MODULAR HEAT TRANSFER SYSTEMS AND ASSOCIATED METHODS OF HEAT TRANSFER

Info

Publication number: 20260227136
Type: Application
Filed: Jan 30, 2026
Publication Date: Aug 6, 2026
Inventors: Zan Liu (Overland Park, KS), Jason Stratman (Lee's Summit, MO), Rajath Subbappa (Kansas City, MO), Glenn Brenneke (Lee's Summit, MO), Mike Partington (Kansas City, MO), Dan Rau (Cleveland, MO), Dustin Jenkins (Olathe, KS)
Application Number: 19/465,170

Abstract

A modular heat transfer system is provided. The modular heat transfer system includes a frame that supports a cooler, where the cooler is designed to cool a process fluid. The frame also includes a mating cleat. The modular heat transfer system further includes a pad module designed to support a media pad, the pad module including a module cleat. The pad module is selectively couplable to the frame via engagement of the module cleat and the mating cleat. The modular heat transfer system also includes a distribution system designed to direct a cooling fluid toward the media pad when the media pad is coupled to the modular heat transfer system.

Description

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application Ser. No. 63/752,472, filed on Jan. 31, 2025, entitled “MODULAR HEAT TRANSFER SYSTEM” and U.S. Provisional Patent Application Ser. No. 63/801,607, filed on May 7, 2025, entitled “MODULAR HEAT TRANSFER SYSTEM,” currently pending, the entire disclosure of which is incorporated herein by reference.

FIELD OF DISCLOSURE

The present disclosure relates generally to heat rejection equipment, and more particularly to heat transfer systems designed to operate in one or more operational modes.

BACKGROUND

Heat rejection or heat transfer equipment is commonly used in industrial, commercial, and residential settings to provide temperature and/or humidity control. Air-cooled heat exchangers, which are a common type of heat rejection equipment, use circulating ambient air to remove heat from a process fluid (e.g., via a “dry cooling” mode). For example, cooling towers are heat exchangers of a type widely used to emanate low-grade heat into the atmosphere and are typically utilized in electricity generation, air conditioning installations, and the like. These towers receive a relatively warm or hot process fluid and pass the process fluid through the tower apparatus so that heat is extracted from the process fluid by interaction with relatively cooler ambient air. Additionally, some air-cooled heat exchangers utilize adiabatic cooling to reduce the temperature of the ambient air by, for example, contacting the air with a wetted pad, thereby increasing the relative humidity of the air and reducing the dry-bulb temperature of the air. The lower dry-bulb temperature of the adiabatically pre-cooled air allows for the process fluid to be cooled to a lower temperature, allows for cooling of the process fluid at a lower airflow rate, and/or allows for cooling of a larger mass of process fluid at the prescribed process fluid out temperature and airflow (e.g., via a “adiabatic cooling” mode).

Heat transfer systems that include the option of adiabatic cooling and/or are capable of adiabatic and dry cooling may be desirable for certain applications or conditions of use. For example, heat exchange systems that include adiabatic cooling are well suited for hot, dry environments where water is scarcer. The mode of operation of the heat exchange system, dry cooling or adiabatic cooling, may be selected based at least in part on the environmental conditions. Separately, modular heat exchange systems may be desirable, because modules can be factory pre-assembled, sized, and configured or designed for ease of shipping and assembly. Thus, a need exists for an improved, modular heat exchange system or cooling tower that is capable of adiabatic cooling and/or operating in an adiabatic and dry cooling mode. Moreover, a need exists for a modular heat transfer system including media pads that can be selectively coupled and decoupled from the modular heat transfer system and a recirculation system or fluid distribution system configured or designed to wet the media pads when the modular heat transfer system is used for adiabatic cooling methods and applications.

SUMMARY

The systems and methods described herein relate to a modular heat transfer system. In a first aspect, the system includes a frame supporting a cooler that is designed to cool a process fluid, the frame including a mating cleat, a pad module designed to support a media pad, the pad module including a module cleat, and a distribution system designed to direct a cooling fluid toward the media pad when the media pad is coupled to the modular heat transfer system. The pad module is selectively couplable to the frame via engagement of the module cleat and the mating cleat.

In some instances, the distribution system includes a recirculation system designed to recirculate fluid collected from the media pad after the distribution system directs the cooling fluid onto the media pad.

In other instances, the distribution system is designed to operate in a once-through mode and a redistribution mode. The once-through mode includes passing the cooling fluid through the distribution system a single time and the redistribution mode includes cycling the cooling fluid through the distribution system more than once.

In yet further instances, the distribution system is selectively couplable to the frame such that the distribution system can be removed from the modular heat transfer system.

In some instances, the distribution system includes one or more collection basins and one or more distribution members. The one or more collection basins are disposed beneath the pad module and designed to collect the cooling fluid. The one or more distribution members are in fluid communication with the one or more collection basins and the distribution system and are designed to direct the cooling fluid collected in the one or more collection basins to the media pad. Each collection basin of the one or more collection basins and each distribution member of the one or more distribution members are selectively couplable to the frame.

In another aspect, a modular heat transfer system is provided. The system includes a frame including at least one frame cleat, a first cooler and a second cooler coupled to the frame, a first plurality of pad modules associated with the first cooler including a first module cleat, and a second plurality of pad modules associated with the second cooler including a second module cleat. Each pad module of the first plurality of pad modules is coupled to the frame via engagement between the first module cleat and the at least one frame cleat. Each pad module of the second plurality of pad modules is coupled to the frame via engagement between the second module cleat and the at least one frame cleat.

In some instances, the system further includes a distribution system designed to distribute a cooling fluid. The distribution system discharges the cooling fluid after the cooling fluid passes through the system a single time when the distribution system operates in a once-through mode.

In other instances, the distribution system includes a distribution pipe imparted with one or more perforations, and the one or more perforations are designed to direct the cooling fluid to the first plurality of pad modules and the second plurality of pad modules.

In yet further instances, the first plurality of pad modules and the second plurality of pad modules are each positioned above one or more collection basins, the one or more collection basins are positioned above a reservoir, and the one or more collection basins are designed to convey fluid collected therein to the reservoir.

In some instances, the first cooler and the second cooler are designed to cool a process fluid.

In other instances, the system further includes a pump affixed to the frame, a riser in fluid communication with the pump, one or more fluid collection bins, and a reservoir in fluid communication with the one or more fluid collection bins and the pump. The pump is designed to move fluid between the reservoir, the riser, and the one or more fluid collection bins.

In yet further instances, one or more fluid collection bins and the reservoir are designed to retain at least a portion of a cooling fluid provided by a distribution system, and the pump is designed to move the cooling fluid from the one or more fluid collection bins and the reservoir to the riser.

In some instances, heat exchanger conduit bundles of the first cooler and the second cooler are configured to be arranged in series or in parallel.

In other instances, the one or more air movement devices draw ambient air through, around, or through and around each of the first plurality of pad modules and the second plurality of pad modules.

In yet further instances, the first plurality of pad modules and the second plurality of pad modules comprise one or more media pads. The one or more media pads comprise a plurality of cellulose sheets,

In yet another aspect, a method of transferring heat in a heat transfer system is provided. The method may be implemented by any of the systems of the first to fifteenth implementations or the twenty-first to thirty-fifth implementations. The method includes providing a modular heat transfer system including a first heat exchanger module, coupling a first plurality of pad modules to the first heat exchanger module, providing a distribution system designed to distribute a cooling fluid, distributing the cooling fluid onto the first plurality of pad modules, drawing a stream of ambient air through the first plurality of pad modules, generating a stream of pre-cooled air, and drawing the stream of pre-cooled air into the first heat exchanger module.

In some instances, the method further includes collecting a stream of used cooling fluid from the first plurality of pad modules in a reservoir, pumping the stream of used cooling fluid from the reservoir to the distribution system, and applying the stream of used cooling fluid to the first plurality of pad modules.

In other instances, the method further includes providing a second plurality of pad modules disposed on, around, or on and around a second heat exchanger module. In some such instances, the second plurality of pad modules may be wetted by cooling fluid provided from the fluid distribution system.

In yet further instances, the first plurality of pad modules includes one or more media pads and the one or more media pads comprise a plurality of cellulose sheets. The one or more media pads are imparted with a density of about 3 to about 6 cellulose sheets per 2.5 centimeters.

In some instances, the method further includes providing a second heat exchanger module and arranging the second heat exchanger module such that the first heat exchanger module and the second heat exchanger module are disposed side-by-side or the second heat exchanger module is disposed on top of the first heat exchanger module.

These and other aspects and advantages of the present disclosure will become apparent to those skilled in the art after considering the following detailed description in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1A is an isometric view of a modular heat transfer system constructed according to the principles of the present disclosure;

FIG. 1B is a left side elevational view of the modular heat transfer system of FIG. 1A;

FIG. 1C is a rear side elevational view of the modular heat transfer system of FIG. 1A;

FIG. 1D is a top plan view of the modular heat transfer system of FIG. 1A;

FIG. 1E is a schematic view of the modular heat transfer system of FIG. 1A in communication with a control system;

FIG. 2A is a front elevational view of a cooler constructed according to the principles of the present disclosure;

FIG. 2B is a front elevational view of another cooler constructed according to the principles of the present disclosure;

FIG. 3A is a front, top, and right side isometric view of a frame for supporting a cooler constructed according to the principles of the present disclosure;

FIG. 3B is a front, top, and right side isometric view of the frame of FIG. 3A with a heat exchanger installed thereon;

FIG. 4A is a right side elevational view of a portion of a distribution pipe of a cooler constructed according to the principles of the present disclosure;

FIG. 4B is a right side isometric view of a portion of a distribution member of a cooler constructed according to the principles of the present disclosure;

FIG. 5 is a top, front, and left side isometric view of a modular heat transfer system constructed according to the principles of the present disclosure;

FIG. 6 is a top, front, and left side isometric view of a first pad module of the modular heat transfer system of FIG. 5;

FIG. 7 is a top, rear, and left side isometric view of the first pad module of FIG. 6;

FIG. 8 is an enlarged view of a first upper cleat of the first pad module of FIG. 7;

FIG. 9 is an enlarged isometric view of a second upper cleat of a frame of the modular heat transfer system of FIG. 5, in which one or more components positioned behind other elements are shown in broken lines to enhance visual clarity and facilitate understanding of the spatial relationships among the parts;

FIG. 10 is an enlarged isometric view of the first upper cleat of FIG. 8 engaging the second upper cleat of FIG. 9, in which one or more components positioned behind other elements are shown in broken lines to enhance visual clarity and facilitate understanding of the spatial relationships among the parts;

FIG. 11 is an enlarged isometric view of a first lower cleat of the first pad module of FIG. 7, in which one or more components positioned behind other elements are shown in broken lines to enhance visual clarity and facilitate understanding of the spatial relationships among the parts;

FIG. 12 is an enlarged isometric view of a second lower cleat of the frame of FIG. 9, in which one or more components positioned behind other elements are shown in broken lines to enhance visual clarity and facilitate understanding of the spatial relationships among the parts;

FIG. 13 is an enlarged isometric view of the first lower cleat of FIG. 11 engaging the second lower cleat of FIG. 12, in which one or more components positioned behind other elements are shown in broken lines to enhance visual clarity and facilitate understanding of the spatial relationships among the parts;

FIG. 14 is a top, front, and left side isometric view of a second pad module of the modular heat transfer system of FIG. 5;

FIG. 15 is a top, rear, and left side isometric view of the second pad module of FIG. 14;

FIG. 16 is an enlarged isometric view of a third upper cleat of the second pad module of FIG. 14;

FIG. 17 is an enlarged isometric view of a fourth upper cleat of the frame of FIG. 9;

FIG. 18 is an enlarged isometric view of the third upper cleat of FIG. 16 engaging the fourth upper cleat of FIG. 17;

FIG. 19 is an enlarged isometric view of a third lower cleat of the second pad module of FIG. 14;

FIG. 20 is an enlarged isometric view of a fourth lower cleat of the frame of FIG. 9;

FIG. 21 is an enlarged isometric view of the third lower cleat of FIG. 19 engaging the fourth lower cleat of FIG. 20;

FIG. 22 is an enlarged isometric view of a collection basin of the modular heat transfer system of FIG. 5, in which one or more components positioned behind other elements are shown in broken lines to enhance visual clarity and facilitate understanding of the spatial relationships among the parts;

FIG. 23 is an enlarged isometric view of a top of the collection basin of FIG. 22;

FIG. 24 is another enlarged isometric view of the top of the collection basin of FIG. 22, in which one or more components positioned behind other elements are shown in broken lines to enhance visual clarity and facilitate understanding of the spatial relationships among the parts;

FIG. 25 is an enlarged isometric view of a bottom of the collection basin of FIG. 22, in which one or more components positioned behind other elements are shown in broken lines to enhance visual clarity and facilitate understanding of the spatial relationships among the parts;

FIG. 26 is an enlarged front and left side isometric view of a distribution system of the modular heat transfer system of FIG. 5;

FIG. 27 is an enlarged top isometric view of a portion of the distribution system of FIG. 26;

FIG. 28 is an enlarged top isometric view of another portion of the distribution system of FIG. 26;

FIG. 29 is another enlarged top isometric view of the portion of the distribution system of FIG. 28;

FIG. 30 is an enlarged top and left side isometric view of a pump of the distribution system of FIG. 26;

FIG. 31 is an enlarged top, front, and left side isometric view of a riser of the distribution system of FIG. 26;

FIG. 32 is an enlarged top, front, and left side isometric view of a portion of the modular heat transfer system of FIG. 5;

FIG. 33 is an enlarged isometric view of a lateral conduit and a distribution member of the distribution system of FIG. 26 with the distribution member in a closed position, in which one or more components positioned behind other elements are shown in broken lines to enhance visual clarity and facilitate understanding of the spatial relationships among the parts;

FIG. 34 is an enlarged top, front, and left side isometric view of the distribution member of FIG. 33 in an open position;

FIG. 35 is an enlarged top view of the distribution member of FIG. 33 in an open position, in which one or more components positioned behind other elements are shown in broken lines to enhance visual clarity and facilitate understanding of the spatial relationships among the parts;

FIG. 36 is a flow chart of a method of transferring heat in a heat transfer system; and

FIG. 37 is a flow chart of a method of transferring heat in a heat transfer system.

DETAILED DESCRIPTION

Before any aspect of the present disclosure are explained in detail, it is to be understood that the present disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The present disclosure is capable of other configurations and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.

Terms indicating relative position such as “above,” “below,” “upper,” “lower,” “rear,” “front,” and so forth are used for purposes of illustration only, unless otherwise noted and are made with reference to the orientation of the drawings. It should be understood that these terms are not generally meant to indicate a preferred orientation when such an orientation is not inherently or explicitly required.

As used herein, “cycles of concentration (COC)” refers to the ratio of the concentration of dissolved solids (e.g., TDS) in the blow-down water as compared to the concentration of dissolved solids in make-up water of a particular water-containing system. Notwithstanding the differences in TDS content between blow-down water and make-up water, typically, COC is measured using the same water source for all of the water associated therewith. The specific TDS content associated with a COC varies with the TDS content of the particular water source in use.

The present disclosure is directed to a modular heat transfer system configured or designed to cool a process fluid. In some instances, the system may include two or more heat exchange modules operably coupled together. For example, the heat exchange modules may be stacked in a vertical configuration. In some instances, the system may be provided in the form of a cooling tower and/or the heat exchange modules of the system may be provided in the form of coolers. Each heat exchange module or cooler may include at least one heat exchanger, such as an indirect heat exchanger that includes conduits or coils through which the process fluid flows. Hot process fluid may enter the at least one heat exchanger through a process fluid inlet and cooled process fluid may exit the at least one heat exchanger through a process fluid outlet. In some instances, the heat exchange modules or coolers may be adiabatic coolers configured or designed to operate in an adiabatic mode, where the heat exchange modules or coolers are equipped with media pads or adiabatic evaporative pads configured or designed to be sprayed with cooling fluid (e.g., water). Thus, the heat exchange modules or coolers may be configured or designed to pre-cool ambient air entering the system. For example, the modular heat transfer system may include a cooling fluid distribution system that is configured or designed to wet a media pad or an adiabatic evaporative pad or a plurality of media pads or adiabatic evaporative pads. In some instances, the media pads or adiabatic evaporative pads are wetted and air entering the adiabatic cooler is pre-cooled, by passing through the wetted pads, before flowing over an indirect heat exchanger located downstream of the wetted pads. The modular heat transfer system may be provided with the media pads factory-mounted or the media pads may be provided separately or aftermarket and mounted on-site. The modular heat transfer system may be provided with or without the cooling fluid distribution system. In some instances, the modular heat transfer system is provided without the cooling fluid distribution system and without media pads or adiabatic evaporative pads (e.g., dry cooling).

Referring to FIG. 1A, a modular heat transfer system 100 is depicted. The modular heat transfer system 100 may be defined by a first end 132 and a second end 134 opposing the first end 132. The modular heat transfer system 100 may include a first (bottom) 106a edge, a second (bottom) edge 106b, a third (top) 106c edge, and a fourth (top) edge 106d. The first edge 106a, the second edge 106b, the third edge 106c, and the fourth edge 106d are disposed between and connect to the first and second ends 132, 134 of the modular heat transfer system 100, defining a generally rectilinear structure. As shown in FIG. 1A, the modular heat transfer system 100 may further include a first side 126 and a second side 128 disposed between the first and second ends 132, 134 of the modular heat transfer system 100. For example, each of the first and second sides 126, 128 may define an air inlet through which ambient air may enter the modular heat transfer system 100.

