Dry Coolers Condensers PDF
Dry Coolers Condensers PDF
Dry Coolers Condensers PDF
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Contents
LU-VE Group
04
Application fields
06
Product configuration
08
Application examples
22
3
The Group
The LU-VE Group name has become the international reference
point for all that is best in the design, production and sales of
heat exchangers and other components for equipment used
in commercial and industrial refrigeration, air conditioning,
industrial applications and close control air conditioning.
The LU-VE Group of today, with its headquarters in Uboldo
(Varese), Italy, has been made possible thanks to a continuous
process of cultural and technological innovation starting in 1928
and still continuing strongly now.
The strength of the Group lies in its 9 production facilities and
sales companies, in 12 countries.
Production facilities
Changshu
ITALY CHINA SWEDEN CZECH REP. ITALY
Sales companies
4
LU-VE S.p.A - Uboldo (Va), Italy
• grooved tube technology • specialized heat exchange surfaces • certified performance levels
• innovative materials and colours • advanced design
The success of LU-VE in the international market stems from its research and development policy, its
great respect for the environment and its rigorous ethical and commercial principles.
In 2000, LU-VE was the first company in Europe to attain the prestigious Eurovent “Certify-All”
certification for the entire range of its products: unit coolers, condensers and dry coolers.
LU-VE and the Group have introduced new ways of conceiving and constructing products for refrigeration,
air conditioning and industrial applications, creating new technologies which have then gone on to
become the benchmark for the entire industry.
AIA (Asarum Industriaktiebolag), established in 1960, has over half a century of experience
in the heat exchanger business and is today one of the leading companies in the industry in
the Scandinavian market. The company is noted in particular for the excellent quality of its
products, which are designed on the principles of high efficiency and energy savings. The defining
characteristics of the company are competence, flexibility, reliability and customer care.
AIA became part of the LU-VE Group in 2012. It has a modern production facility (total area
37000 sqm, 12000 sqm covered) and a research and development laboratory in Asarum, in the
south of Sweden. AIA produces heat exchangers for industrial and commercial refrigeration, air
conditioning and industrial applications, using advanced control systems, high-efficiency motors
and water spray features.
5
DRY COOLERS AND CONDENSERS
FOR INDUSTRIAL APPLICATIONS
6
Dry coolers and condensers ranges.
• Automotive industry
7
Product configuration
Heat exchanger
LU-VE Group has always led the field
in the creation of very high efficiency
heat exchangers.
This has been made possible by
the use of sophisticated methods of
numerical simulation (CFD), capable
of predicting with precision the
fields of pressure, temperature and
velocity which are generated within
the heat exchanger, thus optimizing the heat transfer coefficient and
minimizing pressure drop.
8
Construction materials
The product has copper tubes and aluminium fins. The tubes are
mechanically expanded to guarantee the best contact between tube
and fin.
The headers of the dry cooler version are made of copper with an
aluminium floating flange attachment.
The headers of the condenser version are made of copper or carbon
steel depending on the application.
The casing of the heat exchanger is made of galvanized steel (to UNI
5961 standard), polyester-powder coated, colour RAL9003.
Corrosion resistance in compliance with EN ISO 12944, classification
“C4”.
Different materials for the heat exchanger are available on request, as described here:
The copper tubes used for the heat exchanger conform to the general
indications in Standards EN 1412 – ASTM B 111 – ASTM B 280.
The aluminium used for the heat exchanger fins conforms to the
general indications of ANSI H 35.1-88 and ASTM B 247.
Screws and fasteners are made of stainless steel AISI 304 class A2-70.
9
Fan
Axial fans are fitted, lubricated for life and balanced both statically
and dynamically.
Balance grade G6.3 (to ISO 1940 part 1).
The protective fan grilles conform to the EN 294 Standard.
10
Fan diameters 1,250 mm or more
Fan-motors with traditional internal rotors, directly coupled to the fan,
generally constructed in PPG, PAG, Al.
Insulation class F or H, protection grade IP 55. The motors can be
supplied with different grades of mechanical and electrical protection
depending on the intended type of use. These motors can be regulated
by inverter.
In this configuration, the fan group can be best suited to the needs of
the plant, permitting high levels of air quantity to be achieved and thus
maximizing heat exchange capacity at equal dimensions.
