Heat Exchanger Suitable for Water conservation, moderate cooling?
The most suitable and common type is the Closed-Circuit Cooling Tower (also known as a Fluid Cooler), which is a hybrid device. However, the best choice depends on your specific priorities.
Here’s a breakdown of the top options, starting with the most recommended.
1. Closed-Circuit Cooling Tower / Fluid Cooler
This is the premier solution for water conservation in cooling applications. It operates on the principle of indirect cooling.
How it works:
- The process fluid (e.g., water, glycol mix) to be cooled is pumped through a coil (usually copper or stainless steel).
- A separate water circuit sprays water over the outside of the coil.
- A fan pulls or pushes air across the coil.
- Heat is transferred from the process fluid inside the coil, through the tube wall, to the spray water film, and then evaporated into the airstream.
Why it’s perfect for water conservation:
- Closed Process Loop: The process fluid being cooled is completely sealed from the environment. It never contacts the air and cannot evaporate, scale, or get contaminated. This means you never lose the expensive, treated process fluid.
- Only Evaporates Spray Water: The water that evaporates is the relatively dirty spray water, not the clean process water. This leads to massive savings.
- Reduced Fouling: Because the process loop is closed, it stays clean, maintaining high heat transfer efficiency for longer.
Typical Applications:
- Cooling industrial process water
- Cooling hydraulic systems
- Chiller condenser water loop cooling
- Engine and generator jacket water cooling
- Plastic molding process cooling
Adiabatic Fluid Cooler / Adiabatic Cooler
This is an enhanced version of a standard air-cooled heat exchanger that activates a water-saving feature only when needed.
How it works:
- It is primarily a dry air-cooled heat exchanger.
- Only when the ambient air temperature is too high to achieve the desired cooling (e.g., on the hottest days of the year) does a pre-cooling water mist system activate.
- A fine mist of water is sprayed into the air intake, pre-cooling the air through evaporation before it passes over the heat exchanger coils.
Why it’s excellent for water conservation:
- Runs Dry 80-90% of the Time: It uses zero water for most of the year, relying only on air.
- Minimal Water Use: When the adiabatic pre-cooling is active, it uses a fraction of the water a cooling tower would use.
- No Evaporation of Process Fluid: The process loop remains closed and protected.
Ideal For: Applications in climates with high daytime temperatures but cool nights, where water is scarce but some water use is acceptable during peak loads.