The modular heat transfer system 100 may be provided with or without media pads. For example, as shown in FIG. 1A, one or more unmounted media pads 140 may be provided to the system 100. The one or more media pads 140 may be imparted with a different shape and/or size relative to the depiction of FIG. 1A. In some instances, two or more media pads 140 (e.g., a plurality or set of media pads 140) may be mounted to the modular heat transfer system 100 and may be positioned (e.g., adjacent to each other or side-by-side) between the first end 132 and the second end 134 of the modular heat transfer system 100. The one or more media pads 140 may be provided separately or as an aftermarket component and mounted on-site. The modular heat transfer system 100 may further include a cooling fluid distribution system (such as a cooling fluid distribution system 232 of FIGS. 2A and 2B). In some instances, the cooling fluid distribution system is designed to wet the one or more media pads 140, as described below. The wetted one or more media pads 140 may be configured or designed to pre-cool ambient air entering the system 100, producing pre-cooled air. In such instances, the ambient air flowing through the one or more media pads 140 is wetted or humidified and pre-cooled via evaporation of the cooling fluid.

In some instances, the ambient air may be imparted with a first temperature and the pre-cooled air may be imparted with a second temperature. In some instances, the second temperature may be less than the first temperature. Additionally, the ambient air may also be imparted with a first relative humidity and the pre-cooled air may be imparted with a second relative humidity. In some instances, the second relative humidity may be greater than the first relative humidity.

In some instances, the one or more media pads 140 may be omitted and the ambient air may be pre-cooled in another manner. In some instances, the modular heat transfer system 100 may include a cooling fluid distribution system provided in the form of one or more nozzles configured or designed to spray the incoming ambient air with a mist (e.g., water vapor) to pre-cool and/or humidify the air. Alternatively, the ambient air may not be pre-cooled with cooling fluid (e.g., dry cooling), in which case the one or more media pads 140 and/or the cooling fluid distribution system configured or designed to wet the one or more media pads 140 may be omitted.

The modular heat transfer system 100 may be configured or designed to be convertible such that the modular heat transfer system 100 may be installed without the one or more media pads 140 and/or the cooling fluid distribution system (e.g., dry cooling). In such instances, the one or more media pads 140 and/or the cooling fluid distribution system may be optionally installed at a later time to allow the modular heat transfer system 100 to operate in an adiabatic cooling mode as well as a dry cooling mode. In some instances, the adiabatic cooling mode may be referred to as the adiabatic mode and the dry cooling mode may be referred to as the dry mode. In certain instances, the media pads and/or cooling fluid distribution system may be removable (e.g., to allow for repair or replacement). In some instances, the modular heat transfer system 100 may be convertible between a dry configuration and an adiabatic configuration, e.g., via the installation of a frame member, which may be configured or designed to support and/or house one or more evaporative adiabatic pads and/or a cooling fluid distribution system.

As best seen in FIGS. 1A and 1B, in some instances, the modular heat transfer system 100 may be provided in the form of one or more heat exchangers 110. In some instances, the one or more heat exchangers 110 may be provided in the form of one or more coolers 110. The one or more heat exchangers 110 may be designed to be modular, such that the one or more heat exchangers 110 can be manufactured, transported, installed, or assembled in a variety of configurations (e.g., a stacked configuration, a side-by-side configuration, and/or other configurations). For example, a first heat exchanger 110a and a second heat exchanger 110b (and components thereof) may be manufactured and transported separately for installation at a site. In some instances, as shown in FIGS. 1A-1C, the first heat exchanger 110a and the second heat exchanger 110b may be arranged one on top of another and stacked in a vertical configuration. In certain instances, the modular heat transfer system 100 may be provided in the form of more than two heat exchangers 110 arranged one on top of another and stacked in a vertical configuration. In some instances, the one or more heat exchangers 110 may be provided in the form of one or more coolers. In the example of FIG. 1A, the modular heat transfer system 100 includes a first cooler 110a and a second cooler 110b. The second cooler 110b may be stacked or disposed on top of the first cooler 110a, such that one or more components of the first and second coolers 110a, 110b may be coupled together and/or in fluid communication with each other. In some instances, the second cooler 110b may be manufactured independently of the first cooler 110a and stacked or disposed on top of the first cooler 110a upon installation or assembly of the modular heat transfer system 100.

As shown in FIG. 1A, the second cooler 110b may include at least one air movement device 130 configured or designed to draw ambient air into the modular heat transfer system 100. In certain cases, the at least one air movement device 130 may be an integral or unitary component of the second cooler 110b, although the second cooler 110b and the at least one air movement device 130 may also be provided as separate (modular) components.

In some instances, the modular heat transfer system 100 may include more than two coolers of the one or more coolers 110 (e.g., three coolers, four coolers, five coolers, six coolers, etc.), and the coolers of the one or more coolers 110 may be arranged in any suitable configuration (e.g., a stacked configuration, a side-by-side configuration, and/or other configurations). For example, each of the coolers of the one or more coolers 110 may be arranged in a stacked configuration (e.g., where a second cooler is stacked on a first cooler, and where a third cooler is stacked on a second cooler) or in a side-by-side configuration (e.g., where a first cooler is positioned and located between a second cooler and a third cooler in a side-by-side configuration). As an additional example, a subset of the coolers of the one or more coolers 110 may be arranged above coolers positioned in a side-by-side configuration (e.g., a first cooler and a second cooler may be arranged in a side-by-side configuration, a third cooler and a fourth cooler may be arranged in a side-by-side configuration, and the third cooler and the fourth cooler may be stacked on top of the first cooler and the second cooler). Furthermore, the one or more heat exchangers or coolers 110 may include one or more indirect heat exchangers, one or more direct heat exchangers, and/or one or more other suitable heat exchangers. The one or more heat exchangers or coolers 110 may include one or more adiabatic heat exchangers, one or more evaporative heat exchangers, one or more air-cooled heat exchangers, one or more water-cooled heat exchangers, and the like.

In some instances, each of the first and second heat exchangers 110a, 110b may include one or more sub-modules or sub-units 120, 122. For example, as shown in FIG. 1B, the first cooler 110a includes a first subunit 120a, a second subunit 120b, a third subunit 120c, and a fourth subunit 120d arranged side-by-side in a substantially linear configuration. The second cooler 110b includes a first subunit 122a, a second subunit 122b, a third subunit 122c, and a fourth subunit 122d arranged side-by-side in a substantially linear configuration. As shown in FIG. 1B, the four sub-units 122a-122d of the second cooler 110b may be stacked or disposed on top of the four sub-units 120a-120d of the first cooler 110a. Each of the one or more of the sub-units 122a-122d of the second cooler 110b may include an air movement device or the at least one air movement device 130. The at least one air movement device 130 may be configured or designed to draw ambient air into the modular heat transfer system 100 and/or the first and second coolers 110a, 110b. In other instances, each of the one or more coolers 110 may include a single sub-unit 120, 122. In further instances, each of the one or more coolers 110 may include two, three, five, or any other number of sub-units 120, 122. In some instances, the sub-units 120, 122 may be arranged in any suitable configuration. Thus, for example, the dimensions and operating parameters of the modular heat transfer system 100 may be adjusted by changing the number of coolers of the one or more coolers 110 provided (e.g., adjusting a height of the modular heat transfer system 100) and/or by changing the number of sub-units 120, 122 included in each of the one or more coolers 110 (e.g., adjusting a length of the modular heat transfer system 100).

In some instances, each of the one or more coolers 110 may include a process fluid inlet 114 (see FIG. 1A) to receive hot process fluid entering the one or more coolers 110 and a process fluid outlet 116, through which cooled process fluid exits each of the one or more coolers 110. The process fluid inlet 114 and the process fluid outlet 116 may be positioned at or proximate to the first end 132 or the second end 134 of the modular heat transfer system 100. However, in other instances, the process fluid inlet 114 and the process fluid outlet 116 may be positioned in any suitable location.

In the example of FIG. 1A, the first cooler 110a includes a first process fluid inlet 114a, a second process fluid inlet 114b, a first process fluid outlet 116a, and a second process fluid outlet 116b. The second cooler 110b includes a third process fluid inlet 114c, a fourth process fluid inlet 114d, a third process fluid outlet 116c, and a fourth process fluid outlet 116d. In some instances, the first process fluid inlet 114a and the first process fluid outlet 116a may be in fluid communication with a first heat exchanger conduit bundle 102a (e.g., positioned at or proximate to the first side 126 of the modular heat transfer system 100). In some instances, the second process fluid inlet 114b and the second process fluid outlet 116b may be in fluid communication with a second heat exchanger conduit bundle 102b (e.g., positioned at or proximate to the second side 128 of the modular heat transfer system 100). In some instances, the third process fluid inlet 114c and the third process fluid outlet 116c may be in fluid communication with a third heat exchanger conduit bundle 102c (e.g., positioned at or proximate to the first side 126 of the modular heat transfer system 100). In some instances, the fourth process fluid inlet 114d and the fourth process fluid outlet 116d may be in fluid communication with a fourth heat exchanger conduit bundle 102d (e.g., positioned at or proximate to the second side 128 of the modular heat transfer system 100). In other instances, the coolers 110 may include process fluid inlets 114, process fluid outlets 116, and/or heat exchanger conduit bundles 102 arranged in any suitable configuration.

In some instances, the first heat exchanger conduit bundle 102a and the third heat exchanger conduit bundle 102c may be arranged in a parallel configuration. Similarly, the second heat exchanger conduit bundle 102b and the fourth heat exchanger conduit bundle 102d can be arranged in a parallel configuration. Thus, the multiple heat exchanger conduit bundles 102a-102d are connected simultaneously, via respective process fluid inlets (e.g., the process fluid inlets 114a-114d) of the heat exchanger conduit bundles 102a-102d and respective process fluid outlets 116a-116d. The process fluid may be split into separate streams and flow through each heat exchanger conduit bundle 102a-102d independently (optionally, with common process fluid supply and process fluid return pipes). The parallel configuration of the heat exchanger conduit bundles 102a-102d may allow for a larger volume of process fluid to be cooled. In other instances, the first heat exchanger conduit bundle 102a and the third heat exchanger conduit bundle 102c may be arranged in a serial configuration. Similarly, the second heat exchanger conduit bundle 102b and the fourth heat exchanger conduit bundle 102d can be arranged in a serial configuration. In a serial configuration, the cooled process fluid may exit one heat exchanger conduit bundle 102. For example, the cooled process fluid may exit the third heat exchanger conduit bundle 102c, via its process fluid outlet 116c, and be provided to another (downstream) heat exchange conduit bundle 102. For instance, the cooled process fluid may be provided to the first heat exchanger conduit bundle 102a, as hot/warm process fluid to the process fluid inlet 114a, for further cooling. Arranging heat exchanger conduit bundles 102 in series may allow for the process fluid to have more contact time with the heat transfer surface, thereby increasing heat transfer efficiency. A serial configuration may be optimal when a large temperature change or precise temperature control is desired. A parallel configuration may be optimal when a smaller temperature change and/or a high flow rate is desired.

In some instances, as best shown in FIG. 1C, two or more of the process fluid inlets 114 and/or two or more of the process fluid outlets 116 may be at least partially aligned. For example, the process fluid inlets 114 may be arranged such that: (i) the first process fluid outlet 116a and the third process fluid outlet 116c are substantially aligned along a first vertical plane P1, (ii) the first process fluid inlet 114a and the third process fluid inlet 114c are substantially aligned along a second vertical plane P2, (iii) the second process fluid outlet 116b and the fourth process fluid outlet 116d are substantially aligned along a third vertical plane P3, and (iv) the second process fluid inlet 114b and the fourth process fluid inlet 114d are substantially aligned along a fourth vertical plane P4. In some instances, the first and second vertical planes P1, P2 may be identical planes, and the third and fourth vertical planes P3, P4 may be identical planes. For example, the heat exchanger conduit bundles 102a-102d may be arranged in a serial configuration, as described above, and the serially connected process fluid outlet and process fluid inlet may be aligned in identical vertical planes (i.e., the identical planes being P1, P2 or P3, P4). In other instances, the first, second, third, and fourth vertical planes P1, P2, P3, P4 may each be a different plane, or a subset of the first, second, third, and fourth vertical planes P1, P2, P3, P4 may be different planes. In some instances, the alignment (e.g., vertical alignment) of the process fluid inlets 114 and/or the process fluid outlets 116 in this way may simplify the installation of the associated piping, thereby reducing the cost and complexity of the installation.

In some instances, the first and/or second coolers 110a, 110b may include one or more heat exchanger conduit bundles and/or one or more process fluid inlets and process fluid outlets. In certain instances, the first and/or second coolers 110a, 110b may include two or more heat exchanger conduit bundles and/or two or more process fluid inlets and process fluid outlets. For example, the first and/or second coolers 110a, 110b may include two or more heat exchanger conduit bundles. The two or more heat exchanger bundles may be positioned at or proximate to the first side 126 of the modular heat transfer system 100 and/or the two or more heat exchanger conduit bundles may be positioned at or proximate to the second side 128 of the modular heat transfer system 100. In some instances, one or more of the heat exchanger bundles 102a-102d may include one or more process fluid inlets and process fluid outlets. For example, in some instances, the one or more heat exchanger bundles 102a-102d may include two process fluid inlets and two process fluid outlets.

As discussed above, the modular heat transfer system 100 may be provided with media pads or evaporative adiabatic pads. The adiabatic pads may be any suitable size and shape. For example, the adiabatic pads may be selected from the group consisting of cellulose, PVC, steel, aluminum, a corrugated sheet material, and combinations thereof. In some instances, one or more of the first and second coolers 110a, 110b of the modular heat transfer system 100 may include or be provided with media pads (e.g., in the form of a first media pad 140a or a first plurality of media pads 140a and a second media pad 140b or a second plurality of media pads 140b). For example, the first cooler 110a may include a first and a second plurality of media pads 140a, 140b, while the second cooler 110b may include a third plurality of media pads 140c and a fourth plurality of media pads 140d. In some instances, the media pads 140a, 140b, 140c, 140d may be provided in the form of a plurality of cellulose paper sheets (e.g., engineered cellulose paper sheets that are chemically treated to inhibit degradation). The plurality of cellulose paper sheets may be connected, coupled, attached, or otherwise arranged together to form the media pad 140a, 140b, 140c, 140d. In some instances, each sheet of cellulose paper is formed into a pattern (e.g., a corrugated pattern, a sinusoidal pattern, or other patterns) designed to increase the surface area per unit of volume of the sheet. In certain instances, the plurality of cellulose paper sheets may be arranged such that the pattern of each sheet is opposite or different from the pattern of an adjacent sheet. In other words, the patterns applied to adjacent pairs of cellulose paper sheets may be opposite or alternating. In some instances, the cellulose paper sheets may be spaced apart from one another such that the plurality of cellulose paper sheets is imparted with a density of about 3 sheets to about 6 sheets per inch (or 3 sheets to 6 sheets per inch).

The media pads 140a, 140b, 140c, 140d may be imparted with an air travel (e.g., depth) of about 2 inches to about 6 inches (or 2 inches to 6 inches), although the air travel distance may be smaller or greater than these values. For example, the media pads 140 may be imparted with an air travel depth of about 2 inches, or about 2.5 inches, or about 3 inches, or about 3.5 inches, or about 4 inches, or about 4.5 inches, or about 5 inches, or about 5.5 inches, or about 6 inches. In other instances, the media pads 140 may be imparted with an air travel depth of 2 inches, or 2.5 inches, or 3 inches, or 3.5 inches, or 4 inches, or 4.5 inches, or 5 inches, or 5.5 inches, or 6 inches.

Alternatively, the media pads may be imparted with an air travel (e.g., depth) of about 5 centimeters to about 15 centimeters (or 5 centimeters to 15 centimeters), although the air travel distance may be smaller or greater than these values. For example, the media pads 140 may be imparted with an air travel depth of about 5 centimeters, or about 6 centimeters, or about 7 centimeters, or about 8 centimeters, or about 9 centimeters, or about 10 centimeters, or about 11 centimeters, or about 12 centimeters, or about 13 centimeters, or about 14 centimeters, or about 15 centimeters. In other instances, the media pads 140 may be imparted with an air travel depth of 5 centimeters, or 6 centimeters, or 7 centimeters, or 8 centimeters, or 9 centimeters, or 10 centimeters, or 11 centimeters, or 12 centimeters, or 13 centimeters, or 14 centimeters, or 15 centimeters.

It is to be appreciated that the air travel may be imparted with a value, or a range of values, falling within any minimum and maximum value recited above.

As also discussed above, the modular heat transfer system 100 may be provided with a cooling fluid distribution system, such as a cooling fluid distribution system 232 depicted in FIGS. 2A and 2B. In some instances, one or more of the first and second coolers 110a, 110b of the modular heat transfer system 100 may include a cooling fluid distribution system (e.g., in the form of a first cooling fluid distribution system and a second cooling fluid distribution system). For example, the first cooler 110a may include a first cooling fluid distribution system and the second cooler 110b may include a second cooling fluid distribution system. In some instances, the first and/or second cooling fluid distribution system is mounted on or coupled to the frame member. The cooling fluid may be water (e.g., potable supply water) supplied from a suitable source, such as a municipal water system, and the supply water may flow through the cooling fluid distribution system.

