New Modular Drycooler: a revolutionary concept

The heat generated by several industrial processes needs to be eliminated by means of a warm industrial “water flow” (range of 30ºC - 35ºC). The heat transferred warms up the water and before returning to the process it must be cooled off again to its initial temperature. Several technical alternatives were already approached in the 32nd issue. Those days widely using cooling towers are over, due to excessive loss of water (it may reach 3% of flow) because they need continuous flow-through water and purge chemical treatment and, especially, the need for frequently cleaning of heat exchangers in the process to remove mounts arising from high percentage of salt diluted in water.

An option that has been interesting people lately is the drycooler. In such equipment, water cooling occurs in a serpentine wing that exchanges heat with room air pushed by ventilators, in a similar form as the radiator from a car. Once the water load is completed, the consumption is restricted to occasional leakage in the process and there is no need for continuous chemical treatment and purge. The energy consumed by the ventilators is decreased through modulation of its rotation to meet the demand. The great challenge is to make sure the industrial water leaves the drycooler at less than 35ºC, even in those days which the room air exceeds the temperature. This can be attained by an adiabatic saturation process, based on the principle that water evaporation reduces the temperature of air current. The solution developed by Mecalor uses evaporative cooling panels with algicide cover. A controlled potable water flow is distributed in the upper border of the panel saturating corrugated cellulose leaves impregnated with insoluble compounds, which form channels for the horizontal air flow. A high humidification efficiency of 80%, a lot higher than 40% and 50% reached by more usual channels with water sprinklers, ensures the air reaches the heat exchangers up to 10ºC cooler. Such pre-cooling is responsible for the drycooler’s exceptional performance and it is only thanks to good distribution and low speed of air in the drycooler’s inflow. Also, the plenum formed by evaporative panels and heat exchangers prevents water drops and dust to reach the heat exchanger’s face. Therefore, the incrustation, corrosion, and dust accumulation risks, which reduce significantly the yield and useful life of the drycooler, are kept away.

The new Modular DryCooler developed by Mecalor, incorporates the most advanced technology in a simple and eco-friendly device. Assembled in a stainless steel structure, dismountable and easy to move, uses exclusive microchannel heat exchangers (refer to article at the end of this issue) assembled in an upside-down “V” shape with two 800 mm diameter German axial ventilators, that are quiet and with rotation control. Several 100 kW modules can be overlapped reaching the capacity of up to 1200 kW. Another attractive of this conception is the very low water consumption reached through a non evaporated water recycling system.

“The greatest investment in research and development was fully compensated by major acceptance from customers”, affirms engineer János Szegö, director of Mecalor.

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