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At CSTHEATEXCHANGER, we design and manufacture extreme-climate High-Ambient Adiabatic Closed-Circuit Dry Coolers and Free-Cooling Liquid Systems specifically engineered for the Dholera Special Investment Region (SIR) Mega Data Center Hub in Gujarat, India (addressing extreme semi-arid summer ambient peaks up to +45∘C to +48∘C, high airborne dust loading, and water scarcity quotas, with thermal heat rejection capacities scaled from 500 kW to over 2,500 kW per modular V-bank unit, operating with chilled water or water-glycol supply temperatures of +32∘C to +36∘C for Direct-to-Chip (DTC) liquid cooling CDUs and In-Row/AHU facilities). Featuring hydrophilic blue/epoxy-coated fin matrices, heavy C5-I industrial/coastal anti-corrosion protection, automated intelligent adiabatic evaporative pre-cooling misting pads, high-efficiency EC inverter fan arrays, and integrated PLC intelligent water conservation management, CST dry coolers guarantee year-round PUE <1.25–1.30, reduce annual water consumption by over 85%–90% compared to open cooling towers, and deliver continuous 24/7/365 mission-critical uptime.
The Dholera Smart City & Data Center Hub in Gujarat presents a unique combination of high summer dry-bulb temperatures, high solar radiation, dust/sand accumulation, and strict regional water-use restrictions:
DHOLERA EXTREME AMBIENT PROFILE & DUAL-MODE ADIABATIC COOLING
======================= EXTREME DHOLERA SUMMER AMBIENT (+48°C DB / 28°C WB) =======================
┌────────────────────────────────────────────────────────────────────────────────────────────────┐
│ [OUTDOOR AMBIENT AIR: +45°C to +48°C DRY BULB / HIGH AIRBORNE DUST] │
└───────────────────────────────────────────────┬────────────────────────────────────────────────┘
│
▼
┌────────────────────────────────────────────────────────────────────────────────────────────────┐
│ [STAGE 1: ADIABATIC EVAPORATIVE PRE-COOLING MESH PADS] │
│ • Water misting pre-cools incoming air from +48°C DB down to +30°C/+32°C (Approaching Wet Bulb)│
│ • Zero water droplet contact on finned tubes (100% dry coil prevents mineral scaling) │
│ • Water consumption only occurs during extreme peak hours (> +35°C ambient) │
└───────────────────────────────────────────────┬────────────────────────────────────────────────┘
│
▼
┌────────────────────────────────────────────────────────────────────────────────────────────────┐
│ [STAGE 2: CST V-BANK CLOSED-CIRCUIT FINNED COIL HEAT EXCHANGER] │
│ • Seamless Heavy Copper / 316L Stainless Tubes with Blue Hydrophilic / Epoxy Fins │
│ • High-Efficiency EC Variable Speed Inverter Fan Array (Modbus RTU Controlled) │
└───────────────────────────────────────────────┬────────────────────────────────────────────────┘
│
▼
======================= TO DHOLERA DATA CENTER SERVER HALL (PUE < 1.25) ========================
┌────────────────────────────────────────────────────────────────────────────────────────────────┐
│ • Supplies +35°C Clean Process Water to In-Row Air Handlers & Direct-to-Chip Liquid CDUs │
│ • 100% Sealed Closed Loop: Zero Water Evaporation in Loop, Zero Legionella Risk │
└────────────────────────────────────────────────────────────────────────────────────────────────┘================================================================================
CST ADIABATIC DRY COOLER VS. TRADITIONAL OPEN COOLING TOWERS IN DHOLERA
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Evaluation Metric CST Adiabatic Closed Dry Cooler Traditional Open Evaporative Tower
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Annual Water Consumption 85% to 90% Water Savings (Zero water in winter/nights)Massive continuous water evaporation & blowdown
Coil & Piping Scaling Risk 100% Scale-Free (Closed-circuit loop)Severe scaling & clogging from hard water
Extreme Ambient (+48°C) DefenseAdiabatic pads drop air to +31°C High water drift & thermal loss
Chemical Water Treatment Cost $0 Biocide / Water Conditioning High monthly scale inhibitor & biocide cost
Airborne Dust & Sand Handling Wide 12 FPI pitch + washable padsSludge accumulates rapidly in open basins
Legionella Bacterial Hazard Zero Legionella Risk (Dry fin coil)Severe biological risk in hot climate
Power Usage Effectiveness (PUE)PUE 1.20 to 1.30 in Gujarat climateHigh baseline PUE + high water treatment CapEx
Maintenance Overhead Minimal (Annual pad check & rinse)Weekly basin flushing & chemical monitoring
================================================================================Standard dry coolers cannot produce +35∘C water when ambient air reaches +45∘C to +48∘C. CST’s integrated adiabatic pre-cooling system humidifies and cools incoming air through high-efficiency cellulose/polymeric evaporative pads, lowering the air dry-bulb temperature toward the ambient wet-bulb temperature (+28∘C to +30∘C) before it reaches the coil, allowing supply water temperatures of +33∘C to +35∘C even during Gujarat's hottest heatwaves.
