Special Report

Benefits of evaporative cooling systems in HAVC

thermal power

The demand of energy efficiency and water conservation is increasing every other day. The reason may be the need to transform the energy guzzling HVAC units into more affordable and energy efficient cooling systems.
R Balu, Head – Technology and Engineering Department, Thermax Cooling Solutions Ltd.
Power and water conservation importance is increasing day by day, the HVAC are majorly using open loop cooling tower and the implications are condenser tube chocking and water wastage. If HVAC system opt for Closed Loop Cooling Tower (CLCT) /A diabatic Cooling Tower (ADCT), which will help in Power and water conservation, also KW/TR spent will come down.

Closed loop cooling tower business
To overcome the various challenges over conventional open cycle cooling tower, process industries are shifting towards closed loop cooling tower solutions. CLCT is a ‘concept selling’ product and is getting acceptance in process industries like Polyfilms, Automobile, Glass, Steel, Chemicals and Pharma. Adoption rate by these process industries will decide the proliferation of the product. The product has great potential as it helps reducing energy consumption and overcomes contamination and environmental issues.

Evaporative condenser business EVC is established product in Refrigeration and HVAC industry now. There has been significant adoption of the product over conventional system of plate type and Shell and tube heat exchanger combined with open cycle cooling tower. We believe industry will shift to EVC for easy to maintain solution and there will be good momentum for new and retrofit units.

Following the technological trends in HVAC
Thermax implemented the use of EC fans & IE3 pumps and closed loop heat rejection systems, which is beneficial in energy savings. EC fans are amidst the energy efficient fans consuming possible least amount of energy compared to the other fans. These modern energy saving fans are powered by external motor with integrated control electronic sensors. These fans has turned out to be an essential part in refrigeration and air-conditioning industry.

EVC & CLCT in a refrigeration unit
Prominent benefits of Thermax EVC & CLCT are Power saving, ease of maintenance, long life. Below mentioned are the benefits of the evaporative condensers and closed loop cooling towers.

Benefits of using EVC in refrigeration cycle

  • Lower Condensing Temperature
  • Closed loop refrigerant circuit
  • Smaller foot print

Benefits of using CLCT in refrigeration cycle

  • Closed loop circuit
  • No contamination in closed loop fluid
  • Lower operating cost
  • Smaller foot print

Domestic market for EVC & CLCT
Estimated market for EVC in industrial refrigeration is growing potentially by 5-10 percent every year, approximately 500-550 machines are getting installed every year. There is a huge potential for CTCT in process industry, we need to spread more awareness and knowledge amongst industry and users.

Threats faced by the process cooling industry
Availability of water is one of the top prominent challenges in process cooling industry. There is a restraint and a bit of resistance in the industry when it comes to changing from traditional open loop systems to closed loop systems.

  • EVC business threats – Water quality , Consultant acceptance for newer technology, Fragmented local competition, low quality low price product imports from china, Low entry barriers
  • CLCT business threats- Awareness about the product offering, higher Capex requirements

Closed Loop Cooling Tower (fluid cooler) working principle

  • The process fluid is circulated through the coil of the fluid cooler.
  • Heat from the process fluid is dissipated through the coil tubes.
  • Partial heat is removed directly by the downward natural induced air and discharged to the atmosphere.
  • The rest of the heat is removed by the spray water cascading downward over the tubes and wet deck surface.
  • Simultaneously, air is drawn in through the air inlet louvers at the base of the fluid cooler and travels through the heat exchange fills at a direction perpendicular to the direction of the spray water flow.
  • A small portion of the water is evaporated which removes the heat and cools the spray water. The warm moist air is drawn sidewise by the fan and is discharged to the atmosphere.
  • The remaining cooled water falls to the sump at the bottom of the fluid cooler then it is re-circulated by the pump through the water distribution system and falls down over the coils and fills.

Evaporative condenser working principle

  • The refrigerant is circulated through the coil of the evaporative condenser.
  • Heat from the refrigerant is dissipated through the coil tubes.
  • Partial heat is removed directly by the downward natural induced air and discharged to the atmosphere.
  • The rest of the heat is removed by the spray water cascading downward over the tubes.
  • Simultaneously, air is drawn through the air inlet louvers at the base of the condenser and travels through the heat exchange fills at a direction perpendicular to the direction of the spray water flow.
  • A small portion of the water is evaporated which removes the heat and cools the spray water. The warm moist air is drawn sidewise by the fan and is discharged to the atmosphere.
  • The remaining cooled water falls to the sump at the bottom of the condenser then it is re-circulated by the pump through the water distribution system and falls down over the coils and fills.

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