Saving Water With Evaporative Condensing

Using evaporative cooling makes energy sense, not just in directly cooling the air, but also in cooling the heat rejection portion of a compressorized cooling system. This is because refrigerant compressors can be thought of, simplistically, as pumps. In a pump, two things govern energy use--the flow rate of fluid through the pump, and the head that pump needs to overcome to move the water. The same is essentially true for compressors.

In a compressor, the mass flow rate of the refrigerant essentially determines the cooling capacity it is providing. So for a given cooling load, we can't reduce the flow rate to increase our efficiency. All that is left is the compressor head. And that is something that we can effect.

In a refrigerant system, the condensing pressure of the refrigerant vapor is determined by the temperature of that refrigerant.

Let's look at this relationship for R-410a (from DuPont .pdf here):




We can see that the condensing pressure for 120º R-410a (which is around where an air-cooled condenser would operate) is about 450 psi. Compare that to a condensing pressure of about 280 psi or so at a temperature of 90º-which is an easily attainable condensing temperature in an evaporative condenser in the Pacific Northwest. When you consider that a reasonable suction temperature might be about 42º (or 150 psi) reducing your condensing temperature from 120º to 90º represents a head reduction of nearly 60%! In practice, moving to an evaporatively condensed piece of equipment from a comparable air-cooled piece of equipment can improve NPLV's by about 20% or so.

So, obviously, this makes sense from an energy conservation point of view. But what about water use? The obvious trade-off is that you are now using water where before, in the air-cooled case, you weren't. So how can we reduce the use of water while still benefitting from the reduced head pressure on the compressors?

To understand how how to improve water utilization in these systems, it is important to know what the state of the industry is for evaporative condensing. A typical system is illustrated below:


What you typically have is an induced draft evaporative unit that sprays water over a refrigerant coil. The water evaporates, and that evaporation cools the refrigerant in the coil. The remaining water falls into a basin where a pump then sprays the water back up over the coil again. All the while, a fan operates to draw air past the water and enhance the evaporative process. Importantly, every 1000 btu rejected by this system reflects about pound of water evaporated.

So what can we do to reduce water use? Well, the obvious thing is to reject less heat via evaporation. However, this might seem problematic because we want to maintain the low condensing temperatures that we can reach using evaporation. This is where it is important to understand a little about how refrigerant systems really work.

One of the main concerns with refrigerant compressors is they are designed to move gas--not liquid. A very effective way to break a compressor is to introduce liquid into it. So to be sure that no liquid enters the compressor, refrigeration systems are designe to operate with a few degrees of superheat. This takes the refrigerant safely away from the saturation line, and assures that the compressor will not see any liquid. However, this adds some extra heat into the system that then need to be rejected. Then, through the operation of the compressor, even more heat is added into the system, taking the system even further away from saturation.

However, the additive effect of the intentional pre-compressor superheat and the heat added by the compressor itself means that there is a significant amount of heat in the refrigerant that needs to be rejected before refrigerant condensing can even start. This de-superheat process is illustrated below:

(click for larger image)

If this heat can be removed without requiring evaporation, a significant amount of the water use can be eliminated. And this is exactly the approach that Aaon has taked with their evaporative condensing design. Their solution is illustrated below:



The main difference between the first system and this one is the addition of a finned desuperheater coil located above the spray system, in the cool, saturated air stream above the wetted portion of the condenser. This coil allow the system to reject the superheat without using any water--saving, on average, about 20% of the water use at peak load.

However, the benefits extend beyond there, since at about 70º ambient, this coil can reject about 50% of the total heat in the system, and it can reject 100% at about 30º ambient. So the true water savings range from about 20% to 100% depending on the operating profile and ambient conditions of the unit.

There are still other benefits: If chemical water treatment is being used on this system, the lower water use will translate to lower chemical use. And, since the tube surfaces in the wetted portions are at lower temperature in the Aaon system, there is a corresponding lower chance of creating scale--which is formed primarily from calcium carbonate which exhibits inverse solubility, depositing much more readily at higher temperatures. This lower fouling, in turn means the system will operated more efficiently for years to come, since less scale means better heat transfer at the tube surfaces which means lower head pressure on the compressor!