Recovering Water From Cooling Tower Plumes With Plume Abatement

May 22, 2025 by Maya Posch 24 Comments

Electrostatic droplet capture system installed on an HVAC condenser. (Credit: Infinite Cooling)

As a common feature with thermal power plants, cooling towers enable major water savings compared to straight through cooling methods. Even so, the big clouds of water vapor above them are a clear indication of how much cooling water is still effectively lost, with water vapor also having a negative impact on the environment. Using so-called plume abatement the amount of water vapor making it into the environment can be reduced, with recently a trial taking place at a French nuclear power plant.

This trial featured electrostatic droplet capture by US-based Infinite Cooling, which markets it as able to be retrofitted to existing cooling towers and similar systems, including the condensers of office HVAC systems. The basic principle as the name suggests involves capturing the droplets that form as the heated, saturated air leaves the cooling tower, in this case with an electrostatic charge. The captured droplets are then led to a reservoir from which it can be reused in the cooling system. This reduces both the visible plume and the amount of cooling water used.

In a 2021 review article by [Shuo Li] and [M.R. Flynn] in Environmental Fluid Mechanics the different approaches to plume abatement are looked at. Traditional plume abatement designs use parallel streams of air, with the goal being to have condensation commence as early as possible rather than after having been exhausted into the surrounding air. Some methods used a mesh cover to provide a surface to condense on, while a commercially available technology are condensing modules which use counterflow in an air-to-air heat exchanger.

Other commercial solutions include low-profile, forced-draft hybrid cooling towers, yet it seems that electrostatic droplet capture is a rather new addition here. With even purely passive systems already seeing ~10% recapturing of lost cooling water, these active methods may just be the ticket to significantly reduce cooling water needs without being forced to look at (expensive) dry cooling methods.

Top image: The French Chinon nuclear power plant with its low-profile, forced-draft cooling towers. (Credit: EDF/Marc Mourceau)

An exploded view of an electrostatic motor from manufacturer C-Motive. There is a silvery cylinder on the left, two half silver and half golden disks on either side and two thinner gold disks in the center. A square mountin plate is on the right hand side next to one of the silver/gold disks.

Electrostatic Motors Are Making A Comeback

October 29, 2024 by Navarre Bartz 21 Comments

Electrostatic motors are now common in MEMS applications, but researchers at the University of Wisconsin and spinoff C-Motive Technologies have brought macroscale electrostatic motors back. [via MSN/WSJ]

While the first real application of an electric motor was Ben Franklin’s electrostatically-driven turkey rotisserie, electromagnetic type motors largely supplanted the technology due to the types of materials available to engineers of the time. Newer dielectric fluids and power electronics now allow electrostatic motors to be better at some applications than their electromagnetic peers.

The main advantage of electrostatic motors is their reduced critical materials use. In particular, electrostatic motors don’t require copper windings or any rare earth magnets which are getting more expensive as demand grows for electrically-powered machines. C-Motive is initially targeting direct drive industrial applications, and the “voltage driven nature of an electrostatic machine” means they require less cooling than an electromagnetic motor. They also don’t use much if any power when stalled.

Would you like a refresher on how to make static electricity or a deeper dive on how these motors work?

Static Electricity And The Machines That Make It

September 30, 2024 by Lewin Day 20 Comments

Static electricity often just seems like an everyday annoyance when a wool sweater crackles as you pull it off, or when a doorknob delivers an unexpected zap. Regardless, the phenomenon is much more fascinating and complex than these simple examples suggest. In fact, static electricity is direct observable evidence of the actions of subatomic particles and the charges they carry.

While zaps from a fuzzy carpet or playground slide are funny, humanity has learned how to harness this naturally occurring force in far more deliberate and intriguing ways. In this article, we’ll dive into some of the most iconic machines that generate static electricity and explore how they work.

Continue reading “Static Electricity And The Machines That Make It” →

Reprogrammable Transistors

March 26, 2024 by Bryan Cockfield 21 Comments

Not every computer can make use of a disk drive when it needs to store persistent data. Embedded systems especially have pushed the development of a series of erasable programmable read-only memories (EPROMs) because of their need for speed and reliability. But erasing memory and writing it over again, whether it’s an EPROM, an EEPROM, an FPGA, or some other type of configurable solid-state memory is just scratching the surface of what it might be possible to get integrated circuits and their transistors to do. This team has created a transistor that itself is programmable.

Rather than doping the semiconductor material with impurities to create the electrical characteristics needed for the transistor, the team from TU Wien in Vienna has developed a way to “electrostatically dope” the semiconductor, using electric fields instead of physical impurities to achieve the performance needed in the material. A second gate, called the program gate, can be used to reconfigure the electric fields within the transistor, changing its properties on the fly. This still requires some electrical control, though, so the team doesn’t expect their new invention to outright replace all transistors in the future, and they also note that it’s unlikely that these could be made as small as existing transistors due to the extra complexity.