Moreover, the first cooling fluid distribution system or components thereof may be coupled to and/or in fluid communication with the second cooling fluid distribution system. Thus, for example, cooling fluid distributed onto the third and the fourth plurality of media pads 140c, 140d, which are mounted on the second (top) cooler 110b, by the second cooling fluid distribution system may enter the first cooling fluid distribution system, which may recirculate or redistribute the cooling fluid onto the first and the second plurality of media pads 140a, 140b, which are mounted on the first (bottom) cooler 110a. For example, the first cooling fluid distribution system may include a distribution member (e.g., an intermediate distribution member) designed to collect fluid distributed by the second cooling fluid distribution member (e.g., run-off fluid from the third and the fourth plurality of media pads 140c, 140d) and redistribute this fluid to the first and the second plurality of media pads 140a, 140b located below the distribution member.

In some instances, one or more of the first and second cooling fluid distribution systems may be substantially similar to the cooling fluid distribution system 232 described below with reference to FIGS. 2A and 2B. For example, the first cooling fluid distribution system may include a collection basin, where fluid that is distributed (or redistributed) by the first and second cooling fluid distribution systems is ultimately collected. Some or all of the cooling fluid collected in the collection basin may be directed to a storage tank for later use. In some instances, some or all of the cooling fluid collected in the collection basin may be recirculated to wet the media pads 140a-140d of the first and/or second coolers 110a, 110b again. Thus, the collection basin may include and/or be in fluid communication with a pump, such as a recirculating pump. The collection basin and pump may be substantially similar to the collection basin 260 and pump 270 described below with reference to FIGS. 2A and 2B. The pump may also be in fluid communication with a recirculation pipe or conduit that is substantially similar to the recirculation conduit 280 described below with reference to FIGS. 2A and 2B. In some instances, the recirculation conduit may include an optional recirculation valve, which may be substantially similar to the recirculation valve 282 described below with reference to FIGS. 2A and 2B, designed to control a flow of fluid through the recirculation conduit. The recirculation pipe or conduit (e.g., vertical riser pipe) may be in fluid communication with a distribution pipe, a distribution member, and/or a spray pipe of the (same) first cooler 110a or an adjacent cooler, such as the second cooler 110b.

In some instances, the pump (e.g., recirculating pump) may be located in and/or placed in fluid communication with the collection basin of the first cooling fluid distribution system and may provide the driving force to deliver the cooling fluid to one or more distribution or spray pipes of the first and/or second cooling fluid distribution systems to, for example, wet the media pads of the first and/or second coolers 110a, 110b. The first cooling fluid distribution system may further include at least one drain valve and/or a cooling fluid outlet conduit (e.g., located in and/or placed in fluid communication with the collection basin), which may be substantially similar to the drain valve 283 and cooling fluid outlet conduit 284 described below with reference to FIGS. 2A and 2B, designed to direct some or all of the fluid collected in the basin to a waste system, recirculation tank, storage tank, or other vessel or component. In some instances, the first cooling fluid distribution system may further include one or more flumes (e.g., located in and/or placed in fluid communication with the collection basin), which may be substantially similar to the flumes 330 described below with reference to FIG. 3A, designed to direct a flow of cooling fluid in a collection basin (e.g., a basin 332). Accordingly, in some instances, the cooling fluid outlet conduit may be in fluid communication with the one or more flumes. In some instances, one or more of the pump (e.g., recirculating pump), the recirculation pipe or conduit, the at least one drain valve, the cooling fluid outlet conduit, the collection basin, and/or any other component of the first and/or second cooling fluid distribution system may be mounted on or coupled to the frame member.

As discussed above, the modular heat transfer system may be convertible between a dry configuration and an adiabatic configuration, e.g., via the installation of a frame member, which is configured or designed to support and/or house one or more adiabatic pads and/or one or more cooling fluid distribution systems. In some instances, the frame member may be positioned adjacent to the first heat exchanger conduit bundle, the second heat exchanger conduit bundle, the third heat exchanger conduit bundle, and/or the fourth heat exchanger conduit bundle. In certain instances, the one or more cooling fluid distribution systems may be mounted on, coupled to, or otherwise supported by the frame member. In some instances, one or more adiabatic pads may be mounted to the frame member, such that the one or more adiabatic pads are, for example, upstream of the first heat exchanger conduit bundle, the second heat exchanger conduit bundle, the third heat exchanger conduit bundle, and/or the fourth heat exchanger conduit bundle. In some instances, the installation of the frame member and the cooling fluid distribution system is on-site. In other instances, the frame member and the cooling fluid distribution system are factory-installed. Similarly, the one or more adiabatic pads may be mounted to the frame member on-site or the one or more adiabatic pads may be factory-mounted.

In some instances, the cooling fluid distribution system may be designed, and/or installed to ensure minimal water leakage. Similarly, the one or more adiabatic pads may be mounted to the frame member to ensure minimal air and/or water leakage. In further instances, the cooling fluid distribution system may be configured or designed to be self-contained, such that the cooling fluid distribution system is independent of the one or more heat exchanger modules. For example, the cooling fluid distribution system may be provided as a separate component from the one or more heat exchanger modules. Even in instances in which the cooling fluid distribution system is independent of the one or more heat exchanger modules, an airflow from the cooling fluid distribution system may flow into the one or more heat exchanger modules.

Turning to FIG. 1D, in some instances, each air movement device of the at least one air movement device 130 may be provided in the form of a fan including a motor 144 configured or designed to drive rotation of a plurality of blades, a gear reducer 146 in communication with the motor 144, and a fan guard 148. However, in other instances, the at least one air movement device 130 may be provided in any suitable form, provided that the at least one air movement device 130 is configured or designed to draw ambient air into the modular heat transfer system 100.

Turning to FIG. 1E, the modular heat transfer system 100 may include, or be in communication with, a controller or control system 150 in electronic communication with one or more of the coolers 110. For example, the control system 150 may be configured or designed to monitor and/or control one or more components of the coolers 110, including the at least one air movement device 130. The control system 150 may be communicatively coupled with the coolers 110 (e.g., with sensors or other components positioned on the coolers 110) to control, receive data from, and/or store data from the coolers 110. For example, the control system 150 may be in wireless communication and/or wired communication with a network 160, such that the control system 150 is configured or designed to communicate directly or indirectly with and/or operate one or more of the coolers 110, one or more components of the coolers 110 (e.g., fluid distribution systems, sumps, pumps, valves, sensors, air movement devices), and/or other system components of the modular heat transfer system 100, as discussed below. In some instances, the control system 150 may intelligently manage the fluid flow within, into, and/or out of the modular heat transfer system 100.

In some instances, the control system 150 may determine the cycles of concentration (COC) of the modular heat transfer system 100 and determine if the COC are greater than a maximum COC threshold value. In certain examples, the control system 150 may direct the cooling fluid distribution system of the modular heat transfer system 100 to perform a blowdown or drain process in response to determining the COC is greater than a maximum COC threshold value. In certain instances, recirculation of cooling fluid, blow-down of cooling fluid, and make-up of cooling fluid are managed by the control system 150. For example, make-up of cooling fluid and blow-down of cooling fluid may be managed by the control system 150 based on a parameter and/or threshold value defined to maintain water volume and quality.

In some instances, the control system 150 may be provided in the form of a data-processing device configured or designed to transmit and receive data from the coolers 110. For example, the control system 150 may receive information at a receiver (not shown). The control system 150 may include a processor (not shown) configured or designed to analyze the data received at the receiver and determine an appropriate response. The control system 150 may further include a transmitter (not shown) configured or designed to initiate a response, for example, by sending a signal (e.g., containing instructions) to one or more components of the coolers 110. In some instances, the control system 150 may include a memory (not shown) configured or designed to store data received and/or generated by the control system 150. For example, the memory may be provided in the form of a stand-alone memory unit and/or as part of a processor. Further, in some instances, the network 160 may be coupled to or in communication with the memory, which may include program instructions that are stored therein and are executable by the processor to perform one or more methods or functions.

The network 160 may be provided in the form of a network interface, a local network, and/or other communication or connection systems and protocols, including but not limited to wired, wireless, Bluetooth, cellular, satellite, GPS, RS-485, RF, MODBUS, CAN, CANBUS, DeviceNet, ControlNet, Ethernet, TCP/IP, RS-232, Universal Serial Bus (USB), Firewire, Thread, proprietary protocols, and/or other suitable communication protocols. In some instances, the network 160 may be positioned proximate to one or more components of the coolers 110. The network 160 may include the Internet, intranets, extranets, wide area networks (WANs), local area networks (LANs), wired networks, wireless networks, cloud networks, or other suitable networks, or any combination of two or more networks, Ethernet networks, and other types of networks.

The network 160 may be configured or designed to communicate directly or indirectly with the system 100 and/or a user device 170 provided in the form of a personal computer, tablet, cell phone, display, or other device that enables a user to interface with the control system 150. While FIG. 1B depicts the control system 150 in communication with the network 160 and the user device 170, it should be understood that various communication methodologies and connections can be implemented to work in conjunction with, or independent from, one or more local controllers associated with one or more individual components of the coolers 110 as discussed herein.

The modular heat transfer system 100 may be provided as one or more modular heat transfer systems 100. For example, the modular heat transfer system 100 may include a first and a second modular heat transfer system arranged (e.g., coupled together) in a serial configuration (not shown). In this configuration, heated process fluid may enter the first modular heat transfer system via a process fluid inlet, and cooled process fluid may exit the first modular heat transfer system and flow to the second modular heat transfer system for further cooling, instead of flowing to a heat-generating system (e.g., a data center, HVAC system, etc.) to cool the heat-generating system. Thus, a process fluid outlet of the first modular heat transfer system may be in fluid communication with a process fluid inlet of the second modular heat transfer system. The process fluid may thus be further cooled before exiting the second modular heat transfer system via its process fluid outlet. The process fluid may then be directed from the second modular heat transfer system to the heat-generating system.

Turning to FIGS. 2A and 2B, a front-side elevational view of a first (bottom) 210a and second (top) cooler 210b of a modular heat transfer system in accordance with the teachings of the present disclosure is shown. The first cooler 210a and second cooler 210b may be the same as or may be substantially similar to the first cooler 110a and second cooler 110b of FIG. 1A, respectively. In addition, similar to the first cooler 110a and second cooler 110b of FIG. 1A, the first cooler 210a and second cooler 210b of FIGS. 2A and 2B may be utilized in any of the heat transfer systems, and variations thereof, described herein (e.g., the modular heat transfer system 100 of FIGS. 1A-1E, the modular heat transfer system 500 of FIG. 5).

Each of the first cooler 210a and second cooler 210b may include at least one heat exchanger 202 designed to cool a process fluid. In the example of FIGS. 2A and 2B, each of the first cooler 210a and second cooler 210b includes one heat exchanger 202; however, in other instances, the cooler 210 may include two or more heat exchangers 202. In some instances, the heat exchanger 202 may be provided in the form of an indirect heat exchanger that includes coils or conduits (e.g., a conduit bundle) designed to contain the process fluid, which flows through the coils or conduits. In other instances, the heat exchanger 202 may be provided in the form of a direct heat exchanger or another suitable heat exchanger.

The process fluid within the at least one heat exchanger 202 may be cooled by passing ambient air or pre-cooled ambient air over the at least one heat exchanger 202. In some instances, the heat exchanger 202 may include a first heat exchanger conduit or coil bundle 202a positioned at or proximate to a first side of each of the first cooler 210a and second cooler 210b and a second heat exchanger conduit or coil bundle 202b positioned at or proximate to a second side of each of the first cooler 210a and second cooler 210b opposing the first side. The first and second heat exchanger conduit bundles 202a, 202b may be arranged in a generally diagonal configuration, as shown in FIGS. 2A and 2B. In other instances, the first and second heat exchanger conduit bundles 202a, 202b may be arranged in any other suitable configuration. In some instances, arranging the heat exchangers in a parallel configuration increases the volume of process fluid that can be cooled. In some instances, arranging the heat exchangers in a serial configuration may improve performance of the respective cooler or heat transfer system (e.g., by increasing a cooling time of the process fluid).

In some instances, heated process fluid may enter the heat exchanger 202 via a process fluid inlet 204, and cooled process fluid may exit the heat exchanger 202 via a process fluid outlet 206. The process fluid inlet 204 and the process fluid outlet 206 may be in fluid communication with the first heat exchanger conduit bundle 202a and/or the second heat exchanger conduit bundle 202b.

At least one air movement device 230 may be positioned in an upper portion 211 of the second (top) cooler 210b and may be configured or designed to draw ambient air and/or pre-cooled ambient air into the modular heat transfer system containing the first cooler 210a and second cooler 210b. The ambient air and/or pre-cooled ambient air may be drawn over the surface of the heat exchanger 202 (e.g., the surface of the conduits in the first and second heat exchanger conduit bundles 202a, 202b). In some instances, the at least one air movement device 230 may be the at least one air movement device 130 of the modular heat transfer system 100 (see FIG. 1A). The second (top) cooler 210b may include one, two, four, ten, or any other number of air movement devices 230. In some instances, the second (top) cooler 210b may include a bank of multiple air movement devices (not shown). In certain instances, the second (top) cooler 210b may include any number of air movement devices 230 or air movement device banks arranged in any suitable configuration. In some instances, the at least one air movement device 230 may be provided in the form of a fan (e.g., an axial fan, a centrifugal blower, and/or other fans). The at least one air movement device 230 may be configured or designed to draw ambient air into the modular heat transfer system containing the first cooler 210a and second cooler 210b via at least one air inlet 212. Additionally, in some instances, the modular heat transfer system and/or the first (top) cooler 210a of the modular heat transfer system may include a plurality of air movement devices that are controlled as a single unit (e.g., a control system may be configured or designed to maintain a power, speed, or other setting of each air movement device at an approximately equal setting).

In some instances, each of the first cooler 210a and second cooler 210b may be provided in the form of an adiabatic cooler. For example, each of the first cooler 210a and second cooler 210b may include one or more adiabatic media pads 220 positioned proximate or adjacent to the first and second heat exchanger conduit bundles 202a, 202b and configured or designed to pre-cool ambient air entering each of the first cooler 210a and second cooler 210b before the air contacts the first and second heat exchanger conduit bundles 202a, 202b. In some instances, the pluralities of media pads 220 may be the media pads 140 of the modular heat transfer system 100 (see FIG. 1A). Each of the first cooler 210a and second cooler 210b may be configured or designed to operate in an adiabatic cooling mode or a dry cooling mode. The pluralities of media pads 220 may be configured or designed to be wetted with a cooling fluid (e.g., water) via a cooling fluid distribution system 232 (e.g., positioned above or near an upper portion of the pluralities of media pads 220). The pluralities of media pads 220 can be supported by a frame member 240 extending between the upper portion 211 and an opposing lower portion 213.

The pluralities of media pads 220 may be provided in the form of a first plurality of media pads 220a positioned on a first side of the first (bottom) cooler 210a, a second plurality of media pads 220b positioned on a second side of the first (bottom) cooler 210a, a third plurality of media pads 220c positioned on a first side of the second (top) cooler 210b, and a fourth plurality of media pads 220d positioned on a second side of the second (top) cooler 210b (e.g., where the first side is proximate or adjacent to the first heat exchanger conduit bundle 202a and the second side is proximate or adjacent to the second heat exchanger conduit bundle 202b). Each of the first, second, third, and/or fourth media pads 220a-220d may be provided in the form of a single pad or multiple pads. For example, multiple pads may be arranged adjacent to one another (e.g., side-by-side) such that the multiple pads form a larger pad area that defines the first, second, third, and/or fourth media pads 220a-220d.

In some instances, each of the first cooler 210a and second cooler 210b may include one or more pluralities or sets of media pads 220. The adiabatic pads may be any suitable size and shape and may be made from materials including, but not limited to, cellulose, PVC, steel, aluminum, or a corrugated sheet material. For example, the first (bottom) cooler 210a may include a first plurality of media pads 220a positioned at or proximate to a first side 215 of the first (bottom) cooler 210a and a second plurality of media pads 220b positioned at or proximate to a second side 217 of the first (bottom) cooler 210a opposite the first side 215 (e.g., where the first side 215 is proximate or adjacent to the first heat exchanger conduit bundle 202a and the second side 217 is proximate or adjacent to the second heat exchanger conduit bundle 202b). Similarly, the second (top) cooler 210b may include a third plurality of media pads 220c positioned at or proximate to a first side 219 of the second (top) cooler 210b and a fourth plurality of media pads 220d positioned at or proximate to a second side 221 of the second (top) cooler 210b opposite the first side 219 (e.g., where the first side 219 is proximate or adjacent to the first heat exchanger conduit bundle 202c and the second side 221 is proximate or adjacent to the second heat exchanger conduit bundle 202d). Thus, the third and fourth pluralities of media pads 220c, 220d may be installed on opposing sides of the second (top) cooler 210b. Similarly, the first and second pluralities of media pads 220a, 220b may be installed on opposing sides of the first (bottom) cooler 210a. In such instances, the third and fourth pluralities of media pads 220c, 220d may be disposed above the first and second pluralities of media pads 220a, 220b, respectively. The pluralities of media pads 220 may also be arranged and/or installed in various other configurations.

