Cooling for people and process in ways that are healthy and eco-friendly. For more information log on to www.ategroup.com

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A.T.E. ENTERPRISES PRIVATE LIMITED
Business Unit: HMX
v1.0– updated 17th Feb ‘15
A Seminar on:
Innovative Cooling Solutions with:
“Indirect Evaporative Cooling”
By:
Sunil Tiwari
Sanjiv Sachdeva

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Introduction
To
PSYCHROMETRICS

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PSYCHROMETRIC
PROCESSES

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SENSIBLE HEATING OR COOLING:
The addition or removal of heat,
without any change in the moisture
content (AH), resulting in the change
in DBT.
The status point will move horizontally
to the left (cooling) or to the right
(heating).
Note that while the AH does not
change, the change in temperature
means the relative humidity (RH)
changes. It increases if the
temperature lowers and vice versa.

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If, as a result of cooling, the point
moving towards the left reaches the
saturation line, some condensation will
start. The DBT corresponding to
this point is referred to as the dew-point
temperature of the original atmosphere.
If there is further cooling, the status point
will move along the saturation line and
condensation will occur.
DEHUMIDIFICATION BY COOLING:
The reduction in the vertical ordinate (on the AH scale) represents the amount of
moisture precipitatied, ie, condensed out. This process will reduce the absolute
humidity, but will always end with 100% RH.

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If moisture is evaporated into an air volume
without any heat input or removal (this is
the meaning of the term 'adiabatic'), the
latent heat of evaporation is taken from the
atmosphere.
The sensible heat content - thus the DBT -
is reduced, but the latent heat content is
increased. The status point moves up and
to the left, along a WBT line. This is the
process involved in evaporative cooling.
ADIABATIC HUMIDIFICATION
(EVAPORATIVE COOLING):
Note that by this process, the relative humidity is increased. It increases only until it
hits the saturation line, at which it becomes 100%. Beyond it there is no decrease in
sensible temperature. This is the reason why during hot and humid months,
evaporative cooling is ineffective and uncomfortable.

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If the air is passed through a chemical
sorbent material (eg, silica gel), some of
the moisture is removed and the latent heat
of evaporation is released.
There will be an increase in sensible heat
content, thus in the system (ie, if the
process is adiabatic), the state point will
move down and towards the right along an
enthalpy line.
This process, in effect is the reverse of the
previous one.
ADIABATIC DEHUMIDIFICATION
(BY SORBENTS):

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If two air streams are
mixed, having:
-mass flow rates m1 and m2,
-dry bulb temperatures t1and t2,
-enthalpies H1and H2,
the result will be:
m1t1 + m2t2 = [m1 + m2]t3,
m1H1 + m2H2 = [m1 + m2]H3
Therefore:
t3 = (m1t1 + m2t2) / m1 + m2
H3 = (m1H1 + m2H2) / m1 + m2
MIXING:
The psychrometric chart can be used to establish the value of t3 and H3. The two
state points are connected by a straight line, which is then divided in inverse
proportions of m1 and m2. If the mass flow rate m1 is the greater, the resulting point
P will represent the state of the combined air stream.

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1 →→→→ 2 Return air duct gains
2 →→→→ 4 Outside air load
3 →→→→ 4 Energy recovery
4 →→→→ 5
Cooling /
Dehumidification
5 →→→→ 6 Fan motor gains
6 →→→→ 7 Reheat coil input
7 →→→→ 8 Supply duct gains
Conventional Refrigeration System

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18
Points on the chart
1 Room condition 25°CDB 50%RH
2 Return air to unit 25.5°CDB 18.2°CWB
3 Outside air 35°CDB 24°CWB
4 Mixed air into coil 26.5°CDB 18.8°CWB
5 Air off coil 12°CDB 11°CWB
6 Air off fan 12.7°CDB 11.3°CWB
7 Air off reheat coil 14.3°CDB 12°CWB
8 Air into room 14.8°CDB 12.2°CWB

