Superior reliable performance. Niagara Wet Surface Air Coolers for fluid cooling and vapor condensing

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1 Superior reliable performance Niagara Wet Surface Air Coolers for fluid cooling and vapor condensing

2 Designed for coldest process outlet temperature Alfa Laval Niagara Wet Surface Air Coolers (WSAC ) are efficient closed-loop, evaporative cooling systems designed for the power, process, wastewater, natural gas and petrochemical industries. These fluid cooling and vapor condensing systems are optimized for industrial applications where rugged designs, and cost-effective, efficient closedloop cooling and condensing duties are required. The Alfa Laval Niagara WSAC system is one of the most efficient and durable evaporative coolers available capable of cooling process fluid to within 5 F of the surrounding wet bulb temperature. Our wet surface air coolers are constructed with heavy gauge steel panels, flanged and double broke on all sides with welded corners providing extreme rigidity, extending service life and increasing overall durability to customers worldwide. Our WSAC system offers improved efficiencies over traditional heat exchangers used throughout the industries. Benefits Produces coldest possible process outlet temperature Increased water conservation due to higher concentration cycles Low quality water can be used as makeup Compact footprint Lower parasitic energy (HP) Competitive installed cost Minimal maintenance required Less drift 2

3 Industries and applications Industries Refining Power Natural gas (NGL, LNG, and FLNG) Wastewater Pulp and paper Metals Mining Ethanol and biodiesel Gas transmission and compression General industrial Food and beverage Petrochemical Applications The Alfa Laval Niagara WSAC solution has the ability to cool a broad mix of fluids and vapors. Typical applications include, but are not limited to the following: Fluid cooling Up to 180 F max inlet temperature Water and wastewater Moldwater Glycols Oils Hydrocarbons Drilling mud Gasoline Sour water/gas Vapor cooling Up to 450 F max inlet temperature Supercritical CO 2 Natural gas Nitrogen Vapor condensing Up to 450 F max inlet temperature Vacuum steam (1.4" HgA minimum) Ammonia Hydrocarbons propane, ethane, propylene Refrigerants 3

4 WSAC systems for fluid cooling and vapor condensing The Alfa Laval Niagara WSAC systems are designed for heavy-duty industrial standards, and are engineered to meet the most demanding applications. These systems are tailored to customer specifications for inlet and outlet temperatures, as well as worst case ambient conditions. Packaged WSAC systems Skidded, pre-piped and pre-wired for reduced installation costs Full redundancy of fans and pumps Includes control cabinet and water treatment Factory tested Freeze protection Plug-and-play installation Modular WSAC systems Expand or contract based on process requirements Direct drive fan system Heavy duty gauge steel High flow, low pressure industrial pump system No plastic fill Nut and bolt assembly no zip screws Access package available Field erected WSAC systems Poured in place reinforced concrete Pultruded FRP structure Interchangeable modules Reduced footprint for large systems Lowest optimized cost Economized layout Field supervision available for installation 4

5 Engineered-to-order features and options Each Alfa Laval Niagara WSAC system is engineered to provide optimal performance for your unique application. Tube bundles, electrical panels and accessories are custom designed for each system. Tube bundles Straight tube Mechanically cleanable Removable cover plate headers ASME, PED code designs Lowest pressure drop Individual tube access Various metals (C.S., S.S., Exotics) Electrical controls Serpentine Fully welded headers ASME, PED code designs Cost effective High pressure (3,500 PSI) Various metals (C.S., S.S.) Complete in-house design Custom control panels PLC/HMI programming Operating manuals Quality assurance Experience with designing to UL, cul, CSA, IEC, NFPA, IECex, ATEX, and hazardous area (Class/Zone) installations Ancillary components Pump skids with available redundancy Water treatment skids Field commissioning and start-up Access packages (ladders, walkways, platforms) Complete pre-wired systems with controls 5

6 How it works Warm process fluid flows through tube bundles 1 which are sprayed with water 2. Air is drawn down over the tubes by fans 3, creating a cooling effect by evaporating the water. The water not evaporated is collected in a basin 4 and pumped back to the top of the unit to begin the process again 5. The evaporated water and air are discharged from the top of the unit by the fan to the atmosphere 6. Water saving benefits As compared to cooling tower water costs, the WSAC system provides significant savings in operating expenses including: Water usage Run higher cycles of concentration Purchase less water Dispose/treat less water Use poor quality water Brackish water Seawater Treated effluent Cooling tower blowdown Reverse osmosis reject water Co-current spray system design Lower discharge height Lower PM10 Pump less water Lower horsepower Reduced installation costs 6 Make up water Evaporated water Cycles of concentration in a WSAC Evaporation (GPM) = Heat Load (Btu/hr)/~ (same as CT) Blowdown = Evaporation / Cycles 1 Total makeup = Evaporation + Blowdown Blowdown Y

