Energy Saving Evaporative Air Cooler with Integrated Wet Cooling and Pre-Cooling Section Heat Exchanger for Dry-Wet Air Cooler Systems

The evaporative air cooler (also known as a dry-wet air cooler) is a new energy-saving heat exchanger that integrates wet air cooling with evaporative cooling, combining both heat transfer and mass transfer processes. Built upon the foundation of a conventional evaporative condenser (cooler), this system adds a pre-cooling section heat exchanger to significantly enhance cooling efficiency.

Before the high-temperature medium enters the condenser coil (wet cooling section or evaporative section), it first passes through the finned dry cooling section. Here, it is cooled by the low-temperature humid air discharged from the coil, which features a large air volume and temperature difference. This pre-cools the high-temperature medium inside the finned tubes before it enters the condenser coil.

Spray water is pumped by the spray water pump to the spray system at the top of the condenser coil and sprayed uniformly onto the condenser coil surface, forming a water film that completely covers the coil surface. The high-temperature medium inside the coil exchanges heat with the water and air outside the coil.

An axial-flow fan forces air through the condenser coil and the spray water. The sprayed water outside the tubes evaporates and absorbs heat; some of the spray water turns into steam, taking away heat. Water in the hot air and the un-evaporated water is intercepted by the baffles (water collectors) and falls into the water pan, from where it is recirculated by the pump to the spray water system and sprayed onto the coil surface. This cycle continues for cooling.

Water lost to the air is replenished under the control of the water level regulator, ensuring consistent and reliable operation.

• Integrated dry-wet cooling design combining pre-cooling and evaporative cooling in a single unit.
• Finned dry cooling section pre-cools the high-temperature medium using exhaust humid air for improved energy efficiency.
• Uniform water film distribution across the condenser coil surface for optimal heat exchange.
• Axial-flow fan ensures consistent airflow through the coil and spray water.
• Baffle (water collector) system intercepts water droplets and recirculates them to the water pan.
• Automatic water level regulation replenishes water lost to evaporation.