In some instances, the pluralities of media pads 220 may be provided in the form of a plurality of cellulose paper sheets (e.g., engineered cellulose paper sheets that are chemically treated to inhibit degradation). The plurality of cellulose paper sheets may be connected, coupled, attached, or otherwise arranged together to form the pluralities of media pads 220. In some instances, each sheet of cellulose paper is formed into a pattern (e.g., a corrugated pattern, a sinusoidal pattern, or other patterns) designed to increase the surface area per unit of volume of the sheet. In certain instances, the plurality of cellulose paper sheets may be arranged such that a first cellulose sheet of the plurality of cellulose paper sheets is rotated in a clockwise or counterclockwise orientation relative to a second cellulose sheet of the plurality of cellulose paper sheets. For example, the first cellulose sheet of the plurality of cellulose paper sheets may be rotated 90 degrees or 180 degrees (or about 90 degrees or about 180 degrees) in a clockwise or counterclockwise orientation relative to the second cellulose sheet of the plurality of cellulose paper sheets. In such instances, the orientation of the pattern of one sheet of cellulose paper does not match the orientation of the adjacent sheet of cellulose paper in the media pad 220. In other words, the patterns applied to adjacent pairs of cellulose paper sheets may be arranged to be opposite or alternating.

In some instances, the cellulose paper sheets may be arranged in a spaced-apart relationship from one another such that the plurality of cellulose paper sheets is imparted with a density of about 3 sheets to about 6 sheets per inch (or 3 sheets to 6 sheets per inch). For example, in some instances, the cellulose paper sheets may be imparted with a density of about 3 sheets per inch, or about 4 sheets per inch, or about 5 sheets per inch, or about 6 sheets per inch. In other instances, the cellulose paper sheets may be imparted with a density of 3 sheets per inch, or 4 sheets per inch, or 5 sheets per inch, or 6 sheets per inch, although the density of the cellulose paper sheets may be less than or greater than these values. As an additional example, the cellulose paper sheets may be arranged in a spaced-apart relationship from one another such that the plurality of cellulose paper sheets is imparted with a density of about 3 sheets to about 6 sheets per 2.5 centimeters (or 3 sheets to 6 sheets per 2.5 centimeters). For example, in some instances, the cellulose paper sheets may be imparted with a density of about 3 sheets per 2.5 centimeters, or about 4 sheets per 2.5 centimeters, or about 5 sheets per 2.5 centimeters, or about 6 sheets per 2.5 centimeters. In other instances, the cellulose paper sheets may be imparted with a density of 3 sheets per 2.5 centimeters, or 4 sheets per 2.5 centimeters, or 5 sheets per 2.5 centimeters, or 6 sheets per 2.5 centimeters. It is to be understood that the plurality of cellulose paper sheets may be imparted with a density falling within any minimum and maximum values or ranges recited herein with reference to the density of the plurality of cellulose paper sheets. It is also to be understood that the plurality of cellulose paper sheets may be imparted with a density greater than or less than any minimum or maximum value or range recited herein.

The pluralities of media pads 220 may be imparted with an air travel (e.g., depth) of about 2 inches to about 4 inches (or 2 inches to 4 inches). For example, the pluralities of media pads 220 may be imparted with an air travel of about 2 inches, or about 2.5 inches, or about 3 inches, or about 3.5 inches, or about 4 inches. As an additional example, the pluralities of media pads 220 may be imparted with an air travel of 2 inches, or 2.5 inches, or 3 inches, or 3.5 inches, or 4 inches. In some instances, the pluralities of media pads 220 may be imparted with an air travel (e.g., depth) of about 5 centimeters to about 10 centimeters (or 5 centimeters to 10 centimeters). For example, the pluralities of media pads 220 may be imparted with an air travel of about 5 centimeters, or about 6 centimeters, or about 7 centimeters, or about 8 centimeters, or about 9 centimeters, or about 10 centimeters, or about 11 centimeters. As an additional example, the pluralities of media pads 220 may be imparted with an air travel of 5 centimeters, or 6 centimeters, or 7 centimeters, or 8 centimeters, or 9 centimeters, or 10 centimeters, or 11 centimeters. It is to be understood that the pluralities of media pads 220 may be imparted with an air travel falling within any minimum and maximum value or range recited herein with reference to the air travel depth of the pluralities of media pads 220. It is also to be understood that the pluralities of media pads 220 may be imparted with an air travel greater than or less than any minimum or maximum value or range recited herein.

Alternatively, the pluralities of media pads 220 may be imparted with an air travel (e.g., depth) of about 3 inches to about 6 inches (or 3 inches to 6 inches). For example, the pluralities of media pads 220 may be imparted with an air travel of about 3 inches, or about 3.5 inches, or about 4 inches, or about 4.5 inches, or about 5 inches, or about 5.5 inches, or about 6 inches. In other instances, the pluralities of media pads 220 may be imparted with an air travel of 3 inches, or 3.5 inches, or 4 inches, or 4.5 inches, or 5 inches, or 5.5 inches, or 6 inches. In some instances, the pluralities of media pads 220 may be imparted with an air travel (e.g., depth) of about 7 centimeters to about 16 centimeters (or 7 centimeters to 16 centimeters). For example, the pluralities of media pads 220 may be imparted with an air travel (e.g., depth) of about 7 centimeters, or about 8 centimeters, or about 9 centimeters, or about 10 centimeters, or about 11 centimeters, or about 12 centimeters, or about 13 centimeters, or about 14 centimeters, or about 15 centimeters, or about 16 centimeters. As an additional example, the pluralities of media pads 220 may be imparted with an air travel of 7 centimeters, or 8 centimeters, or 9 centimeters, or 10 centimeters, or 11 centimeters, or 12 centimeters, or 13 centimeters, or 14 centimeters, or 15 centimeters, or 16 centimeters. It is to be understood that the pluralities of media pads 220 may be imparted with an air travel falling within any minimum or maximum value or ranges recited herein with reference to the air travel depth of the pluralities of media pads 220. It is also to be understood that the pluralities of media pads 220 may be imparted with an air travel greater than or less than any minimum or maximum value or range discussed herein.

The cooling fluid distribution system 232 may include at least one inlet for fluid to enter the cooling fluid distribution system 232, at least one outlet for fluid to exit the cooling fluid distribution system 232, and a plurality of nozzles configured or designed to dispense fluid onto the pluralities of media pads 220. In some instances, the cooling fluid distribution system 232 may include a first portion 232a designed to wet the first plurality of media pads 220a and a second portion 232b designed to wet the second plurality of media pads 220b. The first and second portions 232a, 232b may each include one or more nozzles designed to dispense fluid (e.g., water) onto the first and second media pads 220a, 220b, respectively. In some instances, the first portion 232a and the second portion 232b of the fluid distribution system 232 may be operated independently relative to one another. For example, one of the first and second portions 232a, 232b may be “on” and may dispense fluid onto the associated media pad 220 while the other of the first and second portions 232a, 232b may be “off” and may be prevented from dispensing fluid onto the associated pluralities of media pads 220. In other instances, the first and second portions 232a, 232b may operate in unison as a single system such that the first and second portions 232a, 232b are either both “on” or both “off” at any given point in time. In further instances, the cooler 210 (and/or the modular heat transfer system 100) may include two or more fluid distribution systems 232 configured or designed to be in fluid communication with one another, such as a first cooling fluid distribution system and a second cooling fluid distribution system.

In some instances, the first cooling fluid distribution system or components thereof may be coupled to and/or in fluid communication with the second cooling fluid distribution system or components thereof. Thus, for example, cooling fluid distributed onto the third and the fourth plurality of media pads 220c, 220d, which are mounted on the second (top) cooler 210b, by the second cooling fluid distribution system may enter the first cooling fluid distribution system, which may recirculate or redistribute the cooling fluid onto the first and the second plurality of media pads 220a, 220b, which are mounted on the first (bottom) cooler 210a. For example, the first cooling fluid distribution system may include a distribution member (e.g., an intermediate distribution member of FIGS. 4A and 4B) designed to collect fluid distributed by the second cooling fluid distribution system (e.g., run-off fluid from the third and the fourth plurality of media pads 220c, 220d) and redistribute this fluid to the first and the second plurality of media pads 220a, 220b located below the distribution member.

During operation of the heat exchange module or the cooler 210 in the adiabatic mode, ambient air may be drawn through the at least one air inlet 212 and the wetted pluralities of media pads 220. As the air passes through the pluralities of media pads 220, the dry-bulb temperature of the air may be reduced. In this way, the pluralities of media pads 220 may pre-cool the ambient air entering the cooler 210 and increase the heat rejection capacity of the ambient air. The pre-cooled air may then flow across the heat exchanger 202 and cool the process fluid contained within the heat exchanger 202 (e.g., within the first and second heat exchanger conduit bundles 202a, 202b), as heat from the process fluid is transferred to the pre-cooled air. Subsequently, the heated air may be discharged from the cooler 210 via an air outlet 250 positioned at or proximate to the upper portion 211 of the second (top) cooler 210b (e.g., at or proximate to the at least one air movement device 230).

In some instances, the cooling fluid dispensed onto or sprayed over the pluralities of media pads 220 via the cooling fluid distribution system 232 may be collected via a fluid collection system in the first (bottom) cooler 210a. The fluid collection system may include a collection basin 260, which may include one or more sensors 262 designed to detect one or more parameters or characteristics of the fluid contained within the collection basin 260. For example, the sensors 262 may be provided in the form of one or more of a temperature sensor, a level sensor, a conductivity sensor, a turbidity sensor, and/or other known sensors in the art. The level sensor may be selected from the group consisting of a float switch, an ultrasonic level sensor, a capacitive level sensor, or a hydrostatic level sensor.

Fluid collected within the collection basin 260 may be recirculated through the first cooler 210a and/or second cooler 210b. In instances where the fluid is collected and recirculated, the fluid may be reused to wet the pluralities of media pads 220 again. For example, in instances where a modular heat transfer system 100 (see FIG. 1A) is provided in the form of a first and second cooler 210a, 210b, fluid collected in the collection basin 260 of the first (bottom) cooler 210a (or the first (bottom) cooler 110a of FIG. 1A) may be used to wet the pluralities of media pads 220 of the second (top) cooler 210b (or the second (top) cooler 110b of FIG. 1A) before being recirculated, for example, to a storage tank or to wet the pluralities of media pads 220 of the first (bottom) cooler 210a again. Thus, the collection basin 260 may include and/or be in communication with a pump 270. For example, the pump 270 may be positioned within and/or in communication with the collection basin 260. The pump 270 may also be in fluid communication with a recirculation conduit 280, which may be in communication with the fluid distribution system 232 of the same cooler 210a or an adjacent cooler 210b. Therefore, the pump 270 may provide the driving force to deliver the fluid from the collection basin 260 of the first (bottom) cooler 210a to the fluid distribution system 232 to wet the pluralities of media pads 220 of the first (bottom) cooler 210a or the second (top) cooler 210b. In some instances, the recirculation conduit 280 may include an optional recirculation valve 282 designed to control a flow of fluid through the recirculation conduit 280. In other instances, the recirculation valve 282 may be omitted.

The first (bottom) cooler 210a may further include at least one drain valve 283 and/or a cooling fluid outlet conduit 284. The at least one drain valve 283 and the cooling fluid outlet conduit 284 may each be configured or designed to direct some or all of the fluid collected in the collection basin 260 to a waste system, recirculation tank, storage tank, or other vessel or component. As discussed further below with reference to FIG. 3A, the collection basin 260 may be in fluid communication with one or more flumes designed to collect and/or direct cooling fluid run-off from the pluralities of media pads 220. Accordingly, in some instances, the cooling fluid outlet conduit 284 may be in fluid communication with the one or more flumes.

In some instances, the cooling fluid may be recirculated back through the first cooler 210a and/or second cooler 210b. In other instances, some or all of the cooling fluid may be discharged to a waste system to limit the presence of contaminants within the first cooler 210a and/or second cooler 210b. For example, when the water distributed onto the pluralities of media pads 220 has a higher COC, the pluralities of media pads 220 may accumulate mineral deposits or scale at a higher rate. Buildup of scale may impede operation of the pluralities of media pads 220 and/or other components of the first cooler 210a and/or second cooler 210b. Further, a portion of the cooling fluid may evaporate and thus be removed from the first cooler 210a and/or second cooler 210b over time. Accordingly, the first (bottom) cooler 210a may include a cooling fluid make-up conduit 286 designed to deliver fresh cooling fluid to the first (bottom) cooler 210a to replace the discharged and/or evaporated cooling fluid and/or to dilute contaminants present in the cooling fluid being circulated throughout the first cooler 210a and/or second cooler 210b. In some instances, the cooling fluid make-up conduit 286 may be in communication with the collection basin 260. Thus, in certain instances, fluid entering the first (bottom) cooler 210a via the cooling fluid make-up conduit 286 can mix with the cooling fluid collected within the collection basin 260 (e.g., recirculated cooling fluid) before being delivered to the fluid distribution system 232. In some instances, the cooling fluid make-up conduit 286 may be in fluid communication with the fluid distribution system 232 such that the cooling fluid make-up conduit 286 ties into the first cooler 210a and/or second cooler 210b downstream of the collection basin 260.

Further, the first cooler 210a and/or second cooler 210b may include a controller and/or control system 290 configured or designed to monitor and/or control one or more aspects of the operation of the first cooler 210a and/or second cooler 210b (or the modular heat transfer system as a whole). In some instances, the control system 290 may be the control system 150 of the modular heat transfer system 100 (see FIG. 1A). For example, the control system 290 may be configured or designed to control one or more components of the first cooler 210a and/or second cooler 210b, such as the at least one air movement device 230, the fluid distribution system 232, the pump 270, the recirculation valve 282, and/or other components (e.g., sensors, valves, etc.) of the first cooler 210a and/or second cooler 210b.

FIG. 3A depicts a first frame 300 designed to support the first (bottom) cooler 110a of the modular heat transfer system 100 of FIG. 1A or the first cooler 210a of FIG. 2A. The first frame 300 may be configured or designed to support one or more components of the first cooler 110a, 210a, such as the heat exchanger, the optional media pads, and/or other components described above with reference to the first cooler 110a of the modular heat transfer system 100 of FIG. 1A or the first cooler 210a of FIG. 2A. The first frame 300 may include a base 315 coupled to one or more supports 320. In some instances, the base 315 of the first frame 300 may include a basin 332 and one or more flumes 330 in communication with the basin 332 (e.g., the basin 332 may be substantially similar to the collection basin 260 of FIG. 2A). For example, a first flume 341 may be positioned at or proximate to a first side 351 of the first frame 300 (e.g., such that the first flume 341 is arranged to be positioned under or to align with the first plurality of media pads 220a of FIG. 2A), and a second flume 342 may be positioned at or proximate to a second side 352 of the first frame 300 (e.g., such that the second flume 342 is arranged to be positioned under or to align with the second plurality of media pads 220b of FIG. 2A). Thus, the flumes 330 may be configured or designed to collect run-off cooling fluid from the pluralities of media pads 220 and direct the run-off cooling fluid toward the basin 332. In some instances, the basin 332 may include a weir or overflow outlet 331 configured or designed to prevent the basin 332 from overflowing by discharging fluid therefrom when necessary. The basin 332 and the one or more flumes 330 may be referred to collectively as a fluid collection system 360. FIG. 3B depicts a heat exchanger 370 installed on the first frame 300. The heat exchanger 370 may be substantially similar to the heat exchanger 202 of the first cooler 210a of FIG. 2A and/or the first cooler 110a of the modular heat transfer system 100 of FIG. 1A. In some instances, the heat exchangers 370 may be fluidly connected to one or more heat exchange conduit bundles 372 (e.g., the heat exchanger conduit bundles 102 of FIG. 1A). In some such cases, the number of heat exchanger conduit bundles 372 may be equivalent to the number of heat exchangers 370.

In some instances, the second cooler 110b of the modular heat transfer system 100 of FIG. 1A and/or the second cooler 210b of FIG. 2B may be supported by a second frame. The second frame may be substantially similar to the first frame 300 of FIGS. 3A and 3B, except that in some instances the second frame may omit a base, as explained below.

The second frame may be configured or designed to support one or more components of the second cooler 110b, 210b, such as the heat exchanger, the optional media pads, and/or other components described above with reference to the second cooler 110b of the modular heat transfer system 100 of FIG. 1A or the second cooler 210b of FIG. 2B. The second frame may include a first side, a second side, a first end, a second end positioned opposite the first end, and one or more supports coupled to one or more of the first side, the second side, the first end, and the second end. In some instances, the first side of the second frame, the second side of the second frame, the first end of the second frame, and the second end of the second frame define an opening provided in a bottom portion of the second frame. Thus, unlike the first frame 300, the construction of the second frame may omit a base to allow air to flow between the first cooler 110a, 210a (e.g., a plenum of the first cooler 110a, 210a) to the second cooler 110b, 210b (e.g., a plenum of the second cooler 110b, 210b). For example, air may travel from the first cooler 110a, 210a (e.g., a plenum of the first cooler 110a, 210a) and the second cooler 110b, 210b (e.g., a plenum of the second cooler 110b, 210b). Then, the air may exit the second cooler 110b, 210b via the at least one air movement device 130, 230.