7 Technology comparison WSAC systems produce the coldest possible process outlet temperature compared to other technologies. Other WSAC advantages are shown in the comparison below. Design air temperature: 100 F dry bulb 79 F wet bulb (37.7C / 26.1C) Thermal system Practical approach temp. Coldest practical process temp. Water use / management Electrical consumption Total system plot space Wet Surface Air Cooler (WSAC) Cooling tower plus heat exchanger Dry cooler Latent Latent / sensible Sensible 10F WB (5.5C) 10F for CT WB (5.5C) 5F for HX (2.7C) 15F DB (8.3C) 89F (29.5C) 94F (34.4C) 115F (46.1C) High cycles of concentration Low cycles of concentration due to HX Air only Low Medium High Small Medium - Large Medium - Large Water cost Low - Medium High Not applicable Total system cost Low - Medium High Medium - High Benefits Produces coldest possible process outlet temperature Increased water conservation due to higher concentration cycles Low quality water can be used as makeup Compact footprint Lower parasitic energy (HP) Competitive installed cost Minimal maintenance required Less drift 7

8 Alfa Laval wet/dry hybrid auxiliary cooling Our hybrid auxiliary cooling solution is a system designed approach created to maximize site water conservation while still enabling very low process outlet temperatures. To stay below a site s allowed water usage, typically influenced by cooling tower consumption, the Alfa Laval Niagara Wet Surface Air Cooler (WSAC ) is combined with an Alfa Laval ACE dry air cooler to maximize system efficiency by taking advantage of fluctuating ambient air temperatures. Our system approach allows for a consistently low process outlet temperature during all seasons by running dry during colder ambient periods; then utilizing available water only during the hotter summer ambient air temperatures. And unlike typical cooling tower solutions, poor quality water can be collected and used. Finally, total system responsibility for thermal performance is with Alfa Laval. Advantages Having the flexibility to individually or simultaneously cool a process fluid using different heat exchanger technologies provides the following immediate and long term benefits: Our system s increased efficiency significantly reduces plot space and electrical power consumption when compared with pure dry air cooler solutions. The reduction in water consumption, using dry air coolers when possible or increased cycles of concentration, can minimize site permitting and regulatory challenges. Alfa Laval s ability to thermally design a complete hybrid solution provides a consolidated purchasing and engineering experience, and more focused operational and warranty support. Application diagram 8

9 Industry leading technologies The Alfa Laval Niagara range of Wet Surface Air Coolers are engineered-to-order closed-loop, evaporative coolers and condensers, used in oil, gas, power and industrial applications. Each WSAC cooler or condenser is custom-designed to fit the specific application, and are tailored to meet the unique needs of the most demanding applications. Heat exchangers We manufacture a comprehensive range of heat exchangers that are designed to optimize energy utilization, while minimizing downtime. Our heat transfer solutions are efficient and durable and suited for heat transfer and heat recovery applications. Air cooled exchangers The Alfa Laval ACE air cooled exchanger range is a key addition to Alfa Laval s complete heat exchanger portfolio. The range is part of an extensive line of heat transfer, separation and fluid handling technologies. These solutions help our customers to heat, cool, separate and transport products in a wide range of industries, in more than 100 countries around the world. Separators From high-speed separators to efficient decanter centrifuges, filters and strainers, Alfa Laval manufactures advanced products to separate liquids from other liquids, solid particles from liquids, as well as particles from gases. 9

10 Extending performance Alfa Laval s global service network keeps you competitive by minimizing costs and maximizing the return on your equipment investment. With the knowledge, skills and support of Alfa Laval s global service network, you can rely on your equipment for as long as you own it. Our committed team secures performance that keeps you competitive throughout your equipment s life cycle. In short, we bring you peace of mind. Expertise at your service Alfa Laval has deep process and application knowledge, drawn from a vast experience for more than 130 years. You benefit from a long tradition of finding solutions for multiple applications worldwide. 10 Alfa Laval 360 service portfolio

11 360 service portfolio Monitoring Stopping problems before they occur saves time and money. Inspections and audits or even continuous monitoring can keep you informed of any performance changes. Condition (mechanical) audit Performance (thermal) audit Start-up We bring your equipment into operation, smoothly and safely, while respecting global guidelines. We ensure your equipment delivers as it is meant to. Installation supervision Commissioning Commissioning supervision Maintenance With proper maintenance at the right time, you can achieve higher performance and lower operating costs while maximizing your equipment s lifetime. Preventative maintenance Repair Service kits Service tools Spare parts Improvements Performance can be taken to the next level to better match your evolving needs. We can improve your equipment, letting you take advantage of the latest technical developments. Equipment upgrades Redesign Replacement and retrofit Support Assistance is always on hand. Many issues can be solved directly over the phone, and experienced troubleshooting specialists can be dispatched to your site when needed. Telephone support Training Troubleshooting Technical documentation Service hotline:

12 Alfa Laval in brief Alfa Laval is a leading global provider of specialized products and engineered solutions. Our equipment, systems and services are dedicated to helping customers to optimize the performance of their processes. Time and time again. We help our customers to heat, cool, separate and transport products such as oil, water, chemicals, beverages, foodstuffs, starch and pharmaceuticals. Our worldwide organization works closely with customers in almost 100 countries to help them stay ahead. How to contact Alfa Laval Alfa Laval Niagara Phone: sales.niagara@alfalaval.com Web: Contact details for all countries are continually updated on our website. Please visit PEP