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What is ‘Comfort Conditioning’?
Comfort conditioning relates to human comfort. The
surrounding air needs to be treated so that the person
occupying the place feels fresh & comfortable.
Factors that directly affect human comfort:
Temperature
Relative humidity
Air motion
% of fresh air
Personal activity
Clothing

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Adaptive Model of Comfort

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Cooling Solutions -
(For people comfort & process requirements)
COOLING TECHNOLOGIES
Conventional – Refrigerant
Based Technologies
Vapor
Compression
Type
Vapor
Absorption
Type
Non-refrigerant Based (Eco-
friendly) Technologies
Free Cooling
Earth
Cooling
Night
Ventilation
Evaporative
Cooling
Technology
DEC
(Direct
Evaporative
Cooling)
IEC
(Indirect
Evaporative
Cooling)
IDEC
(Indirect
Direct
Evaporative
Cooling)

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Evaporative cooling: Two approaches
Direct Evaporative Cooling (DEC):
Water evaporates directly into the air
stream, thus reducing the air
temperature while humidifying the air.
Indirect Evaporative Cooling (IEC):
Primary air is cooled sensibly with a
heat exchanger, while the secondary
air carries away the heat energy from
the primary air as generated vapor.

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Evaporative cooling continued …
Principle of IDEC (indirect direct evaporative cooling)
Two-stage evaporative air cooling
Dry bulb temp: D1
Wet bulb temp: W1
Enthalpy: h1
Dry bulb temp: D2
Wet bulb temp: W2
Enthalpy: h2
Dry bulb temp: D3
Wet bulb temp: W2
Enthalpy: h2
In IDEC process:
D3<D2<D1
W2<W1
h2<h1
Cooling effectiveness (Є): D1-D3
D1-W1
IDEC process Є is always >100%;
nearly120% for summer

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Psychrometry :
Dubai Conditions DBT-46°C / Rh-30%
Outdoor (Ambient): DB 46⁰C, WB 29.4⁰C, Sp Humidity 19.33 g/Kg
DEC Outlet : DB 30.2⁰C, WB 29.44⁰C, Sp Humidity 26.10 g/Kg
IDEC Outlet : DB 26.7⁰C, WB 26.4⁰C, Sp Humidity 21.90 g/Kg
3.5°c more
cooling
Low moisture
addition -
60% less

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HMX, a business unit of the A.T.E. Group
A.T.E. has a legacy of over 75 years, operates in the domains of:
• Textile Engineering
• Cooling
• Wastewater Treatment
• Energy Efficiency
• Value Enhancing Systems
• Machine-to-Machine Solutions
• Flow Technology
• Print and Packaging Equipment
HMX, a business unit of A.T.E., designs and manufactures unique,
energy efficient and eco-friendly products for space and process cooling
for the industrial and commercial sectors. The core of every HMX product
is DAMA (Dry Air Moist Air), a new generation patented sensible heat
exchanger.

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SO FAR…
Solutions with Indirect Evaporative Cooling
• Stand-alone cooling: Two Stage Evaporative Cooling System
• Pre-cooling: Treated Fresh Air System
• Fresh air air-conditioning: IDEC + Air conditioning
HMX – AMBIATOR
HMX – PCU – F HMX – FAAC

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Stand-alone cooling units….. HMX Ambiator
• These cooling units are a next-generation indirect direct evaporative cooling
solution
• This patented technology provides 100% fresh, clean, cool air – which is an
excellent upgrade over air-washers & ventilation systems which are
commonly used for cooling in industrial and commercial sector
• Can be integrated with other air handling systems and air conditioning
systems to optimize power consumption
• Available in various capacities
Small up to 10000 CFM
Medium 10000 to 30000 CFM
Large 30000 CFM onwards
Energy saving potential upto 60% with regard to conventional air-conditioner

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Indirect Direct Evaporative Cooling (IDEC)
With indirect/direct evaporative cooling, the primary air stream is cooled first with
indirect evaporative cooling and then cooled further with direct evaporative cooling.

