Evaporative Pre-Cooling System

SMART PreCooling™ system is the most effective pre-cooling system for industrial and commercial cooling units

Blue Energy Technologies offers a most effective solution to increase the peak cooling capacity of air conditioning and cooling units without major modifications of your current system –with the evaporative SMART PreCooling™ system. In addition to cooling capacity enhancement, this solution ensures the substantial economy of the electric energy consumed by cooling, reduce maintenance costs, and extend equipment lifecycle.

TECHNICAL ASSISTANCE
  • 36-months-guarantee-gold
  • Tested and approved
  • ROI 24-36 months
Evaporative SMART PreCooling™ system is installed before the condenser of the refrigeration or air conditioning (HVAC) unit which lowers the temperature of the air entering the condenser. To cool the intake air with the SMART PreCooling™ system, we use two-stage evaporative cooling by combining the indirect (first stage) with the direct (second stage) evaporative cooling process.

In indirect evaporative cooling stage, the evaporation of water takes place in the air entering the side of an air cooled unit condenser, causing warm outside air to be cooled through an adiabatic cooling process often referred as FREE COOLING, where the process of reducing heat goes through a change in air pressure caused by volume expansion.

The achievable cooling of outside air depends on the volume of evaporated water and total incoming airflow against the difference between the dry-bulb temperature (DBT) and the wet-bulb temperature conditions at any given time. With SMART PreCooling™ system the incoming air can be humidified up to near saturation from the dry bulb conditions.

The crucial elements here are:
• The air temperature before evaporation: the hotter it is, the more humidity it can absorb, and the more is the cooling effect.
• The humidity before evaporation: the less water the air already contains, the more humidity it can absorb and the larger the temperature drop achieved.

SMART PreCooling™ system performs the best at the exact time when commercial or industrial buildings require increased cooling system performance and operate at the peak demand.

The theoretical limit of evaporative cooling is reached upon complete saturation of the air with water at a relative humidity of 100%. Humidity increases to values of 90% to 95% are realistic at economically viable cost with the SMART PreCooling™ system.

In direct evaporative cooling stage, the evaporation of water takes place when pre-cooled air from stage one now goes through our SMART PreCooling™ air cooling filter panels to attain additional drop of temperature, and protect the condenser from outside pollution.

By combining indirect with direct evaporative cooling process within SMART PreCoolingTM system, we get the most effective evaporative pre-cooling system on the market.

Evaporative SMART PreCooling™ consists of the following components:

  1. High pressure 1000 PSI (70BAR) water pump station skid, includes direct drive water pump, water filtration station, and zone valve manifold, all integrated and controlled with the PLC (Programmable Logic Controller) unit and I/O modules through the HMI control panel and optional industrial VPN routers for easy remote access.
  2. Cooling panel with filtration membrane.
  3. Salt free low maintenance water conditioning system.
  4. Water-spraying (fogging) high-pressure manifold system built from stainless steel tubing and compression fittings.
Smart-cooling-components
At the heart of the functioning of the SMART PreCooling™ system is an adiabatic process – a process in which a substance changes its state (moisture evaporates), and the result is a decrease in temperature. This effect is used to cool the air going into the air conditioning and cooling unit. Accordingly, the lower the temperature of the air entering the unit, the less power is required to cool to a predetermined temperature.

Evaporative SMART PreCooling™ system is installed before the air conditioning and cooling unit condenser. The temperature of air passing through the panel is reduced because warm air is cooled by the very fine water mist (fog) created by the state of the are completely atomized high-pressure water treatment and preparation skid. A schematic example of the work of the SMART PreCooling™ evaporative system.
Adiabatic Panels Air Flow
The temperature of the air passing through the SMART PreCooling™ panels reduces substantially (by 10°C /50F – 20°C /70F), and such lowering of temperature causes meaningful cooling capacity to increase.

Using the SMART PreCooling™, the temperature of the air entering the air conditioning and cooling unit can be reduced to even 20°C/70F. It means that at a temperature like this, the unit must expend much less power for cooling.

To cool the air entering the air conditioning and cooling unit, the processed water mist (fog) is created. After the contact of the mist with hot air, evaporation occurs and as a result, temperature decreases.

Evaporative SMART PreCooling™ system does not directly affect the technical processes of the air conditioning and cooling unit. It only provides a temperature reduction of the air entering the unit. This allows you to return the work of the air conditioning and cooling unit from high speed into normal mode and provide the required cooling capacity.