Turning to FIGS. 4A and 4B, an intermediate distribution system 400 is provided. The intermediate distribution system 400 may be disposed on or in a cooling distribution system (such as the cooling distribution system 232 of FIGS. 2A and 2B). The intermediate distribution system 400 may include a distribution pipe 402 having one or more perforations 404 extending through the distribution pipe 402. In some instances, the one or more perforations 404 may be provided in the form of circular geometries. In other instances, the one or more perforations 404 may be provided in the form of other geometries, including, but not limited to, square, rectangular, hexagonal, octagonal, ovular, or polygonal geometries. It is to be understood that the one or more perforations 404 may be provided in the form of a singular geometry (i.e., each of the one or more perforations 404 are provided in the form of the same geometry) or the one or more perforations 404 may be provided in the form of multiple geometries (e.g., the one or more perforations 404 may be provided in the form of circular and square geometries).

The distribution pipe 402 may be configured or designed to distribute cooling fluid through the one or more perforations 404. The distribution pipe 402 may be disposed above a distribution basin floor 406. The distribution basin floor 406 may be configured or designed to catch or collect at least some of the cooling fluid exiting the one or more perforations 404. In some instances, the distribution basin floor 406 may be in fluid communication with one or more elements of the cooling distribution system.

In some instances, as depicted in FIG. 4B, the distribution basin floor 406 may include one or more basin perforations 408 extending through the distribution basin floor 406. As cooling fluid is collected by the distribution basin floor 406, the cooling fluid may pass through the distribution basin floor 406 through the one or more basin perforations 408. In some instances, the one or more basin perforations 408 may be provided in the form of a circular geometry. In other instances, the one or more basin perforations 408 may be provided in the form of other geometries, including, but not limited to, square, rectangular, ovular, hexagonal, octagonal, or polygonal geometries.

In some instances, a first cooling fluid distribution system (such as the cooling fluid distribution system 232 of FIGS. 2A and 2B) may be configured or designed to distribute fluid onto the first and the second plurality of media pads 140a, 140b of FIGS. 1A-1E. A second cooling fluid distribution system (such as the cooling fluid distribution system 232 of FIGS. 2A and 2B) may be configured or designed to distribute fluid onto the third and the fourth plurality of media pads 140c, 140d of FIGS. 1A-1E. Thus, the first cooling fluid distribution system and the second cooling fluid distribution system may each respectively include a first distribution pipe (such as the distribution pipe 402 of FIGS. 4A and 4B) that is arranged above the third plurality of media pads 140c (e.g., positioned at or proximate to the first side 126 of the modular heat transfer system 100). Additionally, the first cooling fluid distribution system and the second cooling fluid distribution system may each respectively include a second distribution pipe (such as the distribution pipe 402 of FIGS. 4A and 4B) arranged above the fourth plurality of media pads 140d (e.g., positioned at or proximate to the first side 128 of the modular heat transfer system 100). In some instances, the distribution pipes and/or distribution members of the first or second cooling fluid distribution system are mounted on or coupled to a frame member (e.g., the frame member 501 of FIG. 5).

In some instances, the distribution pipe 402 may be perforated and include one or more perforations 404 or openings through which cooling fluid may flow. For example, the distribution pipe 402 may include about one to about twenty, or about one to about eighteen, or about one to about sixteen, or about one to about fourteen, or about one to about twelve, or about one to about ten perforations 404 per about twelve feet of distribution pipe 402. As an additional example, the distribution pipe 402 may include one to twenty, or one to eighteen, or one to sixteen, or one to fourteen, or one to twelve, or one to ten perforations 404.

In other instances, the distribution pipe 402 may include about five to about five thousand, or about one hundred to about five thousand, or about five hundred to about five thousand, or about one thousand to about five thousand, or about two thousand to about five thousand, or about three thousand to about five thousand, or about four thousand to about five thousand perforations 404 per about twelve feet of distribution pipe 402. As an additional example, the distribution pipe 402 may include five to five thousand, or one hundred to five thousand, or five hundred to five thousand, or one thousand to five thousand, or two thousand to five thousand, or three thousand to five thousand, or four thousand to five thousand perforations 404 per twelve feet of distribution pipe 402. It is to be understood that the distribution pipe 402 may include any number of perforations 404 between the minimum or maximum values discussed herein. It is also to be understood that the distribution pipe 402 may include a number of perforations 404 greater than or less than the minimum or maximum values discussed herein.

In some instances, the distribution pipe 402 may be fluidly coupled to one or more nozzles (not depicted). In some instances, the distribution pipe 402 may be housed in a distribution member (not depicted). In other instances, a distribution member cover 410 may be reversibly attached to the distribution pipe 402, as shown in FIGS. 4A, 4B, 33, and 34.

Turning to FIG. 5, a modular heat transfer system 500 may be substantially similar to the modular heat transfer system 100 in one or more respects. For example, the modular heat transfer system 500 may be convertible in the field between an adiabatic cooling mode and a dry cooling mode, and components of the modular heat transfer system 500 and the modular heat transfer system 100 having similar names and/or reference numbers with a difference of four hundred may be substantially similar in form and function. In addition, similar to the modular heat transfer system 100, the modular heat transfer system 500 may include components (e.g., two or more coolers) that are configured or designed to be manufactured, transported, installed, or assembled in a variety of configurations (e.g., the coolers may be arranged in a stacked configuration, a side-by-side configuration, and/or other configurations upon installation or assembly).

The modular heat transfer system 500 may be provided in the form of one or more heat exchange modules or coolers 510, for example, a first cooler 510a and a second cooler 510b, which may be configured or designed to cool a process fluid and arranged in a modular (e.g., stacked) configuration. One or more air movement devices 530 may be provided to draw ambient air into the modular heat transfer system 500. In some instances, the modular heat transfer system 500 may include two, three, four, or any number of coolers of the coolers 510 and may include one or more heat exchangers or heat exchange modules provided in any suitable form.

Each of the coolers 510 may include one or more sub-modules or sub-units. For example, the first cooler 510a may include one or more sub-units 520, and the second cooler 510b may include one or more sub-units 522. In some instances, the sub-units 520, 522 may be arranged or coupled side-by-side in a substantially linear configuration; however, in other instances, the sub-units 520, 522 may be arranged in any suitable configuration. In the example of FIG. 5, the first cooler 510a includes four sub-units 520a-d and the second cooler 510b includes four sub-units 522a-d. Each of the sub-units 522a-d of the second cooler 510b may include an air movement device 530. However, in other instances, each cooler 510 may include any number of sub-units (e.g., a single sub-unit, two sub-units, more than four sub-units, etc.).

Each of the coolers 510 may include one or more heat exchanger conduit bundles 502 in communication with one or more process fluid inlets 514 and one or more process fluid outlets 516. For example, the first cooler 510a may include a first heat exchanger conduit bundle 502a in communication with a first process fluid inlet 514a and a first process fluid outlet 516a, and a second heat exchanger conduit bundle 502b in communication with a second process fluid inlet 514b and a second process fluid outlet 516b, and the second cooler 510b may include a third heat exchanger conduit bundle 502c in communication with a third process fluid inlet 514c and a third process fluid outlet 516c, and a fourth heat exchanger conduit bundle 502d in communication with a fourth process fluid inlet 514d and a fourth process fluid outlet 516d. One or more of the heat exchanger conduit bundles 502a-d may be configured or designed to operate together in any suitable manner (e.g., may be arranged in a parallel configuration, arranged in a serial configuration, etc.) and may be connected simultaneously via the respective process fluid inlets 514a-d and process fluid outlets 516a-d or may be connected in other manners.

The modular heat transfer system 500 may include one or more frame members 501 configured or designed to support and/or retain one or more pad modules 503. Each of the one or more pad modules 503 may include one or more media pads 540, which may be configured or designed to pre-cool ambient air entering the modular heat transfer system 500 in a substantially similar manner to the media pads 140, as described above. For example, each pad module of the one or more pad modules 503 may include up to twenty substantially rectilinear media pads 540 arranged in an array. However, in other instances, the one or more pad modules 503 may include any number of media pads 540 (e.g., a single media pad 540, two media pads 540, more than twenty media pads 540, etc.) positioned in any suitable arrangement. Moreover, one or more media pads 540 may differ in one or more respects as compared to one or more other media pads 540. As shown in FIG. 5, in some instances, the modular heat transfer system 500 may include two frame members 501 positioned on two opposing sides thereof. The frame members 501 may be configured or designed to facilitate coupling between the one or more pad modules 503 and other components of the modular heat transfer system 500 (e.g., the heat exchanger conduit bundles 502a-d).

In some instances, the one or more pad modules 503 may be coupled to or positioned on the frame members 501 via a cleated mounting technique in which the one or more pad modules 503 include angled “cleats” (e.g., positioned proximate to a lower portion and an upper portion thereof) designed to engage corresponding components positioned on the respective frame member 501, as described in further detail below with reference to FIGS. 8-13 and 16-21. The one or more pad modules 503 may be factory-assembled or may be assembled in the field or on a work site, depending on the circumstances. For example, the cleats may be coupled to or installed on the one or more pad modules 503 prior to arrival at a work site or at the work site. In this way, the positioning of the cleats may be customized depending on the circumstances or demands of a particular job. In general, the corresponding cleats or other components positioned on the one or more pad modules 503 and the frame members 501 may encourage a desired alignment or positioning of the one or more pad modules 503 relative to the frame member 501, may retain the one or more pad modules 503 in place while the pad module is coupled (e.g., bolted, fastened, anchored, fixed, attached, clamped, locked, and the like) to the frame member 501, or may facilitate mounting or installation of the one or more pad modules 503 in other manners. In certain instances, cleats may facilitate alignment of the one or more pad modules 503 with the frame member 501 in a desired configuration such that there may be an airtight seal between the one or more pad modules 503 and the frame member 501. The cleats provided on the frame members 501 and/or the one or more pad modules 503 may be provided in the form of French cleats (i.e., “angled” cleats), straight cleats, Z-cleats, keyhole cleats, and the like. In further instances, the one or more pad modules 503 may be coupled to or installed on the frame members 501 via other techniques.

In some instances, each pad module of the one or more pad modules 503 may be provided in a substantially similar form. However, in other instances, the first cooler 510a may include one or more first pad modules 503a, and the second cooler 510b may include one or more second pad modules 503b. In the example of FIG. 5, the first cooler 510a may include four sub-units 520, each including two first pad modules 503a (e.g., positioned on opposing sides of the respective sub-unit 520), and the second cooler 510b may include four sub-units 522, each including two second pad modules 503b (e.g., positioned on opposing sides of the respective sub-unit 522). However, in other instances, any number of pad modules 503 may be provided, and the one or more pad modules 503 may be positioned in any suitable arrangement.

In some instances, the frame members 501 may each be defined by a frame member top 505 (e.g., proximate to the air movement devices 530) and a frame member bottom 507 opposing the frame member top 505 (e.g., proximate to a base of the modular heat transfer system 500). In some instances, the first cooler 510a and the first pad modules 503a may be positioned proximate to the frame member bottom 507, and the second cooler 510b and the second pad modules 503b may be positioned proximate to the frame member top 505.

In some instances, the modular heat transfer system 500 may include a distribution system 511 designed to convey fluid to the media pads 540 while the modular heat transfer system 500 is in use, as explained in further detail below with reference to FIGS. 26-35. For example, the distribution system 511 may be provided in the form of a recirculation system that recirculates or reuses fluid that has already been conveyed to the media pads 540, or the distribution system 511 may be provided in other forms. Additionally, the modular heat transfer system 500 may include a collection basin 524 in communication with the distribution system 511. For example, the distribution system 511 may be configured or designed to wet the media pads 540 with a fluid such that evaporation of the fluid pre-cools air entering the modular heat transfer system 500, and the fluid may be directed by gravity to accumulate within the collection basin 524.

The collection basin 524 may be configured or designed to direct fluid therein back to the distribution system 511 (e.g., the fluid may be continuously recirculated while the modular heat transfer system 500 is in use). In the example of FIG. 5, the collection basin 524 is positioned proximate to the frame member bottom 507 (e.g., beneath the first cooler 510a) and includes collection basin sections 524a-d positioned on the sub-units 520a-d, respectively; however, in other instances, the collection basin 524 may be positioned in any suitable location and may be provided in the form of a singular part or in other forms.

Additionally, in some instances, the modular heat transfer system 500 may include one or more redistribution members 509 positioned between the first cooler 510a and the second cooler 510b. For example, the modular heat transfer system 500 may include two redistribution members 509 positioned on a first side 526 of the modular heat transfer system 500 and a second side 528 of the modular heat transfer system 500, respectively. In some instances, the redistribution member 509 may be provided as an intermediate component that facilitates the travel of fluid from the second pad modules 503b to the first pad modules 503a via the force of gravity. For example, the redistribution member 509 may be configured or designed to prevent distributed fluid from falling from the second pad module 503b in such a way that the distributed fluid bypasses the first pad module 503a. Instead, the redistribution member 509 is designed to facilitate the distributed fluid falling from the second pad modules 503b and distributing substantially evenly to the first pad modules 503a. Additionally, in some instances, the redistribution member 509 may provide containment such that the distributed fluid is not expelled into the external environment while the modular heat transfer system 500 is in use, thereby enhancing an efficiency of the modular heat transfer system 500 and/or improving worker safety.

In some instances, the redistribution member 509 may include one or more media pads 540 positioned between the first pad modules 503a and the second pad modules 503b and configured or designed to redistribute fluid received from the second pad modules 503b such that fluid may be evenly distributed from the redistribution member 509 to the first pad modules 503a. The media pads 540 of the redistribution member 509 may be oriented perpendicularly with respect to the media pads 540 of the first and second pad modules 503a, 503b. In other instances, the redistribution member 509 may be provided in other forms and may not include media pads 540. For example, in certain instances, the redistribution member 509 may be provided in a form substantially similar to that of the distribution system 511 described in further detail below with reference to FIGS. 30-35.

In instances where the modular heat transfer system 500 includes one or more media pads 540, the modular heat transfer system 500 may operate in an adiabatic mode. In instances where the modular heat transfer system 500 omits one or more media pads 540, or where the cooling distribution system 232 is not in operation, the modular heat transfer system 500 may operate in a dry mode. In the adiabatic mode, the modular heat transfer system 500 may distribute a cooling fluid onto various components. In the dry mode, the modular heat transfer system 500 may not distribute a cooling fluid onto various components.

Turning to FIG. 6, the first pad module 503a may be provided in the form of a first pad module frame 521a configured or designed to support and retain a plurality of media pads 540. For example, the first pad module frame 521a may include a lower panel 523a, a first side panel 525a coupled to the lower panel 523a and extending upwardly therefrom, and a second side panel 527a coupled to the lower panel 523a at an opposite location relative to the first side panel 525a and extending upwardly therefrom. The plurality of media pads 540 may be disposed (e.g., in an array) within the space defined by the lower panel 523a, the first side panel 525a, and the second side panel 527a.

The first side panel 525a and the second side panel 527a may each be coupled to the lower panel 523a at a side panel first end 529a and may each include a side panel second end 531a opposing the side panel first end 529a. In some instances, the first pad module frame 521a may include a first horizontal cross member 533a positioned between the side panel first end 529a and the side panel second end 531a and extending between the first side panel 525a and the second side panel 527a. Additionally, the first pad module frame 521a may include a first vertical cross member 535a positioned between the first side panel 525a and the second side panel 527a and extending at least partially between the lower panel 523a and the side panel second end 531a. It is to be appreciated that the components of the first side panel 525a and the second side panel 527a may be alternatively arranged (e.g., the first horizontal cross member 533a may be arranged in a non-horizontal configuration and the first vertical cross member 535a may be arranged in a non-vertical configuration).

The first pad module 503a may include a first pad module lower cleat 537a and a first pad module upper cleat 539a designed to facilitate coupling between the first pad module 503a and the frame member 501 (see FIG. 5). For example, the first pad module lower cleat 537a may be positioned proximate to the side panel first end 529a and extend at least partially between the first side panel 525a and the second side panel 527a (e.g., the first pad module lower cleat 537a may be coupled to or formed integrally with the lower panel 523a), and the first pad module upper cleat 539a may be positioned proximate to the side panel second end 531a and may extend at least partially between the first side panel 525a and the second side panel 527a (e.g., the first pad module upper cleat 539a may be coupled to opposing locations along the first side panel 525a and the second side panel 527a).

The first pad module lower cleat 537a and the first pad module upper cleat 539a may be positioned at or proximate to a mounting face 541a (see also FIG. 7) of the first pad module 503a and extend outwardly therefrom. In this way, the first pad module lower and upper cleats 537a, 539a may be available for engagement with the frame member 501, as described in further detail below with reference to FIGS. 7-13, thereby coupling the first pad module 503a to the frame member 501. The first pad module 503a may include an outward face 543a that opposes the mounting face 541a. In some instances, an upper panel 545a may be positioned at the outward face 543a and proximate to the side panel second end 531a (e.g., positioned opposite the first pad module upper cleat 539a) and extend at least partially between the first side panel 525a and the second side panel 527a. Additionally, in some instances, a member 547a may be provided proximate to the side panel second end 531a and positioned between the first pad module upper cleat 539a and the upper panel 545a. For example, the upper panel 545a and/or the member 547a may control or influence (e.g., divert) a flow of fluid within the modular heat transfer system 500, may impart the first pad module frame 521a with rigidity or structural integrity, or may be configured or designed to facilitate coupling between the modular heat transfer system 500 and additional components or devices.