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Psychrometric representation

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CASE STUDY-1:
IDEC helps a global company improve indoor air quality
Sr. no. Challenges faced by the company Solutions suggested by HMX
1
Possible hazard to health of workers from fumes
generated by carbide grinding wheels
100% fresh, clean and cool air to be supplied to
improve indoor air quality
2
Sensible heat load generated inside was 400000
BTU/hr (117 kW)
40,000 CFM of cool air to be supplied to the shop
floor
3
Extremely hot summer in Hyderabad when the
ambient temperature touches 42°C
Supply air to be cooled by indirect direct
evaporative cooling technology
4
Temperature on the shop floor to be maintained at
29±2°C
Temperature of supply air to be lower by 3-4°C
compared to conventional air-washer systems
• This is an engineering giant, a high technology global industrial group with world-
wide operations
• The group has a carbide grinding facility in Hyderabad, South India

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CASE STUDY-1:
IDEC helps a global company improve indoor air quality
Sr. No. Date Time Ambient temperature °C Room °C
DBT WBT DBT WBT
1 16/4/14 1.30 pm 36 24 25 22
2 16/4/14 2.30 pm 38 24 26 22
3 16/4/14 3.00 pm 38 24 26 21
• The HMX-Ambiator was installed and commissioned at this plant in January 2014

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CASE STUDY-1:
IDEC helps a global company improve indoor air quality
• The fumes and the heat generated by the carbide grinding machines is carried
away by the air supplied by HMX-Ambiator
• This has improved the indoor air quality and is also maintaining comfortable
working conditions inside

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CASE STUDY-2:
IDEC helps Mahindra& Mahindra, Nagpur to improve productivity
Sr. no. Challenges faced by the company Solutions suggested by HMX
1
Extremely hot summer in Nagpur when ambient
temperature goes up to 47°C
Indirect direct evaporative cooling suggested
keeping in mind the excellentWBD during
summer
2 Hot conditions around the tractor assembly line
Dedicated HMX-Ambiator of 32,000 CFM for
people working on the tractor assembly line
3
Cooling provided by installed chiller system
proving to be inadequate for worker comfort
HMX-Ambiator to work in tandem with chiller
system
4 Installing a cooling system with a good product life
HMX-Ambiator of blow through design to
eliminate possibility of blower rusting
• Mahindra & Mahindra is the largest tractor manufacturing company in the world (by volume)
• The manufacturing plant at Hingana Road, Nagpur rolls out 90,000 tractors per year

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CASE STUDY-2:
IDEC helps Mahindra& Mahindra, Nagpur to improve productivity
Sr. No. Date Time Ambient temperature °C Room °C
DBT WBT DBT WBT
1 24/3/14 1.00 pm 38 22 25 21
2 24/3/14 2.30 pm 40 22 26 22
3 24/3/14 4.00 pm 39 23 27 23
• The HMX-Ambiator was installed and commissioned at this plant in February 2014

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CASE STUDY-2:
IDEC helps Mahindra& Mahindra, Nagpur to improve productivity
• Rusting of moving parts eliminated as a result of blow through design
• Filtered secondary air ensured more robust operations
• Excellent performance eliminated the need of the chilled water system
• Reduced carbon footprint

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Pre-cooling units
• Pre-cooling units are an excellent option to supply cooled fresh air to
improve indoor air quality while simultaneously reducing the load on the
compressor of the installed air conditioning system.
• Uses the heat exchanger to pre cool fresh air being supplied to air
conditioned spaces or air handling units in the most economical manner.
• Also an excellent option where the entire fresh air load is handled by the
chiller or a DX system. Retrofitting of the existing fresh air handling unit is
also possible with Pre-cooling units.
• Can be modified to use the room return air to pre-cool the fresh air being
supplied.
Energy Efficiency Ratio (EER) is more than 15

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Pre-cooling (IEC + DX/CWC)
The primary air stream is cooled first with indirect evaporative cooling. This cools the
primary air stream to the desired temperature. When more cooling is required,
the supplemental DX/CWC module cools the air further to reach the desired temperature.