11
Accessories
The machines can be equipped with various accessories to facilitate
installation and maintenance, such as:
External connecting
headers between
the various connections
2
of the heat exchanger
12
3 Inspection panels and hinged fan shrouds
to facilitate maintenance and cleaning of the heat exchanger
13
Control and regulation systems
The machines can be supplied with different electrical
configurations for the various plant requirements, both at the
level of electrical panels and also for speed controllers capable
of modulating the capacity of the heat exchanger depending on
conditions in order to save energy.
14
Benefits of electronic regulation
15
LU-VE Group proposes EC brushless fan technology.
This guarantees even greater energy savings, thanks to the superior
efficiency of the motor.
Energy saving
90
EC- Motor
80
3~AC
70
Motor efficiency [%]
1~AC
60
50
40
30
20
10
0 50 100 150 200 250 300 350 400 450 500
Main advantages
16
In order to best command the EC fans and fully exploit all
potentialities, LU-VE Group has developed the innovative WMC2
controller which permits extremely precise regulation, reducing
noise and energy consumption at the same time. And thanks to
Modbus RTU digital communication, all information concerning
the functioning of the unit can be made available.
MODBUS
17
Codice di commessa N° 43/09 – “Ottimizzazione
Ottimizzazione strutturale di uno scambiatore di calore al fine del trasporto”
trasporto
Codice di commessa N° 43/09 – “Ottimizzazione
Ottimizzazione strutturale di uno scambiatore di calore al fine del trasporto”
trasporto
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SILENCER - THE WHISPERER®
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DRY and SPRAY®
For large capacity air cooled condensers and dry coolers.
The “DRY and SPRAY®” products work as traditional dry units until
the ambient air temperature is low enough to maintain the cooling
capacity and the coolant temperature (or condensing pressure) at the
planned conditions (dry operation).
The temperature passage from dry to spray operation is a planning
choice and usually is about 20°C.
This innovative technology also enables, depending on the ambient
air wet bulb temperature, a coolant temperature equal to or lower
than the dry bulb temperature of ambient air with significant energy
advantages.
A sophisticated control system adjusts the speed of the fans and the
nebulised water capacity as required.
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ANNUAL WATER CONSUMPTION
DRY AND SPRAY OPERATION ANNUAL WATER CONSUMPTION
SPRAY
LOWER WATER CONSUMPTION
°C Ambient Temperature OPERATING
36
33
100%
30
27 90%
24
80%
21
20 20 °C
18 70%
15
60%
COOLING
12 TOWER
9 50%
6 40%
3
0 30%
-3 HYBRID
20%
COOLER
-6
10%
-9 DRY and SPRAY
-12 0% LU-VE
-15 I N D U S T R I A L P L A N T
1 10 100 1000 10000 DRY
Annual water consumption for a generic industrial installation
Hours/Year 930 OPERATING
(on average from 3 to 10 times less than a traditional cooling tower)
The use of “DRY and SPRAY®” liquid coolers and condensers instead of
traditional “evaporative cooling towers” and “evaporative condensers”
is characterized by the following important advantages:
LESS
Water consumption! thus excluding any chance of impure water concentration and the
Energy!
Noise! general risk of environmental contamination (NO Legionella)
Pollution!
Operating cost! • Plant operating without water droplet drag-out to the environment
and the formation of ugly vapour plumes
• Low energy consumption
• Low noise operation
• Short plant redemption period
• High thermal capacity can be obtained by free cooling
NO
Health hazards (i.e. LEGIONELLA)
related to open warm
water reservoirs
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Applications and fields of use
1
Cogeneration, cooling reciprocating engines and gas turbines
CASE
This concerns applications where the maximization of the ratio of
capacity to the amount of occupied space plays a decisive role ,
especially in larger plants.
For this reason, LU-VE Group has developed the POWER range
with fan diameter of 1,250 mm, adapted for transportation by
container, having following features:
• Footprint reduction
• Shipping cost reduction (two machines can be shipped in the
same container)
• Low energy consumption.
125
120
Capacity with same foot print
115
110
105
100
95
90
EAL range ran Ø 900 mm EAL range ran Ø 1250 mm
22
23
Circuits can be single or with two circuits superimposed with
two different temperature levels (LT, HT), depending on the plant
requirements of the circuit to be cooled.
24
USING CONDENSERS
FOR ORGANIC FLUIDS
(ORCs)
CASE
2 Recently, electrical energy production plants of limited capacity
(about 100kW-5MW) based on Organic Rankine Cycles
operating with organic fluids (siloxanes, HFCs) have become more
widespread. For this kind of plant, LU-VE Group can offer an air
cooled condenser and an internal recuperator coil.