Unlike open cooling towers that consume millions of liters of water daily through continuous evaporation, CST adiabatic dry coolers operate in 100% dry mode for more than 70% of the year (during nights, winter, and moderate seasons). Adiabatic water spray is engaged only when ambient temperatures exceed +35∘C, drastically conserving municipal and desalinated water resources.
Located near the Gulf of Khambhat, Dholera experiences airborne saline moisture combined with industrial and desert dust:
CST DHOLERA SPECIFICATION DRY COOLER METALLURGY
┌─────────────────────────────────────────────────────────────────────────┐
│ [1. TUBE MATRIX (CLOSED REFRIGERANT / WATER-GLYCOL CIRCUIT)] │
│ • Seamless Deoxidized High-Conductivity Copper (Cu-DHP / ASTM B75). │
│ • Heavy-wall AISI 304 / 316L Stainless Steel for high-saline atmospheres│
├─────────────────────────────────────────────────────────────────────────┤
│ [2. EXTENDED FINS & SURFACE COATINGS] │
│ • Hydrophilic Blue Aluminum Fins (Resists dust adhesion & facilitates wash)│
│ • Full Blygold / Cathodic E-Coating for extreme C5-I/C5-M corrosion zones│
├─────────────────────────────────────────────────────────────────────────┤
│ [3. INDUSTRIAL CASING & FRAMEWORK] │
│ • Heavy Hot-Dip Galvanized Steel (2.5–3.0 mm) with C4/C5 Powder Coating.│
│ • Stainless steel hardware, fasteners, and motorized drain valves. │
└─────────────────────────────────────────────────────────────────────────┘ CST ADIABATIC CONTROL LOGIC WORKFLOW IN GUJARAT CLIMATE
FROM AMBIENT SENSORS & SERVER ROOM RETURN WATER TEMPERATURE (+45°C)
┌─────────────────────────────────────────────────────────────────────────┐
│ [ MODE 1: 100% DRY FREE-COOLING MODE (AMBIENT < +32°C) ] │
│ EC variable-speed fans modulate speed; zero water consumption (Winter/Night)
├─────────────────────────────────────────────────────────────────────────┤
│ [ MODE 2: SMART ADIABATIC PRE-COOLING MODE (AMBIENT > +35°C) ] │
│ PLC pulses water over evaporative pads; dry bulb drops 10°C to 14°C │
├─────────────────────────────────────────────────────────────────────────┤
│ [ MODE 3: AUTOMATIC NIGHTTIME DRAIN & PURGE CYCLE ] │
│ Automated solenoid valves drain distribution pipes to prevent stagnation│
└─────────────────────────────────────────────────────────────────────────┘
CONTINUOUS UNINTERRUPTED TIER III / TIER IV DATA CENTER UPTIMEAirborne particulate matter and sandstorms in western India can quickly foul high-density fin packs. CST engineers dry coolers for Dholera with wide 10 to 12 FPI fin spacing and sine-wave corrugated profiles, preventing dust accumulation and allowing easy seasonal washdown with high-pressure water sprays.
To protect against airborne industrial emissions and maritime air from the Gulf of Khambhat, all casing steel receives 2.5 mm hot-dip galvanization plus a baked polyester powder coat (RAL 7035), while the heat exchanger coils feature epoxy blue hydrophilic coatings or complete electro-dip E-coatings (ASTM B117 >3,000 hours).
CSTHEATEXCHANGER DHOLERA PROJECT MODULAR ARRAYS
[1. CST-ADC-500KW (1.5 MW TO 3.0 MW MODULAR POD ARRAY)]
• Heat Rejection: 500 kW per unit; 4 to 6 units per computing pod.
• Ideal for standardized edge pods, telecommunications buildings, and containerized data centers.
─────────────────────────────────────────────────────────────────────────────
[2. CST-ADC-1000KW (5.0 MW TO 10.0 MW SERVER HALL BLOCK)]
• Heat Rejection: 1,000 kW per unit; Dual V-Bank with 8 to 10 EC fan arrays.
• Sized for hyperscale enterprise halls, colocation suites, and central mechanical yards.
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[3. CST-ADC-2000KW+ (HIGH-DENSITY MEGA-WATT AI/GPU CLUSTER BLOCKS)]
• Heat Rejection: 2,000 kW to 2,500 kW per mega-module; High-flow flanged manifolds.
• Engineered for Direct-to-Chip (DTC) liquid cooling loops handling ultra-dense AI workloads.(Note: The following engineering parameters represent standard manufacturing design envelopes for the Dholera Project specification. Dimensions, fan quantities, water pipe connections, and acoustic packages are 100% tailored to client MEP blueprints.)