As best shown in FIG. 8, in some instances, the first pad module upper cleat 539a may be provided in the form of a substantially planar first pad module upper cleat panel 549a coupled to one or more of the first side panel 525a, the second side panel 527a, and the member 547a, and the first pad module upper cleat 539a may include a first pad module upper cleat flange 551a extending along an edge of the first pad module upper cleat panel 549a and extending outwardly therefrom. For example, the first pad module upper cleat flange 551a may either be formed integrally with or coupled to the first pad module upper cleat panel 549a and may be oriented substantially perpendicularly thereto. While not depicted in FIG. 8, in some instances, the redistribution member 509, or a portion thereof (e.g., one or more media pads 540 of the redistribution member 509), may be positioned proximate to the first pad module upper cleat 539a and/or the upper panel 545a. For example, in some instances, the redistribution member 509 may include one or more media pads 540 that extend at least partially between the first and second side panels 525a, 527a and/or extend at least partially between the first pad module upper cleat 539a and the upper panel 545a.

Turning to FIG. 9, the frame member 501 of the modular heat transfer system 500 may include a frame member upper cleat 553a configured or designed to receive or otherwise engage the first pad module upper cleat 539a. For example, the frame member upper cleat 553a may be positioned between the frame member bottom 507 and the frame member top 505 (see FIG. 5). In some instances, the frame member upper cleat 553a may be provided in the form of a frame member upper cleat panel 555a either coupled to or formed integrally with the frame member 501 and a frame member upper cleat dock member 557a extending outwardly therefrom (e.g., the frame member upper cleat dock member 557a may define a receiving space 559a shaped and sized to accommodate the first pad module upper cleat 539a). Thus, as shown in FIG. 10, the first pad module upper cleat flange 551a and/or the first pad module upper cleat panel 549a may be at least partially received within the receiving space 559a or may otherwise engage the frame member upper cleat 553a when the first pad module 503a is coupled to the frame member 501.

As best shown in FIG. 11, the first pad module lower cleat 537a may be provided in the form of a substantially planar first pad module lower cleat panel 561a coupled to the first side panel 525a and/or the second side panel 527a (or other portions of the first pad module frame 521a), and the first pad module lower cleat 537a may include a first pad module lower cleat flange 563a extending along an edge of the first pad module lower cleat panel 561a and extending outwardly therefrom. For example, the first pad module lower cleat flange 563a may either be formed integrally with or coupled to the first pad module lower cleat panel 561a and may be oriented substantially perpendicularly thereto.

In some instances, the first pad module frame 521a may include a lower cleat protrusion 565a, and the first pad module lower cleat 537a may include a mating portion 567a configured or designed to be coupled to the lower cleat protrusion 565a. One or more fasteners 569a may be provided to couple the first pad module lower cleat 537a to the first pad module frame 521a (e.g., via the lower cleat protrusion 565a, the first side panel 525a, the second side panel 527a, and/or other portions of the first pad module frame 521a). The one or more fasteners 569a may be provided in the form of nuts, bolts, screws, clamps, clasps, and the like.

Turning to FIG. 12, the frame member 501 of the modular heat transfer system 500 may include a frame member lower cleat 571a configured or designed to receive or otherwise engage the first pad module lower cleat 537a. For example, the frame member lower cleat 571a may be positioned on or proximate to the frame member bottom 507 (see FIG. 5). In some instances, the frame member lower cleat 571a may be provided in the form of a frame member lower cleat base 573a flanked by frame member lower cleat walls 575a on opposing sides thereof, such that a frame member lower cleat channel 577a is defined therein and configured or designed to receive or accommodate the first pad module lower cleat 537a. Thus, as shown in FIG. 13, the first pad module lower cleat flange 563a and/or the first pad module lower cleat panel 561a may be at least partially received within the frame member lower cleat channel 577a or may otherwise engage the frame member lower cleat 571a when the first pad module 503a is coupled to the frame member 501.

In some instances, when the first pad module upper cleat 539a engages the frame member upper cleat 553a (see FIG. 10) and the first pad module lower cleat 537a engages the frame member lower cleat 571a (see FIG. 13), the first pad module 503a may subsequently be coupled (e.g., bolted, fastened, anchored, fixed, attached, clamped, locked, and the like) to the respective frame member 501.

Turning next to FIGS. 14-21, the second pad module 503b may be provided in a form substantially similar to the first pad module 503a of FIGS. 6-13 in one or more respects. For example, components of the first pad module 503a and the second pad module 503b having similar names and reference numbers may be substantially similar in form and/or function.

The second pad module 503b may be provided in the form of a second pad module frame 521b including a lower panel 523b, a first side panel 525b, and a second side panel 527b. The first and second side panels 525b, 527b may be coupled to opposing ends of the lower panel 523b and may extend upwardly therefrom, and a plurality of media pads 540 may be disposed (e.g., in an array) within the space defined by the lower panel 523b, the first side panel 525b, and the second side panel 527b. The first and second side panels 525b, 527b may each be defined by a side panel first end 529b (e.g., proximate to the lower panel 523b) and a side panel second end 531b opposing the side panel first end 529b.

In some instances, the second pad module frame 521b may include a second horizontal cross member 533b positioned between the side panel first end 529b and the side panel second end 531b and extending between the first side panel 525b and the second side panel 527b. Additionally, the second pad module frame 521b may include a second vertical cross member 535b positioned between the first side panel 525b and the second side panel 527b and extending at least partially, or entirely, between the lower panel 523b and the side panel second end 531b. It is to be appreciated that the second pad module frame 521b may be constructed in alternative configurations (e.g., the second horizontal cross member 533b may be arranged in a non-horizontal configuration and the second vertical cross member 535b may be arranged in a non-vertical configuration).

The second pad module 503b may include a second pad module lower cleat 537b and a second pad module upper cleat 539b designed to facilitate coupling between the second pad module 503b and the frame member 501 (see FIG. 5). The second pad module lower cleat 537b may be positioned proximate to the side panel first end 529b, and the second pad module upper cleat 539b may be positioned proximate to the side panel second end 531b. The second pad module lower cleat 537b and the second pad module upper cleat 539b may be positioned at or proximate to a mounting face 541b of the second pad module 503b and extend outwardly therefrom. In this way, the second pad module lower and upper cleats 537b, 539b may be available for engagement with the frame member 501, as described in further detail below with reference to FIGS. 16-21, thereby coupling the second pad module 503b to the frame member 501. The second pad module 503b may also include an outward face 543b that opposes the mounting face 541b. In some instances, an upper panel 545b may be positioned at or proximate to the side panel second end 531b and may extend at least partially, or entirely, between the first side panel 525b and the second side panel 527b. For example, the upper panel 545b may impart the second pad module frame 521b with rigidity or structural integrity.

As shown in FIG. 15, in some instances, the second pad module 503b may include a projection 579b positioned on the mounting face 541b and extending outwardly therefrom. In some instances, the projection 579b may be positioned proximate to the side panel first end 529b and/or the second pad module lower cleat 537b. For example, the projection 579b may be positioned just above the second pad module lower cleat 537b and may extend outwardly therefrom at a slightly upward angle. In some instances, the projection 579b may be configured or designed to capture fluid falling from the media pads 540 due to the force of gravity and direct or guide such fluid toward the distribution system 511 to be recirculated back to the media pads 540, as described in further detail below with reference to FIGS. 26-35. However, in other instances, the projection 579b may be provided in other forms and may be arranged in any suitable location relative to the second pad module 503b. In further instances, the projection 579b may be omitted.

As best shown in FIG. 16, the second pad module upper cleat 539b may be provided in the form of a substantially planar second pad module upper cleat panel 549b coupled to one or more of the first side panel 525b, the second side panel 527b, and the upper panel 545b, and the second pad module upper cleat 539b may include a second pad module upper cleat flange 551b extending along an edge of the second pad module upper cleat panel 549b and extending outwardly therefrom. For example, the second pad module upper cleat flange 551b may either be formed integrally with or coupled to the second pad module upper cleat panel 549b and may be oriented substantially perpendicularly thereto.

Turning to FIG. 17, the frame member 501 of the modular heat transfer system 500 may include a frame member upper cleat 553b configured or designed to receive or otherwise engage the second pad module upper cleat 539b. For example, the frame member upper cleat 553b may be positioned on or proximate to the frame member top 505 (see FIG. 5). In some instances, the frame member upper cleat 553b may be provided in the form of a frame member upper cleat panel 555b either coupled to or formed integrally with the frame member 501 and a frame member upper cleat dock member 557b extending outwardly therefrom (e.g., the frame member upper cleat dock member 557b may define a receiving space 559b shaped and sized to accommodate the second pad module upper cleat 539b). Thus, as shown in FIG. 18, the second pad module upper cleat flange 551b and/or the second pad module upper cleat panel 549b may be at least partially, or entirely, received within the receiving space 559b or may otherwise engage the frame member upper cleat 553b when the second pad module 503b is coupled to the frame member 501. In some instances, the module cleats and the mating cleats may be configured or designed to secure the modular heat transfer system 500 to the frame member 501.

As best shown in FIG. 19, the second pad module lower cleat 537b may be provided in the form of a substantially planar second pad module lower cleat panel 561b coupled to the first side panel 525b and/or the second side panel 527b (or other portions of the second pad module frame 521b), and the second pad module lower cleat 537b may include a second pad module lower cleat flange 563b extending along an edge of the second pad module lower cleat panel 561b and extending outwardly therefrom. For example, the second pad module lower cleat flange 563b may either be formed integrally with or coupled to the second pad module lower cleat panel 561b and may be oriented substantially perpendicularly thereto.

Turning to FIG. 20, the frame member 501 of the modular heat transfer system 500 may include a frame member lower cleat 571b configured or designed to receive or otherwise engage the second pad module lower cleat 537b. For example, the frame member lower cleat 571b may be positioned between the frame member bottom 507 and the frame member top 505 (see FIG. 5). In some instances, the frame member lower cleat 571b may be provided in the form of a frame member lower cleat base 573b flanked by frame member lower cleat walls 575b on opposing sides thereof, such that a frame member lower cleat channel 577b is defined therein and configured or designed to receive or accommodate the second pad module lower cleat 537b. Thus, as shown in FIG. 21, the second pad module lower cleat flange 563b and/or the second pad module lower cleat panel 561b may be at least partially, or entirely, received within the frame member lower cleat channel 577b or may otherwise engage the frame member lower cleat 571b when the second pad module 503b is coupled to the frame member 501.

In some instances, when the second pad module upper cleat 539b engages the frame member upper cleat 553b (see FIG. 18) and the second pad module lower cleat 537b engages the frame member lower cleat 571b (see FIG. 21), the second pad module 503b may subsequently be coupled (e.g., bolted, fastened, anchored, fixed, attached, clamped, locked, and the like) to the respective frame member 501.

In some instances, one or more pad modules 503 may be installed on or coupled to one or more frame members 501 in accordance with the foregoing description made with reference to FIGS. 6-21. However, in other instances, the one or more pad modules 503 may be installed on or coupled to the frame member 501 according to a cleated mounting technique that differs in one or more respects from the technique described above, or according to other suitable methods or techniques. For example, the one or more pad modules 503 may include at least one module cleat (e.g., the first pad module lower cleat 537a, the first pad module upper cleat 539a, the second pad module lower cleat 537b, the second pad module upper cleat 539b, and/or other cleats positioned on the one or more pad modules 503 but not specifically described and depicted herein) and the frame member 501 may include at least one mating cleat (e.g., the frame member upper cleat 553a, the frame member upper cleat 553b, the frame member lower cleat 571a, the frame member lower cleat 571b, and/or other cleats positioned on the frame member 501 but not specifically described and depicted herein). Thus, the one or more pad modules 503 may be coupled to the frame member 501 via mating or other engagement between one or more module cleats of the one or more pad modules 503 and one or more mating cleats of the frame member 501.

In some instances, one or more cleats positioned on the one or more pad modules 503 (e.g., the first pad module lower cleat 537a, the first pad module upper cleat 539a, the second pad module lower cleat 537b, the second pad module upper cleat 539b, and/or other cleats positioned on the one or more pad modules 503 but not specifically described and depicted herein) may be imparted with a first angle. Additionally, one or more cleats positioned on the frame members 501 (e.g., the frame member upper cleat 553a, the frame member upper cleat 553b, the frame member lower cleat 571a, the frame member lower cleat 571b, and/or other cleats positioned on the frame members 501 but not specifically described and depicted herein) may be imparted with a second angle. For example, the second angle may be configured or designed to complement the first angle such that the cleats of the one or more pad modules 503 mate with or are received by the cleats of the frame members 501 in instances where the cleats of the one or more pad modules 503 are coupled to the frame members 501. When the cleats of the one or more pad modules 503 mate with or are received by the cleats of the frame members 501, the one or more pad modules 503 may be aligned with the frame members 501. In some instances, the first angle may be substantially the same as the second angle, but in other instances, the first and second angles may be imparted with different values. The first angle and/or the second angle may be provided in the form of an acute angle imparted with a value of less than 90 degrees. However, in other instances, the first angle and/or the second angle may each be imparted with a value of approximately 90 degrees or may each be imparted with a value greater than 90 degrees.

Turning to FIG. 22, the lower panel 523a of the first pad module 503a may be positioned adjacent to, or may rest on, the collection basin 524 of the modular heat transfer system 500 when the first pad module 503a is coupled to the frame member 501. In some instances, the lower panel may be provided in the form of a lower panel mating surface 581a and a lower panel flange 583a coupled to the lower panel mating surface 581a and extending outwardly at an angle therefrom. In such instances, the lower panel mating surface 581a and the lower panel flange 583a may be configured or designed to receive an adjacent surface of the collection basin 524. However, in other instances, the lower panel 523a may be provided in other suitable forms.

Additionally, as shown in FIG. 22, the modular heat transfer system 500 may include one or more mounting flanges 585 including one or more collection basin mounting openings 587 configured or designed to facilitate coupling between the collection basin 524 and the modular heat transfer system 500. For example, the mounting flanges 585 may be provided as part of the frame member 501, or may be coupled to another component of the modular heat transfer system 500. The collection basin 524 may be provided as a modular part in that the collection basin 524 may be selectively coupled to and decoupled from the modular heat transfer system 500 without disassembling other components.

As best shown in FIG. 23, the collection basin 524 may be provided in the form of a trough 589. The trough 589 may be disposed such that the trough 589 is at least partially, or entirely, between a first end 532 and a second end 534 of the modular heat transfer system 500. The trough 589 may be provided in a generally rectangular geometry in which at least one side of the trough 589 is open, but the trough 589 may also be provided in the form of other geometries. Additionally, as shown in FIG. 23, where the first pad modules 503a are removed, the frame member 501 may include a plurality of frame member portions 591 arranged to be coupled with the first side panel 525a and the second side panel 525b of the first pad modules 503a. In the example of FIG. 23, where the frame member 501 is configured or designed to accommodate four first pad modules 503a, the frame member 501 may include five substantially vertical frame member portions 591 spaced evenly apart from one another between the first and second ends 532, 534. However, in other instances, the frame member 501 may include any number of frame member portions 591, or the frame member 501 may facilitate coupling with the first pad modules 503a in other manners.

As mentioned above, the collection basin 524 may be provided in the form of two or more collection basin sections, such as four collection basin sections 524a-d, coupled together to form the trough 589. In such instances, each of the collection basin sections 524a-d may include one or more collection basin section openings 593 to facilitate coupling between adjacent sections of the collection basin 524. For example, as shown in FIG. 24, the collection basin section openings 593 of the second collection basin section 524b and the third collection basin section 524c may be arranged to align with one another such that the second and third collection basin sections 524b, 524c can be coupled together via one or more fasteners (not shown) extending through each pair of aligned collection basin section openings 593.

Turning to FIG. 25, the collection basin 524 (or the sections of the collection basin 524) may include one or more collection basin flanges 595 configured or designed to facilitate coupling between the collection basin 524 and the modular heat transfer system 500. For example, the collection basin flanges 595 may extend downwardly from the collection basin 524 and be arranged to be positioned adjacent to one of the mounting flanges 585. The collection basin flanges 595 may each include one or more collection basin flange openings 597 arranged to align with one or more mounting flange openings 599 positioned on the mounting flanges 585. Thus, one or more fasteners (not shown) may extend through each collection basin flange opening 597 and the associated mounting flange opening 599, thereby coupling the collection basin 524 to the modular heat transfer system 500.

As shown in FIG. 26, one or more components of the distribution system 511 may be positioned at or proximate to the first end 532 of the modular heat transfer system 500. The distribution system 511 may be configured or designed to distribute fluid (e.g., water) to the media pads 540 while the modular heat transfer system 500 is in use. Additionally, the distribution system 511 may be in communication with the collection basin 524 such that fluid that accumulates in the collection basin 524 may be recirculated back to the media pads 540 via the distribution system 511. For example, the distribution system 511 may be in communication with two collection basins 524, including a first collection basin 524a positioned on the first side 526 of the modular heat transfer system 500 and a second collection basin positioned on the second side 528 of the modular heat transfer system 500.

In some instances, the distribution system 511 may include a reservoir 601 (e.g., an open space designed to retain fluid) at least partially defined by a side cover 603 and a top cover 605. In some instances, a fluid level sensor 606 may be positioned on an interior surface of the side cover 603 and/or the top cover 605 and may be configured or designed to detect a level of fluid within the reservoir 601. The reservoir 601 may extend at least partially between the first and second sides 526, 528 of the modular heat transfer system 500 such that the reservoir 601 may be in communication with the first collection basin section 524a and the second collection basin section 524b.

