Heat Exchangers

Practical Free Cooling System Operation Techniques

By Clayton Penhallegon, Jr., P.E., Managing Member, Integrated Services Group

Free cooling offers a highly efficient alternative to chiller-based cooling, but its success depends on effective operation and control—especially during system transitions. This article outlines practical techniques for improving the shift between chiller and free cooling modes, minimizing temperature spikes and maintaining process stability in industrial environments. It also covers strategies for enhancing chiller performance under low-temperature conditions, optimizing heat exchanger startup, setting reliable control triggers and addressing maintenance and freeze protection. With proper tuning and operation, facilities can significantly increase free cooling hours, reduce energy use and extend chiller life without risking production disruptions.

Air Compressor Heat Recovery

By Dr.-Ing. Uwe Kaiser, Research & Development Manager, BOGE Compressors
When compressed air is generated, heat is inevitably produced as a by-product. Anyone looking to enhance efficiency can use this heat and increase the efficiency of compressors to about 95 percent as a result. To achieve this, there are easy-fit heat exchangers which can be fitted to existing air compressor stations. This investment often pays for itself within less than a year.  
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The Six Basic Types of Liquid Cooling Systems

By Bruce Williams, Regional Sales Manager, Hydrothrift Corporation
There are six basic types of cooling systems that you can choose from to meet the cooling needs of your load. Each one has its strengths and weaknesses. This article was written to identify the different types of cooling systems and identify their strengths and weaknesses so that you can make an informed choice based on your needs.
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Calculating the Water Costs of Water-Cooled Air Compressors

By Manhar Grewal, Sullair
Compressed air systems are present in almost all industrial processes and facilities. They have been correctly identified as an area of opportunity to reduce electrical (kW) energy costs through measures like reducing compressed air leaks and identifying artificial demand and inappropriate uses. Water-cooled air compressors can also be significant consumers of water and reducing these costs can represent a second area of opportunity.
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Heat Recovery and Compressed Air Systems

By Frank Moskowitz for the Compressed Air Challenge®
Its simple physics that compressing air gives off heat. The heat energy is concentrated in the decreasing volume of air. To maintain proper operating temperatures, the compressor must transfer excess heat to a cooling media before the air goes out into the pipe system. As much as 90 percent of that heat can be recovered for use in your operation. If you can supplement or replace the electricity, gas or oil needed to create hot water for washrooms, or direct warm air into a workspace, warehouse, loading dock, or entryway, the savings can really add up.
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Heat-Reclaim Economics of Air and Water-Cooled Air Compressors

By Mike Wlodarski, HydroThrift Corporation
It is widely recognized that compressed air systems account for ten percent of all electricity and roughly sixteen percent of U.S. industrial motor system energy use. Seventy percent of all manufacturing facilities in the United States use compressed air to drive a variety of process equipment.
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Sustainability Projects: HVAC Optimization

By Thomas Mort, CEM
Reducing energy costs and pollution emissions involves many areas within an industrial facility.  My studies have found key (or common) areas where low cost practical projects can be implemented.  Combined, these projects provide savings exceeding 10% of the annual energy spend with an average payback of less than one year.
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