While the article from IEEE lists some potential applications for this technology in the broad sense, we’d like to see what these transistors are actually capable of doing on a more specific level. It seems like these types of circuits could improve efficiency, as fewer transistors might be needed for a wider variety of tasks, and that there are certainly some enhanced security features these could provide as well. For a refresher on the operation of an everyday transistor, though, take a look at this guide to the field-effect transistor.

Giving Solar Power’s Mortal Enemies A Dusting Without Wasting Water

August 16, 2023 by Maya Posch 28 Comments

A prerequisite for photovoltaic (PV) and concentrated solar power (CSP) technologies to work efficiently is as direct an exposure to the electromagnetic radiation from the sun as possible. Since dust and similar particulates are excellent at blocking the parts of the EM spectrum that determine their efficiency, keeping the panels and mirrors free from the build-up of dust, lichen, bird droppings and other perks of planetary life is a daily task for solar farm operators. Generally cleaning the panels and mirrors involves having trucks drive around with a large water tank to pressure wash the dirt off, but the use of so much water is problematic in many regions.

Keeping PV panels clean is also a consideration on other planets than Earth. So far multiple Mars rovers and landers have found their demise at the hands of Martian dust after a layer covered their PV panels, and Moon dust (lunar regolith) is little better. Despite repeated suggestions by the peanut gallery to install wipers, blowers or similar dust removal techniques, keeping particulates from sticking to a surface is not as easy an engineering challenge as it may seem, even before considering details such as the scaling issues between a singular robot on Mars versus millions of panels and mirrors on Earth.

There has been research into the use of the electrostatic effect to repel dust, but is there a method that can keep both solar-powered robots on Mars and solar farms on Earth clean and sparkling, rather than soiled and dark?

Continue reading “Giving Solar Power’s Mortal Enemies A Dusting Without Wasting Water” →

ElectriPop Turns Cut Mylar Into Custom 3D Structures

May 6, 2022 by Tom Nardi 14 Comments

Mylar has a lot of useful properties, and as such as see it pop up pretty often, not just in DIY projects but in our day-to-day lives. But until today, we’ve never seen a piece of Mylar jump up and try to get our attention. But that’s precisely the promise offered by ElectriPop, a fascinating project from Carnegie Mellon University’s Future Interfaces Group.

The core principle at work here is fairly simple. When electrostatically charged, a strip of Mylar can be made to lift up vertically into the air. Cut that strip down the center, and the two sides will repel each other and produce a “Y” shape. By expanding on that concept with enough carefully placed cuts, it’s possible to create surprisingly complex three dimensional shapes that pop up once a charge is applied. A certain degree of motion can even be introduced by adjusting the input power. The video after the break offers several examples of this principle in action: such as a 3D flower that either stands up tall or wilts in relation to an external source of data, or an avatar that flails its arms wildly to get the user’s attention.

Continue reading “ElectriPop Turns Cut Mylar Into Custom 3D Structures” →

Simple Tip Helps With Powder Coating Perfection On Difficult Parts

July 24, 2021 by Dan Maloney 8 Comments

To say that that the commercially available garden path lights commonly available at dollar stores are cheap is a vast overstatement of their true worthlessness. These solar-powered lights are so cheaply built that there’s almost no point in buying them, a fact that led [Mark Presling] down a fabrication rabbit hole that ends with some great tips on powder coating parts with difficult geometries.

Powder coating might seem a bit overkill for something as mundane as garden lights, but [Mark] has a point — if you buy something and it fails after a few weeks in the sun, you might as well build it right yourself. And a proper finish is a big part of not only getting the right look, but to making these totally un-Tardis-like light fixtures last in the weather. The video series below covers the entire design and build process, which ended up having an aluminum grille with some deep grooves. Such features prove hard to reach with powder coating, where the tiny particles of the coating are attracted to the workpiece thanks to a high potential difference between them. After coating, the part is heated to melt the particles and form a tough, beautiful finish.

But for grooves and other high-aspect-ratio features, the particles tend to avoid collecting in the nooks and crannies, leading to an uneven finish. [Mark]’s solution was to turn to “hot flocking”, where the part is heated before applying uncharged coating to the deep features. This gets the corners and grooves well coated before the rest of the coating is applied in the standard way, leading to a much better finish.

We love [Presser]’s attention to detail on this build, as well as the excellent fabrication tips and tricks sprinkled throughout the series. You might want to check out some of his other builds, like this professional-looking spot welder.

Continue reading “Simple Tip Helps With Powder Coating Perfection On Difficult Parts” →