ELECTRICAL POWER
DISTRICT HEATING
HIGH TEMPERATURE
DIATHERMIC OIL
HEAT SINK
Turboden ORC units can also be run on saturated steam or superheated water.
25
The special feature of air-cooled condensers for this use is the
combination of high capacity of heat transfer, reduced temperature
difference between ambient temperature and condensing
temperature, and limited energy consumption for the fan
ventilation.
26
For this application, LU-VE Group has developed a product
equipped with low-consumption EC fans and a spray system can
also be fitted to keep the condensing temperature low even during
the hottest months of the year.
The two graphs below show the optimization for an ORC plant:
obviously, the optimum point may be found in a different
condition depending on the different design conditions. However,
the contribution of an optimized condenser to the efficiency of the
cycle appears to be very significant.
0.14 0.13
0.12
0.13
0.11
Net efficiency
Net efficiency
0.12 0.10
0.09
0.11
0.08
0.10 0.07
300 400 500 600 700 800 900 300 400 500 600 700 800 900
fan speed, RPM fan speed, RPM
Also in these cases there is an optimal fan speed, maximizing net efficiency.
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Oil & Gas industry
and special ATEX versions
The oil and gas industry requires highly reliable products, involving
thermodynamic and mechanical design aspects and also great
attention to safety considerations.
LU-VE Group can completely comply with all the criteria, thanks
also to the ASME Certification Mark with “U” designator of official
approval on its machines.
One more aspect of great relevance is the use of tubes with reduced
diameter (normally 3/8” or ½”) which drastically reduces the internal
volume. In other words, the charge of hydrocarbons present inside the
heat exchangers.
100%
30%
Traditional aircoolers Innovative LU-VE
API661 products
28
For applications in explosion risk environments, LU-VE Group has
a specific range equipped with fans which comply with the ATEX
Directive 94/9/EC for zones 1 and 2. To guarantee its complete
adherence to the official regulations, the machine displays the
EX mark. Therefore, all the sheet metal parts are treated with a
special paint which conducts current, guaranteeing the absolute
equipotential of all the surfaces: as an alternative, the machines
can also be supplied with stainless steel casings.
29
Cooling liquids in industrial processes
30
Automotive industry
The car industry has to frequently update its production and testing
facilities, increasing their efficiency, reliability and environmental
compatibility. As a result of this urgent necessity, LU-VE Group has
become the privileged supplier to the most important European
car manufactures, especially concerning the plant serving
the climatic rooms dedicated to testing vehicles and related
components. The key to success has always been LU-VE Group’s
ability to offer technologically advanced solutions, capable of
guaranteeing the best ratio of performance to cost calculated over
the entire operating life of the plant. Below, some data relative to
the consumption of energy and water for a large-scale plant in this
sector.
9000 3500
8000 2500
3000
7000
(distribution)
2000
(cumulative)
CUMULATIVE
5000 1500 2000
4000 1500
1000
3000
1000
2000 500
1000 500
0 0 0
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 34.0 26.5 24.0 21.8 19.8 17.0
ON
TRIBUTION TOTAL WATER
TOTALCONSUMPTION
WATER CONSUMPTION
FOR PERIOD
FOR PERIOD TOTAL ENERGY
TOTAL CONSUMPTION
ENERGY CONSUMPTION
FOR PERIOD
FOR PERIOD
3000 3000 4000 4000 120.000 120.000
No. HOURS IN EACH PERIOD
m3 PERIOD
3500 3500
2500 2500 100.000 100.000
3000 3000
(distribution)
(distribution)
2500 2500
kWh
kWh
m3
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Waste treatment plants
32
Chemical and pharmaceutical industry
33
Die-cooling for the production of plastics
34
Manufacturing standards
The heat exchangers are designed and constructed in compliance with the
standards and regulations in force within the European Union listed here:
Performance
All products are guaranteed to provide the performance levels indicated in our
catalogues, and all standard ranges are certified by Eurovent.
To ensure that the indicated performance levels are achieved, the products must
be correctly installed in line with the general standards of best technical practice
and following the instructions in the company manuals for use and maintenance.
ENERGY CERTIFIED
MANAGEMENT QUALITY
CERTIFY ALL SYSTEM SYSTEM
DRY COOLERS AIR COOLED CONDENSERS DX AIR COOLERS
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leadership with passion
www.luvegroup.com