ACS Engineering AuPub Date : 2025-06-18DOI: 10.1021/acsengineeringau.4c00052
Lilly Zacherl, and , Thomas Baumann*,
{"title":"Digital Twin of an Open Cooling Tower: Experimental Studies and Numerical Validation","authors":"Lilly Zacherl, and , Thomas Baumann*, ","doi":"10.1021/acsengineeringau.4c00052","DOIUrl":"https://doi.org/10.1021/acsengineeringau.4c00052","url":null,"abstract":"<p >Increasing dynamics in surface water bodies and all-time low groundwater levels, both a consequence of global warming, put high stress on the water supply chain and require a re-evaluation of all water uses. Industry uses a significant amount of water for cooling, often in open cooling towers. We developed a digital twin for an evaporative open cooling tower, focusing on the hydrochemistry to optimize water consumption and use of inhibitor chemicals to prevent scaling. The model is based on the USGS hydrochemical standard model PhreeqC, which is controlled by Python scripts. The digital twin implements evaporation in the cooling tower, recharge of water with added inhibitors, and desalination to avoid corrosion. In contrast to previous operation strategies, which rely on a thickening ratio that can be measured using the electrical conductivity, the model allows prediction of the behavior of the cooling tower based on the saturation index for the mineral precipitates. Additionally, the digital twin offers the option of controlling the cooling tower. We present a workflow to adapt the digital twin to the actual cooling tower and to parametrize the chemicals used for the prevention of mineral scaling. The optimization objectives were to reduce the consumption of inhibitors while maintaining stable hydrochemical conditions and a benign corrosion behavior. Additionally, the digital twin should reveal possibilities for demand-driven load balancing. After site-specific adaptation of flow and evaporation rates, volumes, temperatures, and equilibrium constants for the inhibitors, the model was able to forecast the hydrochemical conditions in the cooling tower. The parameter and sensitivity analyses revealed that the total volume of water in the system and the thickening ratio have a large effect on water consumption. While slightly increased concentrations of the inhibitor would allow for significantly higher thickening ratios and slightly lower water consumption, the corrosion stability of the materials in the cooling system puts limits on this approach. Evaporation remains the main factor in water consumption. For the reference site, the digital twin revealed that the implemented operation scheme was already close to optimal conditions, considering water consumption and the use of inhibitors.</p>","PeriodicalId":29804,"journal":{"name":"ACS Engineering Au","volume":"5 4","pages":"347–358"},"PeriodicalIF":5.1,"publicationDate":"2025-06-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://pubs.acs.org/doi/pdf/10.1021/acsengineeringau.4c00052","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144863056","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Balachandran Subramanian*, K. Jeeva Jothi, Mohamedazeem M. Mohideen, R. Karthikeyan, A. Santhana Krishna Kumar*, Ganeshraja Ayyakannu Sundaram, K. Thirumalai, Munirah D. Albaqami, Saikh Mohammad and M. Swaminathan*,
{"title":"","authors":"Balachandran Subramanian*, K. Jeeva Jothi, Mohamedazeem M. Mohideen, R. Karthikeyan, A. Santhana Krishna Kumar*, Ganeshraja Ayyakannu Sundaram, K. Thirumalai, Munirah D. Albaqami, Saikh Mohammad and M. Swaminathan*, ","doi":"","DOIUrl":"","url":null,"abstract":"","PeriodicalId":29804,"journal":{"name":"ACS Engineering Au","volume":"5 3","pages":"XXX-XXX XXX-XXX"},"PeriodicalIF":4.3,"publicationDate":"2025-06-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://pubs.acs.org/doi/pdf/10.1021/acsengineeringau.5c00015","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144429466","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
ACS Engineering AuPub Date : 2025-06-13DOI: 10.1021/acsengineeringau.4c00060
Philip Widmaier, Leon P. M. Brendel, Stefan S. Bertsch, André Bardow and Dennis Roskosch*,
{"title":"One Mixture to Rule Them All: Enhancing Efficiency and Standardization of Industrial High-Temperature Heat Pumps","authors":"Philip Widmaier, Leon P. M. Brendel, Stefan S. Bertsch, André Bardow and Dennis Roskosch*, ","doi":"10.1021/acsengineeringau.4c00060","DOIUrl":"https://doi.org/10.1021/acsengineeringau.4c00060","url":null,"abstract":"<p >High-temperature heat pumps are preferred for decarbonizing many industrial processes, but are still being adopted slowly. Major barriers to adoption are low efficiency, leading to high operational cost, and the need for custom-made designs, increasing investment cost. In this work, refrigerant mixtures are exploited to overcome these barriers for high-temperature heat pump adoption. Mixtures have been known to improve heat pump efficiency if their nonisothermal phase change is matched to heat source and sink temperature changes. Beyond that, we improve standardization by using mixture composition as an additional degree of freedom to tailor a standard heat pump designed for a specific refrigerant pair to various applications. By model-band screening of 703 refrigerant pairs across 81 combinations of heat source and sink temperature changes, we identify a maximum COP advantage of 26% for a refrigerant mixture when the maximum heat source and sink temperature changes of 40 K occur. Several mixtures are identified yielding near-optimal efficiencies across all 81 heat source and sink temperature changes. The best all-rounder mixture, diethyl ether/cyclopropane, retains, on average, 97% efficiency of the individually optimal mixtures. These findings support the development of more efficient and less costly high-temperature heat pumps, a crucial step in the heat transition.</p>","PeriodicalId":29804,"journal":{"name":"ACS Engineering Au","volume":"5 4","pages":"359–369"},"PeriodicalIF":5.1,"publicationDate":"2025-06-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://pubs.acs.org/doi/pdf/10.1021/acsengineeringau.4c00060","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144863114","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}