For example, as shown in FIG. 27, where the top cover 605 is removed, the first collection basin 524a may be configured or designed to empty into the reservoir 601 such that fluid collected from the media pads 540 may be directed to the distribution system 511. In some instances, a first drain valve 607a and a replacement valve 609 may be positioned proximate to the first side 526 and may each be in communication with the reservoir 601. For example, the first drain valve 607a may enable fluid within the reservoir 601 to be removed or discharged (e.g., to prevent overflowing), and the replacement valve 609 may enable fluid to be added to the reservoir 601 from an external source when required. Additionally, in some instances, one or more weir plates 611 may be positioned within the reservoir 601 and designed to control a flow or distribution of fluid therein. The one or more weir plates 611 may be provided in the form of a substantially rectilinear panel, as can be seen in FIG. 27, but in other instances, one or more weir plates 611 may be provided, and the one or more weir plates 611 may be provided in any suitable form.

As shown in FIG. 28, the second collection basin 524b may be configured or designed to empty into the reservoir 601 such that fluid collected from the media pads 540 may be directed to the distribution system 511. In some instances, a second drain valve 607b may be positioned proximate to the second side 528 and may be in communication with the reservoir 601 such that fluid may be removed or discharged from the reservoir 601 via the second drain valve 607b. The first and second drain valves 607a, 607b may be operable independently of one another or may be configured or designed to operate together. Additionally, as seen in FIG. 28, one or more weir plates 611 and one or more sensor housings 613 may be positioned within the reservoir 601. For example, the one or more sensor housings 613 may include one or more sensors (see FIG. 29).

In some instances, an overflow failsafe 615 may be provided in communication with the reservoir 601 (e.g., positioned on the side cover 603) to prevent or reduce the likelihood of fluid within the reservoir 601 overflowing. For example, the overflow failsafe 615 may be provided in the form of an angled channel 617 positioned proximate to an upper edge 619 of the side cover 603 and a reservoir outlet 621 providing communication between the angled channel 617 and an exterior of the reservoir 601. Thus, if fluid within the reservoir 601 begins to approach the upper edge 619 and creates a risk of overflowing, the fluid may be directed into the angled channel 617 and out of the reservoir 601 via the reservoir outlet 621 once the fluid passes the upper threshold of the angled channel 617. In other instances, the overflow failsafe 615 may be provided in other suitable forms, or the overflow failsafe 615 may be omitted.

As best shown in FIG. 29, in some instances, one or more sensors 623 may be positioned within the reservoir 601. For example, the one or more sensors 623 may be positioned within a respective sensor housing 613. The one or more sensors 623 may include a fluid level sensor, a conductivity sensor, a temperature sensor, and/or any other suitable sensor or detection device. For example, the one or more sensors 623 may be selected from the group consisting of a fluid level sensor, a conductivity sensor, a temperature sensor, and combinations thereof. The one or more sensors 623 are configured or designed to collect data pertaining to the fluid within the reservoir 601, the operation of the distribution system 511, or other aspects of the modular heat transfer system 500. In certain instances, the one or more sensors 623 and/or the sensor housings 613 may be positioned at a distance from the replacement valve 609 (e.g., to avoid interference or confusion of the sensors 623). For example, the replacement valve 609 may be positioned proximate to the first side 526, and the sensors 623 and/or the sensor housings 613 may be positioned proximate to the second side 528 (see FIG. 26). However, in other instances, the sensors 623 may be positioned in other suitable manners. For example, in certain instances, the sensor housing 613 may be omitted and the one or more sensors 623 may be positioned directly within the reservoir 601.

Turning to FIG. 30, the distribution system 511 may include a suction hood 625 and a pump 627. Together, the suction hood 625 and the pump 627 may be configured or designed to direct fluid from the reservoir 601 to an upper portion of the modular heat transfer system 500, as described in further detail below with reference to FIGS. 31-35. For example, the suction hood 625 and the pump 627 may be configured or designed to direct fluid from the reservoir 601 into a riser 629 that extends toward an upper portion of the modular heat transfer system 500. The riser 629 may be coupled (e.g., bolted, fastened, anchored, fixed, attached, clamped, locked, and the like) to a portion of the modular heat transfer system 500 such as a portion of at least one frame member 501. Additionally, the riser 629 may be positioned at or proximate to one of the short faces or lateral ends of the modular heat transfer system 500. In some instances, the distribution system 511 may include two or more risers 629, and in such instances, each riser 629 may be associated with (e.g., in communication with) a distinct pump 627 (or each riser 629 may be associated with two or more distinct pumps 627).

As best shown in FIG. 31, the riser 629 may extend upwardly from the pump 627 and may be coupled to a lateral conduit 631 positioned proximate to an upper edge 633 of the modular heat transfer system 500. The riser 629 may be in fluid communication with the lateral conduit 631, and the lateral conduit 631 may be coupled to and/or in communication with one or more distribution members 635. The distribution members 635 may be positioned at or proximate to the upper edge 633 and may be configured or designed to wet the media pads (e.g., by distributing fluid thereto, such as the intermediate distribution system 400 of FIGS. 4A and 4B). For example, in some instances, the lateral conduit 631 may be in communication with a first distribution member 635a positioned proximate to the first side 526 of the modular heat transfer system 500 and a second distribution member 635b positioned proximate to the second side 528 of the modular heat transfer system 500. However, in other instances, the lateral conduit 631 may be in communication with a single distribution member 635 or with three or more distribution members 635 positioned in any suitable location relative to the modular heat transfer system 500. Fluid may be directed from the reservoir 601 to the first and second distribution members 635a, 635b via the pump 627, the riser 629, and/or the lateral conduit 631.

In some instances, the first and second distribution members 635a, 635b may be provided in substantially the same form. Thus, while the description below refers specifically to the second distribution member 635b as shown in FIGS. 32-35, it should be understood that the same description may be equally applicable to the first distribution member 635a.

Turning to FIG. 32, the first and second distribution members 635a, 635b may be configured or designed to wet the media pads 540 with the fluid received from the lateral conduit 631. For example, the second distribution member 635b may be positioned above the sub-units 422a-d such that fluid within the second distribution member 635b may be directed to the media pads 540 thereof by gravity.

As best shown in FIG. 33, the second distribution member 635b may be provided in the form of a distribution member base 637 and a distribution member cover 639, which may together constitute a substantially rectilinear passageway for fluid received from the lateral conduit 631. The distribution member cover 639 may be movably or hingedly coupled to the distribution member base 637 such that the distribution member cover 639 is movable between a closed position and an open position. For example, FIG. 33 depicts the distribution member cover 639 in the closed position, and FIG. 34 depicts the distribution member cover 639 in the open position.

As shown in FIG. 34, the lateral conduit 631 may extend into an interior 641 of the second distribution member 635b. For example, the lateral conduit 631 may extend along a length (or along a portion of a length) of the second distribution member 635b. The lateral conduit 631 may include a plurality of openings (not shown) configured or designed to allow fluid within the lateral conduit 631 to escape therefrom. For example, the openings of the lateral conduit 631 may be positioned on the portion of the lateral conduit 631 disposed within the second distribution member 635b such that fluid can be distributed from the lateral conduit 631 to the second distribution member 635b (and thus may be distributed to the media pads 540).

Turning to FIG. 35, in some instances, the second distribution member 635b may include a distribution surface 643 positioned within the interior 641. For example, the distribution surface 643 may be provided as a lower surface of the distribution member base 637 and may be positioned beneath the lateral conduit 631. Thus, fluid that enters the interior 641 from the lateral conduit 631 may flow through a plurality of distribution openings 645 positioned on the distribution surface 643 via the influence of gravity. In this way, the distribution surface 643 may facilitate the distribution of fluid from within the second distribution member 635b to the media pads 540.

Thus, the modular heat transfer system 500 may include a distribution system designed to distribute, circulate, recirculate, or otherwise direct fluid to the media pads 540. In some instances, the distribution system may include one or more of the projection 579b of each of the second pad modules 503b, one or more collection basins 524 positioned beneath the media pads 540, the distribution system 511 in communication with the one or more collection basins 524 (e.g., the distribution system 511 including the reservoir 601, the suction hood 625, the pump 627, the riser 629, and/or the lateral conduit 631), the redistribution member 509, and one or more distribution members 635 positioned above the media pads 540. For example, the one or more distribution members 635 may direct fluid toward the media pads 540, the collection basins 524 may collect fluid that falls or drips from the media pads 540, and the distribution system 511 may be in communication with each of the one or more distribution members 635 and the collection basins 524 such that fluid collected by the collection basins 524 may be recirculated to the one or more distribution members 635. In instances where the redistribution member 509 is provided in substantially the same form as the one or more distribution members 635, the one or more distribution members 635 may be configured or designed to convey fluid to the second pad modules 503b, fluid falling from the second pad modules 503b may be collected by the redistribution member 509, and the redistribution member 509 may distribute fluid received therein evenly (or substantially evenly) to the first pad modules 503a.

In certain instances, the distribution system 511 may further include one or more of the side cover 603, the top cover 605, the fluid level sensor 606, one or more drain valves 607, the replacement valve 609, one or more weir plates 611 (e.g., positioned within the reservoir 601), one or more sensors 623 positioned within one or more sensor housings 613, the overflow failsafe 615, and/or other components not specifically described or depicted herein.

Furthermore, the components of the distribution system 511 may be provided in the form of modular components designed to be selectively coupled to or decoupled from the remainder of the modular heat transfer system 500. Thus, the modular heat transfer system 500 may be capable of operation with or without the distribution system 511. Likewise, the one or more pad modules 503 may be provided in the form of modular components such that the modular heat transfer system 500 may be capable of operation with or without the one or more pad modules 503 (e.g., with or without media pads 540 that pre-cool ambient air entering the modular heat transfer system 500).

The distribution system 511 may be configured or designed to operate in a variety of modes, such as a once-through mode, a recirculation mode, and/or other modes. In some instances, the distribution system 511 may be configured or designed to operate in a once-through mode in which the distribution system 511 distributes a supply of fluid that is discharged (e.g., collected as waste) after the fluid completes a pass through the distribution system 511.

In other instances, the distribution system 511 may be configured or designed to operate in a recirculation mode in which a supply of fluid is continuously cycled or recirculated through the distribution system 511 (e.g., a closed-loop system in which the same fluid is used to wet the media pads 540 multiple times). In such instances, the distribution system 511 may be provided in the form of a self-contained distribution system. For example, operating the distribution system 511 in the recirculation mode may increase an efficiency of the modular heat transfer system 500 (e.g., by reducing a rate of water consumption).

Turning next to FIG. 36, a method of transferring heat within a modular heat transfer system, a method 3600, is provided. The method 3600 may be implemented by the modular heat transfer system 100 of FIG. 1A or the modular heat transfer system 500 of FIG. 5, including any variations thereof provided herein. At 3602, the method 3600 includes providing a modular heat transfer system comprising a first heat exchanger module. At 3604, the method 3600 includes arranging a first plurality of pad modules disposed on, around, or on and around the first heat exchanger module. In some cases, the first plurality of pad modules may be disposed proximate or adjacent to the first heat exchanger module. At 3606, the method 3600 includes providing a distribution system configured to distribute a cooling fluid. At 3608, the method 3600 includes distributing the cooling fluid onto the first plurality of pad modules. At 3610, the method 3600 includes drawing a stream of ambient air through the first plurality of pad modules. At 3612, the method 3600 includes generating a stream of pre-cooled air. In some cases, the pre-cooled air of 3612 may instead be provided in the form of a humidified air. In other cases, the pre-cooled air of 3612 may be provided in the form of pre-cooled and humidified air. At 3614, the method 3600 includes drawing the stream of pre-cooled air into the first heat exchanger. In some instances, the modular heat transfer system further comprises a second heat exchanger module, and wherein the first heat exchanger module and the second heat exchanger module are disposed side-by-side or such that the second heat exchanger module is disposed on top of the first heat exchanger module.

In some instances, the modular heat transfer system of the method 3600 further includes a third heat exchanger module and a fourth heat exchanger module. The third heat exchanger module may be arranged in series with the first heat exchanger module and the fourth heat exchanger module may be arranged in series with the second heat exchanger module. In some instances, the fourth heat exchanger module may be disposed on top of the third heat exchanger module. In other instances, the third heat exchanger and the fourth heat exchanger may be disposed side-by-side.

The method 3600 may further include collecting a stream of used cooling fluid from the first plurality of pad modules in a reservoir, pumping the stream of used cooling fluid from the reservoir to the distribution system, and applying the stream of used cooling fluid to the first plurality of pad modules.

The method 3600 may additionally include providing a second plurality of pad modules disposed on, around, or on and around a second heat exchanger module. For example, the second plurality of pad modules may be disposed proximate or adjacent to the second heat exchanger module.

The method 3600 may further include providing the first plurality of pad modules or the second plurality of pad modules in the form of one or more media pads, where the one or more media pads may be provided in the form of a plurality of cellulose sheets, wherein the one or more pad modules are imparted with a density of 3 to 6 cellulose sheets per inch.

The modular heat transfer system of the method 3600 may additionally include a second heat exchanger module, where the first heat exchanger module and the second heat exchanger module are disposed side-by-side or such that the second heat exchanger module is disposed on top of or above the first heat exchanger module.

In some instances, the distribution system of the method 3600 may be provided in the form of the distribution system 511 of FIGS. 26-35.

It is to be understood that the steps of method 3600 may be performed in any order, repeated, or omitted. It is also to be understood that the method 3600 may be implemented by any of the modular heat transfer systems, or any variations thereof, discussed herein.

Turning to FIG. 37, a method of transferring heat (e.g., a method 3700) is provided. The method 3700 may be implemented by the modular heat transfer system 100 of FIG. 1A or the modular heat transfer system 500 of FIG. 5, including any variations thereof provided herein. At 3702, the method 3700 may include providing a modular heat transfer system, where the modular heat transfer system includes a first heat exchanger module and a second heat exchanger module. The modular heat transfer system may be designed to be operated in an adiabatic cooling mode and a dry cooling mode. The modular heat transfer system may include a first heat exchanger module, a second heat exchanger module, at least one air movement device, and a frame. In some instances, the first heat exchanger module and the second heat exchanger module are coupled to the frame.

At 3704, the method 3700 may include drawing ambient air into the modular heat transfer system.

At 3706, the method 3700 may include cooling the first heat exchanger module and the second heat exchanger module.

At 3708, the method 3700 may include expelling exhaust air from the modular heat transfer system.

At 3710, the method 3700 may include installing a frame member including a first plurality of adiabatic pads and a cooling fluid distribution system. In some instances, the first plurality of adiabatic pads are disposed adjacent to the first heat exchanger module and the second heat exchanger module.

At 3712, the method 3700 may include wetting the first plurality of adiabatic pads.

At 3714, the method 3700 may include drawing ambient air through the first plurality of adiabatic pads and into the modular heat transfer system. In some instances, 3712 is performed before 3714, such that the first plurality of adiabatic pads are wetted before ambient air is drawn through the first plurality of adiabatic pads.

In some instances, the method 3700 may further include installing adiabatic pads around the modular heat transfer system (e.g., proximate or adjacent to one or more heat exchangers of the modular heat transfer system), drawing ambient air through the adiabatic pads, producing a pre-cooled air imparted with one or more of a lower temperature than the ambient air, or a higher humidity than the ambient air, and drawing the process stream of air into the interior of the modular heat transfer system. The adiabatic pads may be designed to provide one or more of a pre-cooled air stream, a humidified air stream, or a pre-cooled and humidified air stream to an interior of the modular heat transfer system.

In some instances, the method 3700 may further include expelling excess fluid from the first plurality of adiabatic pads and collecting the excess fluid in a basin.

In certain cases, the cooling fluid distribution system of the method 3700 may be provided in the form of the cooling fluid distribution system 232 of FIGS. 2A and 2B.

It is to be understood that the steps of method 3700 may be performed in any order, repeated, or omitted. It is also to be understood that the method 3700 may be implemented by any of the modular heat transfer systems, or any variations thereof, discussed herein.

In a first implementation, a modular heat transfer system is provided. The system includes a frame assembly including a first sub-frame and a second sub-frame, a first heat exchanger conduit bundle and a second heat exchanger conduit bundle coupled to the first sub-frame, a third heat exchanger conduit bundle and a fourth heat exchanger conduit bundle coupled to the second sub-frame, and at least one air movement device designed to draw ambient air into the modular heat transfer system and coupled to the second sub-frame above the third and fourth heat exchanger conduit bundles. Each of the first heat exchanger conduit bundle, the second heat exchanger conduit bundle, the third heat exchanger conduit bundle, and the fourth heat exchanger conduit bundle includes a process fluid inlet and a process fluid outlet.

In a second implementation, which may include the first implementation, a first process fluid inlet of the first heat exchanger conduit bundle is provided on a first side of the modular heat transfer system, a second process fluid inlet of the third heat exchanger conduit bundle is provided on the first side of the modular heat transfer system. The second fluid inlet is situated above the first fluid inlet along a common vertical axis.

