Dry Air–Water Cooling System for Prototype Plants

Prototype plants typically generate significant process heat, especially in closed-loop thermal circuits where pumps, reactors, compressors, or electrical equipment operate continuously. When water consumption must be minimized and plume-free operation is required, a dry air cooler becomes the preferred solution.

In this application, the dry cooler functions as a primary heat-rejection device, ensuring consistent cooling capacity regardless of process variations. The water/glycol mixture prevents freezing and corrosion while maintaining stable thermal performance.

Cooling Duty and Thermal Requirements

Heat Load

• Required heat rejection: 260 kW
  This duty level demands a robust heat exchanger surface area combined with high-performance fans to handle heat rejection at elevated ambient temperatures.

Process Fluid Conditions

• Fluid: Water/glycol mixture

• Inlet temperature: 60°C

• Outlet temperature: 45°C

• Temperature drop: 15°C

The system operates with a moderate approach temperature, ensuring effective heat transfer while keeping fan power consumption reasonable.

Ambient and Environmental Conditions

• Design ambient air temperature: up to 35°C

• Cooling method: Dry, forced-air convection

• No water consumption: Eliminates evaporation, drift loss, chemical treatment, and legionella risks.

The combination of 60°C inlet fluid and 35°C ambient ensures sufficient driving temperature difference for dry cooling, even at peak summer conditions.

The 260 kW dry air–water cooling system described here provides a robust and efficient method to reject heat from a water/glycol loop operating between 60°C and 45°C at a modest pressure of 3 bar. With its high-performance heat exchanger, efficient fans, and water-free operation, the dry cooler ensures reliable thermal management for prototype plants operating under demanding conditions.