Doubles (IDD line)The most common uses of dry cooler refrigeration systems are the cooling of independent fluids or as part of air conditioning or refrigeration systems. In the latter case, its function is to cool fluids in intermediate heat exchangers and water chiller evaporators, among other purposes. Dry cooler equipment have very diverse industrial and commercial applications. Therefore, they can be present in chemical plants, data centers and shopping malls.

Are you interested in knowing more about this technology and its advantages to incorporate it into your company? Keep reading!


What are dry cooler refrigeration systems?

Dry cooler systems make up a group of technologies capable of cooling or condensing a fluid in a heat exchanger without consuming water. To do this, the heat exchangers are cooled on the outside by a flow of cold air. More broadly, these devices function as heat rejection devices and are used to cool process liquids -water, glycols and oils- through the forced dissipation of thermal energy to the atmosphere.

Dry coolers are closed loop systems and do not create direct contact between the air and the process fluid. This is its main difference with wet cooling systems (open, such as the cooling tower). In itself, they are simple equipment, made up of two essential elements: air-liquid heat exchangers and fans. Generally, the fans used are of the axial type. For their part, the heat exchangers are finned or micro-channel batteries. The latter are used in small or medium-sized systems.


Classification of dry cooler systems

In effect, there are two classifications for dry cooling units, according to their process and according to their location.


Classification by its process:

  • Direct dry cooling. As its name indicates, a direct dry cooler system directly condenses the exhaust flow of the steam turbine, returning the condensate to the boiler without losing water. In this sense, the steam is condensed directly inside the air-cooled finned tubes, without the need for an intermediate surface condenser. In general, they are common in industrial processes, utilities and renewable energy for small or large plants.
  • Indirect systems. Indirect dry cooler systems couple an indirect dry cooling tower (IDCT) with a surface or steam jet condenser. They are ideal for high capacity condensing units. Its casing – made of steel or concrete – prevents the recirculation of hot air. In this way, it reduces the need for auxiliary power and the number of mechanical components.
  • Natural Draft Condenser. A draft or natural draft condenser (NDACC) is an air-cooled condenser (ACC) that uses a natural draft tower instead of fans. This reduces the electrical power consumption of the ACC.

Sorting by location:

  • A general purpose, remote dry cooler that is separate from, but connected to, the air-cooled chiller by piping.
    Stacked coil, that is, those that join the coils of the refrigerant condenser of the chiller.
    Bolted, or modular, dry cooler coupled directly to the air-cooled chiller. Devices of this mode can supply the proper amount of free cooling required for the purpose.
  • Stacked coil, that is, those that join the coils of the refrigerant condenser of the chiller.
  • Bolted, or modular, dry cooler coupled directly to the air-cooled chiller. Devices of this mode can supply the proper amount of free cooling required for the purpose.


Advantages of dry cooler systems

As closed loop systems, dry coolers provide many advantages over wet coolers. Here we include:

  • Minimal initial installation and maintenance costs.
  • Increased system reliability and longer run time.

On the other hand, they offer a heat rejection option for companies that need to reduce water consumption and equipment maintenance. Although open-loop cooling towers remove heat in a smaller footprint than closed-loop fluid coolers (because of direct latent heat transfer cooling of the process fluid), closed-loop fluid coolers take advantage of the constant thermal performance of the whole system.

In facilities that generate a large amount of heat for their operation, such as data centers, dry cooling systems are the most suitable for their ability to work 24/7. This implies that they will be able to use this type of free cooling for a good part of the year.


Easy maintenance and other relevant advantages of dry cooler systems

Maintenance of dry cooler systems is relatively simple. They only require a general inspection to look for and evaluate possible mechanical problems and damage. Among these, evidence of excessive vibrations from the fans and visual check for signs of corrosion. When it comes to cleaning cooling coils, common debris such as paper, dust, leaves, and pollen can be brushed away. As with compressed air blowing against the direction of the airflow. In the case of heavier deposits, these should be removed with a pressurized water jet, also against the direction of the air flow. As a complement, a neutral cleaning agent should be used if necessary.

As if that were not enough, dry coolers have other specific benefits such as:

  • Overall running costs after initial installation are low.
  • Convenient separation of components allows operators to save vital space for other equipment.
  • These systems do not need a constant supply of water, so they do not create supply and disposal problems..
  • The heat produced can be channeled directly to other processes. This reduces energy waste and improves overall system efficiency.
  • The chillers we are dealing with can be programmed to operate all year round, even in geographical areas with low temperatures.


Intersam dry cooler systems

At Intersam we offer your company a wide variety of options in customized dry cooler systems. For example, our dry cooler equipment:

  • Simples, from the IDR series
  • Doubles (IDD series)
  • In V (IDV series)
  • In W (IDW series)

All of them offer nominal power ranging from 10Kw to 1,025Kw. In general, they are installations used as water coolers, both in conditioning and refrigeration for water-based and free-cooling condensers. In the industrial sector, its main applications are as process coolers, mineral oils and other fluids.


General characteristics

Similarly, all the wind turbines mentioned are made up of high performance condensing batteries, made of 1/2” and 5/8” copper tube and corrugated aluminum fins with 2.1mm separation. Also, the frame, made of galvanized sheet metal, has a floating system that prevents eventual breakage of the tube due to vibrations.

The systems have high performance fans, 500, 560, 630 and 800mm in diameter. These have three-phase motors with external rotor, double speed and low consumption, with IP-54 protection degree and internal safety clickon.

On the other hand, the outer structure consists of a galvanized steel sheet, compact and rigid to avoid vibrations; painted in RAL-9018 polyester. The parts and panels are easily removable, which makes the maintenance process very simple. To do this, it has the necessary supports and anchors for its fixing and lifting.


We are specialists in refrigeration and air conditioning systems

At Intersam we have been developing heat exchangers tailored to the needs of our customers for 27 years. Our experience allows us to design and build fully customized industrial and commercial refrigeration and air conditioning solutions for all types of companies, such as dry cooler systems. We serve the requirements of your business wherever you are, inside or outside of Spain. Contact us now and tell us about your refrigeration needs!

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