In a third implementation, which may include the first or second implementation, the first heat exchanger conduit bundle further includes a first process fluid inlet and a first process fluid outlet, the second heat exchanger conduit bundle further includes a second process fluid inlet and a second process fluid outlet, the third heat exchanger conduit bundle further includes a third process fluid inlet and a third process fluid outlet, and the fourth heat exchanger conduit bundle further includes a fourth process fluid inlet and a fourth process fluid outlet. The first and third process fluid inlets are substantially aligned in a first vertical plane, and the first and third process fluid outlets are substantially aligned in a second vertical plane, the second and fourth process fluid inlets are substantially aligned in a third vertical plane, and the second and fourth process fluid outlets are substantially aligned in a fourth vertical plane.

In a fourth implementation, which may include any of the first through third implementations, the process fluid inlets and the process fluid outlets of the first and third heat exchanger conduit bundles are positioned and located on a first side of the modular heat transfer system, the process fluid inlets and the process fluid outlets of the second and fourth heat exchanger conduit bundles are positioned and located on a second side of the modular heat transfer system, and the first side is opposite the second side.

In a fifth implementation, which may include any of the first through fourth implementations, the first heat exchanger conduit bundle includes a first process fluid inlet and a first process fluid outlet positioned proximate to a first side of the modular heat transfer system, and the second heat exchanger conduit bundle includes a second process fluid inlet and a second process fluid outlet positioned proximate to a second side of the modular heat transfer system.

In a sixth implementation, a modular heat transfer system is provided. The system includes a modular frame system including a first frame and a second frame, a first heat exchanger module and a second heat exchanger module, the first heat exchanger module coupled to the first frame and the second heat exchanger module coupled to the first frame, a third heat exchanger module and a fourth heat exchanger module, the third heat exchanger module and the fourth heat exchanger module coupled to the second frame and disposed above the first heat exchanger module and the second heat exchanger module, and at least one air movement device disposed above the third heat exchanger module and the fourth heat exchanger module. The at least one air movement device is configured to draw air into the modular heat transfer system. The at least one air movement device is coupled to the modular frame system. The modular heat transfer system is designed to operate in an adiabatic mode and a dry mode.

In a seventh implementation, which may include the sixth implementation, the system further includes a first frame member including a first plurality of adiabatic pads, a basin, one or more flumes, and a cooling fluid distribution system. The first frame member is selectively couplable to the modular frame system. The first plurality of adiabatic pads and the cooling fluid distribution system are designed to operate the modular heat transfer system in the adiabatic mode.

In an eighth implementation, which may include the seventh implementation, the first frame member further includes a second plurality of adiabatic pads. The first plurality of adiabatic pads is disposed on a first side of the modular heat transfer system. The second plurality of adiabatic pads is disposed on a second side of the heat transfer system.

In a ninth implementation, which may include the seventh or eighth implementation, the cooling fluid distribution system is designed to distribute or apply a cooling fluid to the first plurality of adiabatic pads.

In a tenth implementation, which may include any of the seventh through ninth implementations, the modular heat transfer system is designed to operate in the dry mode when the frame member is not coupled to the frame system or when the cooling fluid distribution system is not operated.

In an eleventh implementation, which may include any of the seventh through tenth implementations, the at least one air movement device draws air through wetted media pads of the first plurality of adiabatic pads when the modular heat transfer system operates in the adiabatic mode.

In a twelfth implementation, which may include any of the seventh through eleventh implementations, the frame member is disposed adjacent to the first heat exchanger module, the second heat exchanger module, the third heat exchanger module, and the fourth heat exchanger module when the first frame member is coupled to the modular frame system.

In a thirteenth implementation, which may include the sixth implementation, the at least one air movement device draws air into the modular heat transfer system when the modular heat transfer system operates in the dry mode.

In a fourteenth implementation, which may include the sixth or thirteenth implementation, the system further includes a first frame member including a first plurality of adiabatic pads.

In a fifteenth implementation, which may include any of the sixth, thirteenth, or fourteenth implementations, the first plurality of adiabatic pads includes a plurality of cellulose paper sheets, where each of the first plurality of adiabatic pads may be imparted with a density of 3 to 6 cellulose sheets per 2.5 centimeters, and wherein each of the first plurality of adiabatic pads may be imparted with an air travel of 5 centimeters to 15 centimeters.

In a sixteenth implementation, a method of transferring heat is provided. The method may be implemented by any of the systems of the first to fifteenth implementations or the twenty-first to thirty-fifth implementations. The method includes providing a modular heat transfer system designed to be operated in an adiabatic cooling mode and a dry cooling mode, drawing ambient air into the modular heat transfer system, cooling the first heat exchanger module and the second heat exchanger module, and expelling exhaust air from the modular heat transfer system. The modular heat transfer system includes a first heat exchanger module, a second heat exchanger module, at least one air movement device, and a frame. The first heat exchanger module and the second heat exchanger module are coupled to the frame.

In a seventeenth implementation, which may include the sixteenth implementation, the method further includes installing a frame member including a first plurality of adiabatic pads and a cooling fluid distribution system, wetting the first plurality of adiabatic pads, and drawing ambient air through the first plurality of adiabatic pads and into the modular heat transfer system. The first plurality of adiabatic pads are disposed adjacent to the first heat exchanger module and the second heat exchanger module.

In an eighteenth implementation, which may include the seventeenth implementation, the ambient air is drawn through the first plurality of adiabatic pads after the first plurality of adiabatic pads are wetted.

In a nineteenth implementation, which may include the sixteenth or the seventeenth implementations, the method further includes installing adiabatic pads around the modular heat transfer system, drawing ambient air through the adiabatic pads, producing a pre-cooled air imparted with one or more of a lower temperature than the ambient air, or a higher humidity than the ambient air, and drawing the process stream of air into the interior of the modular heat transfer system. The adiabatic pads are designed to provide one or more of a pre-cooled air stream, a humidified air stream, or a pre-cooled and humidified air stream to an interior of the modular heat transfer system.

In a twentieth implementation, which may include the sixteenth to nineteenth implementations, the method further includes expelling excess fluid from the first plurality of adiabatic pads and collecting the excess fluid in a basin.

In a twenty-first implementation, a modular heat transfer system is provided. The system includes a frame supporting a cooler that is designed to cool a process fluid, the frame including a mating cleat, a pad module designed to support a media pad, the pad module including a module cleat, and a distribution system designed to direct a cooling fluid toward the media pad when the media pad is coupled to the modular heat transfer system. The pad module is selectively couplable to the frame via engagement of the module cleat and the mating cleat.

In a twenty-second implementation, which may include the twenty-first implementation, the distribution system includes a recirculation system designed to recirculate fluid collected from the media pad after the distribution system directs the cooling fluid onto the media pad.

In a twenty-third implementation, which may include the twenty-first or twenty-second implementations, the distribution system is designed to operate in a once-through mode and a redistribution mode. The once-through mode includes passing the cooling fluid through the distribution system a single time and the redistribution mode includes cycling the cooling fluid through the distribution system more than once.

In a twenty-fourth implementation, which may include any of the twenty-first through twenty-third implementations, the distribution system is selectively couplable to the frame such that the distribution system can be removed from the modular heat transfer system.

In a twenty-fifth implementation, which may include the twenty-fourth implementation, the distribution system includes one or more collection basins and one or more distribution members. The one or more collection basins are disposed beneath the pad module and designed to collect the cooling fluid. The one or more distribution members are in fluid communication with the one or more collection basins and the distribution system and are designed to direct the cooling fluid collected in the one or more collection basins to the media pad. Each collection basin of the one or more collection basins and each distribution member of the one or more distribution members are selectively couplable to the frame.

In a twenty-sixth implementation, a modular heat transfer system is provided. The system includes a frame including at least one frame cleat, a first cooler and a second cooler coupled to the frame, a first plurality of pad modules associated with the first cooler including a first module cleat, and a second plurality of pad modules associated with the second cooler including a second module cleat. Each pad module of the first plurality of pad modules is coupled to the frame via engagement between the first module cleat and the at least one frame cleat. Each pad module of the second plurality of pad modules is coupled to the frame via engagement between the second module cleat and the at least one frame cleat.

In a twenty-seventh implementation, which may include the twenty-sixth implementation, the system further includes a distribution system designed to distribute a cooling fluid. The distribution system discharges the cooling fluid after the cooling fluid passes through the system a single time when the distribution system operates in a once-through mode.

In a twenty-eighth implementation, which may include the twenty-seventh implementation, the distribution system includes a distribution pipe imparted with one or more perforations, and the one or more perforations are designed to direct the cooling fluid to the first plurality of pad modules and the second plurality of pad modules.

In a twenty-ninth implementation, which may include the twenty-sixth or twenty-seventh implementations, the first plurality of pad modules and the second plurality of pad modules are each positioned above one or more collection basins, the one or more collection basins are positioned above a reservoir, and the one or more collection basins are designed to convey fluid collected therein to the reservoir.

In a thirtieth implementation, which may include the twenty-sixth, twenty-seventh, or twenty-ninth implementation, the first cooler and the second cooler are designed to cool a process fluid.

In a thirty-first implementation, which may include any of the twenty-sixth, twenty-seventh, twenty-ninth, or thirtieth implementations, the system further includes a pump affixed to the frame, a riser in fluid communication with the pump, one or more fluid collection bins, and a reservoir in fluid communication with the one or more fluid collection bins and the pump. The pump is designed to move fluid between the reservoir, the riser, and the one or more fluid collection bins.

In a thirty-second implementation, which may include the thirty-first implementation, one or more fluid collection bins and the reservoir are designed to retain at least a portion of a cooling fluid provided by a distribution system, and the pump is designed to move the cooling fluid from the one or more fluid collection bins and the reservoir to the riser.

In a thirty-third implementation, which may include any of the twenty-sixth, twenty-seventh, or twenty-ninth through thirty-first implementations, heat exchanger conduit bundles of the first cooler and the second cooler are configured to be arranged in series or in parallel.

In a thirty-fourth implementation, which may include the thirty-third implementation, the one or more air movement devices draw ambient air through, around, or through and around each of the first plurality of pad modules and the second plurality of pad modules.

In a thirty-fifth implementation, which may include any of the twenty-sixth, twenty-seventh, twenty-ninth through thirty-first, or thirty-third implementations, the first plurality of pad modules and the second plurality of pad modules comprise one or more media pads. The one or more media pads comprise a plurality of cellulose sheets,

In a thirty-sixth implementation, a method of transferring heat in a heat transfer system is provided. The method may be implemented by any of the systems of the first to fifteenth implementations or the twenty-first to thirty-fifth implementations. The method includes providing a modular heat transfer system including a first heat exchanger module, coupling a first plurality of pad modules to the first heat exchanger module, providing a distribution system designed to distribute a cooling fluid, distributing the cooling fluid onto the first plurality of pad modules, drawing a stream of ambient air through the first plurality of pad modules, generating a stream of pre-cooled air, and drawing the stream of pre-cooled air into the first heat exchanger module.

In a thirty-seventh implementation, which may include the thirty-sixth implementation, the method further includes collecting a stream of used cooling fluid from the first plurality of pad modules in a reservoir, pumping the stream of used cooling fluid from the reservoir to the distribution system, and applying the stream of used cooling fluid to the first plurality of pad modules.

In a thirty-eighth implementation, which may include the thirty-sixth or thirty-seventh implementations, the method further includes providing a second plurality of pad modules disposed on, around, or on and around a second heat exchanger module.

In a thirty-ninth implementation, which may include any of the thirty-sixth through thirty-eighth implementations, the first plurality of pad modules includes one or more media pads and the one or more media pads comprise a plurality of cellulose sheets. The one or more media pads are imparted with a density of about 3 to about 6 cellulose sheets per 2.5 centimeters.

In a fortieth implementation, which may include any of the thirty-sixth through thirty-ninth implementations, the method further includes providing a second heat exchanger module and arranging the second heat exchanger module such that the first heat exchanger module and the second heat exchanger module are disposed side-by-side or the second heat exchanger module is disposed on top of the first heat exchanger module.

It will be appreciated by those skilled in the art that while the above description is provided in connection with particular instances and examples, the present disclosure is not necessarily so limited, and that numerous other instances, examples, uses, modifications, and departures from the instances, examples, and uses are intended to be encompassed by the claims attached hereto. The entire disclosure of each patent and publication cited herein is incorporated by reference as if each such patent or publication were individually incorporated by reference herein. Various features and advantages of the above disclosure are set forth in the following claims.

Claims

1. A modular heat transfer system, comprising:

a frame supporting a cooler that is designed to cool a process fluid, wherein the frame includes a mating cleat;

a pad module designed to support a media pad, wherein the pad module includes a module cleat; and

a distribution system designed to direct a cooling fluid toward the media pad when the media pad is coupled to the modular heat transfer system,

wherein the pad module is selectively couplable to the frame via engagement of the module cleat and the mating cleat.

2. The modular heat transfer system of claim 1, wherein the distribution system includes a recirculation system designed to recirculate fluid collected from the media pad after the distribution system directs the cooling fluid onto the media pad.

3. The modular heat transfer system of claim 1, wherein the distribution system is designed to operate in a once-through mode and a redistribution mode, wherein the once-through mode comprises passing the cooling fluid through the distribution system a single time and the redistribution mode comprises cycling the cooling fluid through the distribution system more than once.

4. The modular heat transfer system of claim 1, wherein the distribution system is selectively couplable to the frame such that the distribution system can be removed from the modular heat transfer system.

5. The modular heat transfer system of claim 4, wherein:

the distribution system comprises one or more collection basins and one or more distribution members,

the one or more collection basins are disposed beneath the pad module and designed to collect the cooling fluid,

the one or more distribution members are in fluid communication with the one or more collection basins and the distribution system and are designed to direct the cooling fluid collected in the one or more collection basins to the media pad,

each collection basin of the one or more collection basins and each distribution member of the one or more distribution members are selectively couplable to the frame.

6. A modular heat transfer system, comprising:

a frame including at least one frame cleat;

a first cooler and a second cooler coupled to the frame;

a first plurality of pad modules associated with the first cooler, wherein each pad module of the first plurality of pad modules includes a first module cleat; and

a second plurality of pad modules associated with the second cooler, wherein each pad module of the second plurality of pad modules includes a second module cleat,

wherein each pad module of the first plurality of pad modules is coupled to the frame via engagement between the first module cleat and the at least one frame cleat,

wherein each pad module of the second plurality of pad modules is coupled to the frame via engagement between the second module cleat and the at least one frame cleat.

7. The modular heat transfer system of claim 6 further comprising a distribution system designed to distribute a cooling fluid, wherein the distribution system discharges the cooling fluid after the cooling fluid passes through the system a single time when the distribution system operates in a once-through mode.

8. The modular heat transfer system of claim 7, wherein the distribution system includes a distribution pipe imparted with one or more perforations, where the one or more perforations are designed to direct the cooling fluid to the first plurality of pad modules and the second plurality of pad modules.

9. The modular heat transfer system of claim 6, wherein the first plurality of pad modules and the second plurality of pad modules are each positioned above one or more collection basins, wherein the one or more collection basins are positioned above a reservoir, and wherein the one or more collection basins are designed to convey fluid collected therein to the reservoir.

10. The modular heat transfer system of claim 6, wherein the first cooler and the second cooler are designed to cool a process fluid.

11. The modular heat transfer system of claim 6 further comprising:

a pump affixed to the frame;

a riser in fluid communication with the pump;

one or more fluid collection bins; and

a reservoir in fluid communication with the one or more fluid collection bins and the pump,

wherein the pump is designed to move fluid between the reservoir, the riser, and the one or more fluid collection bins.

12. The modular heat transfer system of claim 11, wherein the one or more fluid collection bins and the reservoir are designed to retain at least a portion of a cooling fluid provided by a distribution system and wherein the pump is designed to move the cooling fluid from the one or more fluid collection bins and the reservoir to the riser.

13. The modular heat transfer system of any of claims 6, wherein heat exchanger conduit bundles of the first cooler and the second cooler are configured to be arranged in series or in parallel.

14. The modular heat transfer system of claim 13, wherein the one or more air movement devices draw ambient air through, around, or through and around each of the first plurality of pad modules and the second plurality of pad modules.

15. The modular heat transfer system of claim 6, wherein the first plurality of pad modules and the second plurality of pad modules comprise one or more media pads, wherein the one or more media pads comprise a plurality of cellulose sheets.

16. A method of transferring heat in a heat transfer system, the method comprising:

providing a modular heat transfer system including a first heat exchanger module;

coupling a first plurality of pad modules to the first heat exchanger module;

providing a distribution system designed to distribute a cooling fluid;

distributing the cooling fluid onto the first plurality of pad modules;

drawing a stream of ambient air through the first plurality of pad modules;

generating a stream of pre-cooled air; and

drawing the stream of pre-cooled air into the first heat exchanger module.

17. The method of claim 16, the method further comprising:

collecting a stream of used cooling fluid from the first plurality of pad modules in a reservoir;

pumping the stream of used cooling fluid from the reservoir to the distribution system; and

applying the stream of used cooling fluid to the first plurality of pad modules.

18. The method of claim 16, the method further comprising providing a second plurality of pad modules disposed on, around, or on and around a second heat exchanger module.

19. The method of claim 16, wherein the first plurality of pad modules includes one or more media pads, wherein the one or more media pads comprise a plurality of cellulose sheets, wherein the one or more media pads are imparted with a density of about 3 to about 6 cellulose sheets per 2.5 centimeters.

20. The method of claim 16 further comprising:

providing a second heat exchanger module; and

arranging the second heat exchanger module such that: the first heat exchanger module and the second heat exchanger module are disposed side-by-side, or the second heat exchanger module is disposed on top of the first heat exchanger module.