When designing an ozone generator's cooling system, the primary consideration is selecting an appropriate cooling method based on the device's power and application scenario, balancing heat dissipation efficiency with system complexity. Small, low-power ozone generators (such as those used in homes or laboratories) often use air cooling due to their simple structure and easy maintenance. This design requires densely packed aluminum heat sinks around the discharge unit (the core ozone generator) to maximize heat dissipation surface area. High-speed, silent fans are also used to force heat out through directional air ducts. The fan layout must avoid the high-frequency electric field of the discharge unit to prevent electromagnetic interference from affecting fan operation. The air ducts must be designed as a closed-loop "intake-heat absorption-exhaust" path to prevent hot air from backflowing inside the device and ensure continuous flow of cool air through the heat sink, keeping the discharge unit temperature within the optimal range for stable ozone production. Medium- to large-scale, high-power ozone generators (such as those used in industrial wastewater treatment) generate significant heat and therefore require water cooling. This involves circulating coolant directly in contact with the heat-generating components, efficiently removing heat. The coolant circulation loop design must ensure adequate heat exchange with the discharge unit without compromising electrical safety.
The coupling design between the cooling system and the discharge unit is crucial for temperature control. The cooling medium must be directly applied to the core heat-generating area. The ozone generator's discharge unit (e.g., electrodes and dielectric) generates a significant amount of heat during high-voltage discharge. If this heat cannot be removed promptly, the electrode temperature rises, accelerating oxidation and loss. The dielectric may also age and fail due to high-temperature aging. High temperatures also accelerate ozone decomposition (the decomposition rate of ozone accelerates significantly above 30°C). In a water-cooling system, the discharge electrode is designed to be hollow, allowing coolant (such as deionized water) to flow directly within the electrode, rapidly dissipating heat through heat conduction through the metal walls. A cooling jacket surrounds the dielectric, which is filled with coolant, creating a dual "electrode-dielectric" cooling system, ensuring the overall temperature of the discharge area remains stable within the optimal ozone generation range of 20-30°C. In an air-cooling system, the heat sink must be tightly fitted to the metal casing of the discharge unit. Thermal grease should be applied to the mating surfaces, filling any small gaps to reduce thermal resistance, prevent local overheating due to poor contact, and ensure rapid heat transfer from the discharge unit to the heat sink.
The integration of temperature monitoring and dynamic adjustment mechanisms prevents the cooling system from overcooling or overheating, ensuring stable ozone production and equipment life. Temperature sensors (such as platinum resistance sensors) should be installed near the discharge unit and at the cooling medium inlet and outlet to collect real-time temperature data and transmit it to the control system. When the discharge unit temperature exceeds a set threshold (e.g., 35°C), the control system automatically increases cooling intensity—in air-cooled systems, this can be done by increasing fan speed; in water-cooled systems, this can be done by increasing circulation pump power and coolant flow. If the temperature falls below 15°C (which can cause condensation on the dielectric surface, affecting discharge efficiency), the cooling intensity is appropriately reduced, such as by lowering fan speed or reducing water flow. This dynamic adjustment not only maintains ozone production efficiency but also avoids energy waste and component wear caused by long-term full-load operation of the cooling system, extending the service life of vulnerable components such as the water pump and fan.
Coolant selection and circulation optimization are essential for the long-term stable operation of a water-cooled system. To prevent the coolant from conducting electricity and impacting discharge safety, a medium with good insulation and high thermal conductivity should be selected, such as deionized water (the resistivity should be regularly tested to prevent impurities from contaminating the circuit) or a dedicated insulating coolant. Furthermore, the coolant must be corrosion-resistant and anti-scaling to prevent scale from forming on the pipe walls or corroding metal components after long-term circulation. A small amount of corrosion inhibitor can be added to the coolant, and filters should be installed in the circulation loop to remove impurities and scale particles. The circuit design should avoid dead zones (areas that water cannot reach) to prevent localized water temperature increases. The coolant inlet and outlet should be located at each end of the discharge unit, creating a unidirectional "low-temperature in, high-temperature out" flow pattern. This ensures that every hotspot is effectively cooled and avoids uneven heat dissipation caused by water short-circuiting.
The air duct and heat dissipation structure of the air cooling system should be optimized, balancing heat dissipation efficiency and overall equipment sealing. Industrial ozone generators often operate in dusty or humid environments. Improper air duct design allows dust to enter the equipment and adhere to the heat sink or discharge unit, compromising heat dissipation and discharge efficiency. Humid air can also cause short circuits in electrical components. Therefore, air-cooling systems require dust and water-resistant filters at the air inlet, which should be easily removable and cleanable. The duct walls should also be smooth to reduce dust accumulation. Heat sinks should be made of corrosion-resistant materials (such as anodized aluminum alloy) to prevent rust in humid environments. Furthermore, the air duct must be strictly isolated from the electrical compartment within the equipment, with sealing strips or partitions blocking airflow. This prevents moisture and dust introduced during the heat dissipation process from affecting electrical components, ensuring overall safe operation.
Redundant cooling system design and fault warning functions can reduce the risk of equipment damage caused by cooling failure. Medium and large ozone generators are highly dependent on the cooling system. A sudden cooling system failure (such as a pump failure or fan failure) can rapidly increase the discharge unit temperature, potentially burning the electrodes or rupturing the dielectric. A "dual backup" solution can be adopted during design: the water cooling system is equipped with two parallel circulation pumps, and the air cooling system is equipped with two independent fans. During normal operation, one unit operates and the other is in standby mode. If a fault in the active component is detected, the control system can switch to the standby unit within milliseconds to ensure uninterrupted cooling. Furthermore, the system must include a fault warning function. By monitoring parameters such as coolant flow, fan speed, and water pump current, it can proactively identify potential faults (such as reduced flow due to filter clogs or abnormal fan speed due to fan bearing wear). This function can promptly issue an alarm signal to alert personnel to perform maintenance and prevent the fault from escalating.
Coordinating the cooling system with the overall operating parameters of the ozone generator is crucial for achieving efficient temperature control and energy conservation. The heat generated by the ozone generator varies with parameters such as discharge power and air source humidity. For example, higher discharge power increases heat generation, while higher air source humidity causes water evaporation during the discharge process to dissipate some heat. The cooling system must be regulated in conjunction with these parameters. For example, when the equipment increases ozone production and discharge power, the control system will increase the cooling intensity. When the air source humidity is high, the cooling intensity can be appropriately reduced to prevent excessive cooling and condensation on the dielectric surface. This coordinated matching can not only ensure that the temperature is always within the optimal range, but also avoid "ineffective operation" of the cooling system, reduce overall energy consumption, and at the same time reduce the start and stop frequency of cooling components, extend the service life of the equipment, and achieve the design goals of "precise temperature control, stable operation, and reasonable energy consumption."