The use of the evaporative pre-cooling system SMART PreCooling™ provides a number of benefits that reduce energy costs, increase peak cooling capacity, reduce maintenance costs, reduce energy (kWh) usage, and peak demand (kw) of refrigeration and air conditioning (HVAC) unit. The application  performs best at the exact time when commercial buildings require increased cooling system performance, during peak ambient periods. This creates situation that the higher the ambient temperature, the greater saving potential is from SMART PreCooling™ systems:
  • Cooling Filter Panels
    In pre-cooling filter panels special material is used which provides a second stage cooling and protecting the condenser of refrigeration and air conditioning (HVAC) unit from direct sun rays and air polution. Panels are built with very low air flow resistance which is extremely important in the proper operation of today’s high efficient cooling systems. As a result, an air pollution and additional increase in the temperature of the air entering the refrigeration and air conditioning (HVAC) unit is avoided.
  • Stainless Steel Micro-Nozzles Manifolds
    For producing fine water mist (fog), a special system Smart Release Technology combined with cooling zone valves is used to spray water droplets into very small water molecules. This provides substantial savings in water consumption.
  • No Risk of Calcium Deposition
    The high-pressure micro-orifice nozzle installation design combined with pre-cooling panels helps ensure flash-evaporation, thereby moisture contact with the condenser is very minimal. To protect the cooling unit from calcium deposits, anti-scaling preparation equipment is used with each system. Due to this step, calcium buildups are not formed on the surfaces of the refrigeration and air conditioning (HVAC) unit condenser.
  • The Risk of Condenser Overheating is Eliminated
    Avoid the risk of cooling and conditioning equipment overheating. As the SMART PreCooling™ system reduces the air temperature that flows into refrigeration and air conditioning (HVAC) unit, thus reducing the energy needed to produce the necessary amount of cooling power, there is practically no risk of equipment overheating, which can cause huge damage to the equipment. This allows the condensers to reject more heat which lowers head pressures and compression ratios, thereby causing the compressors to draw less power. After the evaporative SMART PreCooling™ installation, refrigeration and air conditioning (HVAC) unit do not work at full power to produce the necessary amount of cooling energy, the cooling capacity increases, requires less maintenance, and last longer. Evaporative SMART PreCooling™ system is compatible with the most manufacturer refrigeration and air conditioning (HVAC) units and comes in flexible design and engineering configurations. It operates completely independently of the technological processes of the unit, providing only the cooling of the air going in.
  • Compatible With Most Refrigeration and Air Cooled HVAC Units
    Evaporative SMART PreCooling™ system is compatible with the refrigeration and air conditioning (HVAC) units of any capacity and make. Due to a special module assembly, the installation of the Evaporative SMART PreCooling™ system occurs in a few days. If the problem of the lack of capacity of air conditioning and cooling is expected in the near future or is relevant to the point, you already have a prompt and proven solution!
  • Minimum maintenance
    All our units are built with easy and economical maintenance in mind.
  • No Legionella risk
    There is no risk of the presence of Legionella (Leģionellas) because the Evaporative SMART PreCooling™ system optionally can be equipped with UV lamps, which prevent bacteria from entering the water (including Legionella).
Once it is used in air-cooled systems, the application will lower energy consumption (kWh) as well as demand (kW) while expanding peak cooling load.

 

Why is an Evaporative Pre-Cooling System a particularly crucial innovation?

Air conditioning and refrigeration represent about 70% of the energy usage of a normal commercial building. Data centers and supermarkets can use a significantly higher rate.

Cooling systems do not just function longer in heightened ambient conditions; they additionally pull more power when they function. Hence, the kWh as well as the kW increases significantly.

It is hard to additionally lower the energy consumption of the HVAC system using the common methods, for example, higher thermostat settings and night setback modes. Hence, the best approach to lower energy use is to use an evaporative pre-cooling system to make the systems run more efficiently.

How does it work?

A custom-made evaporative pre-cooling unit is attached to every one of the HVAC Unit, which reduces the temperature of the air allowed into the condenser. This enables the condensers to get rid of heat which reduces the compression proportions and head pressures, making the compressors to utilize less power. HVAC unit cooling limit increases, they function less, utilize lower energy, need little maintenance, and unit last longer.

The application works perfect at the particular period when commercial and industrial buildings need more refrigeration system performance: at the highest ambient moments. Actually, the higher the ambient temperature, the higher the savings capability.

