness
Temoeraturedrop/°C
19.0
16.3
16.3
17.0
19.0
Wet-bulbeffec6veness
comparison
Temperaturedropcomparison
20
18
16
14
12
10
8
6
4
2
0
21.5
20.8
18.8
COP
Project
prototype*
18.4
0
Coolerado®M30
Project
prototype
Project
prototype*
Performance Comparison
Type
Source
1
2
PIIF-GA-2008Keda-DMU10 [6]
220079[11, 6]
3
4
5
Coolerado USA [12]
Proposed
product[7, 9]
Conventional airconditioner [13]
Image
Cooling
capacity, kW
COP
0.45
7.4
7.49
10
4.8
10.7
15
16.5
16
22 52.5
2.7
Power input,
30
450
470
455
3800
91.5
W
Sizes (mm x
1600 x 1320 x
1800 x 800 x 400 1219 x 1175 x 667 1219 x 1175 x 667 1800x1050x500 1226×890×799
mm x mm)
450
(0.945)
(0.576)
(0.956)
(0.955)
(0.87)
3
(m )
(0.95)
Cost, £/kW
600
260
280
250
240
240
ParallelComparisonofthePerformanceofVariousAirCoolers
How It Was Structured
1.  Establishedwork/personalrela6onship
•  Hull/Tsinghuahavebeenworkingonthistopicfor10years,withjoint
IP,backgroundtechnology,publicaTonsetc
•  Hull/SinogreenhavebeenworkingononeMOSTprojectthatwas
directlyrelatedtothisproject
•  HullhasconnecTonwithebm-papstduringthepreviousproject
progress,receivingthetechnicalsupportfromebmandknowits
qualityinfan/control.
2.  Fullypreparedmaterialspriortoprojectapplica6on
•  Ideas,preliminaryresultsandprojecttargetsweremadeclearprior
toapplicaTon
•  WaiTngforacalltoputthisthroughandgetitapproved
•  Technical/economic/markeTnginformaTonwerefullyprepared.
How It Was Structured
3.  Industrialpartneriswillingtotakeupthistechnologyandbringitinto
market
•  SinogreenhasanintenTontouptakethistechnologytobringitinto
market
•  Ebm-papstiskeentofindanewareathathashighdemandinitsfan/
controltechnologies
•  Partnershavedevelopedasecondlevelplanforthistechnologythat
istodevelopamarketincompterdatacentre;acTonhasbeen
made.
4.  Follow-onworkshavebeenwellplanned
•  IP,andsojwareregistraTon
•  Workshop
•  DemonstraTon
•  CerTficaTon
Thank you for your attention