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CST DHOLERA PROJECT ADIABATIC DRY COOLER (CST-ADC-DHOLERA SERIES)
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Engineering Parameter Project Specification Envelope (Per Unit)
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Nominal Heat Rejection Capacity 500 kW, 1,000 kW, 1,500 kW, up to 2,500+ kW per unit
Design Ambient Conditions (Peak)+48°C Dry Bulb / +28°C Wet Bulb (Extreme Gujarat Summer)
Effective Air Temperature to Coil+32°C to +34°C (Post-Adiabatic Pre-Cooling Pad Matrix)
Process Fluid Medium Clean Treated Water or 20% Ethylene / Propylene Glycol
Process Fluid Supply Temperature+33°C to +36°C (Chilled Loop for In-Row & Liquid CDUs)
Process Fluid Return Temperature+43°C to +48°C (Delta T = 10 K to 12 K High Efficiency)
Design Operating Pressure Range Up to 1.6 MPa (16 bar / 232 psi) Heavy Industrial Rating
Hydrostatic Proof Test Pressure 2.5 MPa (25 bar / 362 psi) Leak Integrity Quality Gate
Core Tube Metallurgy Options Seamless Copper (Cu-DHP Ø 5/8") or AISI 316L Stainless Steel
Fin Metallurgy & Surface Finish Corrugated Hydrophilic Blue Aluminum / Cathodic E-Coated
Fin Density / Spacing Range 10 to 12 FPI (Optimized for dust shedding & low air dP)
Adiabatic Pre-Cooling Media High-Efficiency Inorganic / Fluted Cellulose Pad Matrix
Adiabatic Water Spray Control Intelligent Pulse-Width Modulation (PWM) via PLC Control
Fan Technology & Architecture High-Efficiency Brushless EC (Electronically Commutated) Fans
Fan Diameter & Ingress Rating Ø 800 mm to Ø 910 mm; IP55 / IP56 Dust and Water Sealed
Acoustic Noise Pressure Level Standard: 65–70 dBA @ 10m; Low-Noise Silencer Pack: < 58 dBA @ 10m
Structural Casing Construction 2.5 mm Hot-Dip Galvanized Steel with C4/C5-I Industrial Coating
BMS & DCIM Communication Native Modbus RTU (RS485), BACnet IP, SNMP v3 Protocols
Quality Standards & Compliance CE / PED 2014/68/EU, ISO 9001:2015, TIA-942 Tier III/IV Ready
Testing & Quality Assurance 100% Helium Mass Spectrometer Testing + Factory Acceptance Test
================================================================================In Dholera, summer ambient temperatures routinely exceed +45∘C to +48∘C. A standard dry cooler without adiabatic assist cannot cool process water below ambient temperature (+48∘C), which causes data center chillers and servers to trip. An adiabatic dry cooler pre-cools the air to +32∘C using evaporative pads, enabling reliable +35∘C water delivery under peak desert heat.
Unlike direct evaporative coolers that spray water directly onto the metal fins (causing rapid calcium carbonate scaling), CST’s indirect adiabatic pads are positioned in the air intake stream separate from the coil. The moisture evaporates entirely into the airstream before reaching the finned tubes, ensuring the heat exchanger coil remains completely dry and 100% scale-free.
The adiabatic system can utilize standard municipal, treated RO, or recycled greywater. Because water evaporates off the replaceable, low-cost evaporative pads rather than the expensive metallic heat exchanger tubes, mineral deposits remain on the pads, which can be easily cleaned or replaced after multiple operating seasons.
Ensure Tier III/IV data center compliance, achieve ultra-low PUE (<1.25), and eliminate water waste with CSTHEATEXCHANGER:
Custom High-Ambient Adiabatic Dry Coolers (500 kW to 2,500 kW+) for Dholera SIR
Engineered for +48∘C Gujarat Summer Ambient Extremes with 85%–90% Water Savings
Seamless Copper or AISI 316L Stainless Coils with Hydrophilic Blue / E-Coated Fins
High-Efficiency EC Inverter Fan Arrays with Native Modbus RTU / BACnet DCIM Integration
Heavy-Duty Weatherproof & Anti-Corrosion Enclosures with C4/C5-I Protective Finishes
Full TIA-942 Tier III/IV Readiness, 100% Helium Vacuum Leak Tested & Factory-Direct Project Export
Contact our specialized data center infrastructure and high-ambient thermal engineering team today with your project heat loads (MW), target chilled water temperatures, site ambient meteorological data, and mechanical layout for comprehensive thermal modeling simulations and factory-direct project proposals.
Website: https://www.cstheatexchanger.com/
Technical Inquiries: info@cstheatexchanger.com