System Benefits

Evaporative pre-cooling system offers a couple of great advantages:

Reduced Energy Costs
The lower energy and demand usage prompts a lower demand and usage bills and considerably brings down energy charges.

Reduced Maintenance Costs
By reducing head pressures and improving compressor life, reduced maintenance expenses can be achieved. Compressor life can be greatly diminished by high head pressures. On the other hand, by reducing top head pressures via evaporative pre-cooling, life span of compressor can be significantly increased.

Increased Peak Cooling Capacity
By lowering the temperature of incoming air to 70F from 95F, peak cooling capacity of the system can be extended by up to 25%.

Reduced Energy (kWh) Usage
The system will lower kWh across the whole ambient temperature span from 75 F and more. Contingent upon the exact ambient situations, about 11% to 20% savings in KW can be achieved.

Reduced Peak Demand (kW)
The system will decrease kW across the whole ambient temperature starting from 75 F and upwards. Also, contingent upon exact ambient situations, about 25% savings on peak kW can be achieved.

Is it a good investment?

Yes. Evaporative Pre-Cooling system will often recoup its initial investment inside two years and keep on minimizing energy and maintenance expenses for the foreseeable future.

What is evaporative pre-cooling?

Using “thermal dynamics”, a pump has water pumped through it, increasing its pressure to 1,000psi, and it is passed through high-pressure pipes and fogging nozzles for the water droplets to be atomized to 10 microns or lower. At the point the water fog is injected into an air stream passing over an air-cooled condenser (condenser air), it becomes “flash-evaporated” and the condenser air has its temperature reduced.

Is evaporative pre-cooling a new practice?

No. Evaporative cooling or sometimes referred as fogging has been in existence for over 25 years and was once used for open air cooling in places like porches and outdoor eateries.

What proof exist that fogging condenser air will advance the performance of air-cooled condensers?

Research proves significant savings. Moreover, an autonomous review authorized by Southern California Edison as of late confirmed the savings to be accomplished through evaporative fogging. Furthermore, the data sheets of manufacturers recommend that air cooled systems function better under cooler ambient surroundings.

Why does cooling system energy usage rise as the ambient temperature increases?

There are three essential causes:

As the ambient temperature increases, the condenser can’t dissipate enough heat; as such the head pressure likewise increases. This builds the compression proportion (head pressure/suction pressure) making the compressors use more power to function.

As the head pressure rises, the temperature of the saturated liquid (refrigerant) increases and the cooling capacity of the system drop. Hence, the system needs to function for longer in order to balance the load and as such it utilizes more energy.

In cases where the cooling load demand is increased due to the higher ambient temperatures, the cooling system must function longer which in return increase energy usage.

Can it be retrofitted without major alterations?

Yes.  Our system does not need the condenser be switched off or changed. It is basically mounted in an appropriate area, water piping is channeled to the condensers, and then the system is switched on and controlled via a programmable logic controller in the auto mode.

What benefits are derived when condenser air is cooled through evaporative pre-cooling?

As the temperature drops in the condenser air, the more heat the condenser can dispel, so the head pressure is decreased. This reduces the compression ratio making the compressors to utilize less power when running.

As the head pressure drops, the saturated liquid temperature likewise drops, and cooling limit rises. Hence, the system doesn’t need to function for long to balance the load and reduce energy usage.

Lower head pressures increases compressor durability, improves cooling dependability, and reduces maintenance expenses.

Will using evaporative pre-cooling lower peak demand (kW) and energy usage (kWh), or both?

Both. Due to the fact that the compressors will use reduced power to function due to lower head pressures, there will be a decrease in demand. Since there will be an increase in the cooling limit of the system, the compressors will function less, thereby lowering energy usage.

Will the energy savings be relatively constant across the whole range of ambient conditions?

No. The highest temperature drops will happen under the driest and hottest ambient surroundings. In such times, the highest percentage of energy savings will be achieved. Nonetheless, over the span of a year there are lots of hours when the ambient conditions are much more temperate; hence the highest savings in kWh will be achieved during such times.

Can it cause coil corrosion?

No. The high-pressure micro-orifice nozzle installation design combined with pre-cooling panels helps ensure flash-evaporation, thereby moisture contact with the condenser is very minimal. To protect the cooling unit from calcium deposits, anti-scaling preparation equipment is used with each system.

Evaporative SMART PreCooling™ System

Pre-Cool & Save with Evaporative (Adiabatic) Cooling Systems