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Psychrometric representation

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Air Conditioning in commercial spaces
SO FAR…SO FAR…SO FAR…SO FAR…SO FAR…
Conditioned space
ReturnDuct
SupplyDuct
MixingBox
Filter
CoolingCoil
Exhaust Air
Fresh Air

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Schematic of pre-cooling unit
SO FAR…SO FAR…SO FAR…SO FAR…SO FAR…
Conditioned space
ReturnDuct
SupplyDuct
MixingBox
Filter
CoolingCoil
Exhaust Air
CoolingCoil
DAMA
Filter
Fresh Air
Secondary Air to Atm.
PCU – F AHU

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Retrofitting PCU to conventional HVAC
Office Complex, 50,000 ft2
Space temperature 24 ˚C
Occupancy 1000 people
Ventilation requirement 10000 cfm
Sensible Heat Exchanger: HMX’s
proprietary “DAMA” inside the PCU - F
Energy
Consumption
08.00 – 18.00 h 08.00 – 24.00 h 24 h operation
Benchmark
With
PCU - F
Benchmark
With PCU -
F
Benchmark
With PCU
- F
Total energy
consumption,
MWh / year
126 93 186 144 246 198
Energy savings,
MWh / year
33 42 48

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Case Study: HMX PCU
Bilcare saves chiller opex
• Bilcare is an innovation-led solutions provider that is a global
leader in the field of pharmaceutical packaging.
• The Rajgurunagar plant of Bilcare had set up a new triplex
laminating line with a raw material storage area.
• The temperature inside was to be maintained at 26 ± 0°C
throughout the year with a RH level of 55 ± 5%.
• Two Air Handling Units (AHUs) with chilled water coils, one with
26,000 CFM and the other with 13,000 CFM were used.
• The summer months the fresh air coming into the chilled water
AHUs was at 40-45°C

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Case Study: HMX PCU
Bilcare saves chiller opex
Two fresh air pre-cooling units HMX-PCU-F without blowers were installed
for the two chilled water AHUs
Airflow Ambient
DBT
Ambient
WBT
WBD After
HE-1
DBT
After
HE-1
WBT
Savings
–
Sensible
cooling
Savings –
Sensible
cooling
Power
consu
mption
/ TR
Power
saved
CFM °C °C °C °C °C kW TR kW/TR kW/h
26000 33 21 12 24 16.5 136.5 39 1.2 46.8
13000 33 21 12 23.5 16.5 68.25 20 1.2 23.4

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Fresh Air Air-conditioning (FAAC)
Different modes of operation to suit prevailing ambient conditions
1. Ventilation mode: only fresh air
2. Indirect evaporative cooling mode: only DAMA (sensible heat
exchanger)
3. Ambiator mode: indirect + direct evaporative cooling
4. Fresh air pre-cooling mode: DAMA + cooling coil
5. Air-conditioner mode: cooling coil with re-circulated air
6. Heating with humidification mode: cooling pad + heater with re-
circulated air

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Case Study:
FAAC For Himalaya Drug’s Stores
• The Himalaya Drug Company is a leading multinational medicinal drug company.
It produces health care products under the name Himalaya Herbal Healthcare.
• Its existing finished goods warehouse of approximately 16,000 square feet area
faced issues of high temperature during the summer season and high humidity
during the monsoon season.
• The ideal environment to store the manufactured goods was to maintain
temperatures under 26°C throughout the year and humidity levels between 55%
and 60% in the monsoon season.
• The HMX-Ambiator was sufficient to deliver these temperatures 70% of the time
in a year. For the balance 30% time of the year, air-conditioning of the warehouse
was the ideal solution.
• As a result an air-conditioning system of only 25 TR was required instead of the
originally planned 80 TR.

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Case Study:
FAAC For Himalaya Drug’s Stores
Time Ambient – DBT
°C
Ambient – WBT
°C
Room – DBT °C Room – WBT °C
1:30 PM 27°C 23°C 25°C 22°C
3:30 PM 26°C 23°C 25°C 22°C
Time Ambient –
DBT °C
Ambient –
WBT °C
Room – DBT
°C
Room – WBT
°C
1:30 PM 36°C 22°C 25°C 18°C
3:30 PM 34°C 22°C 25°C 18°C
Temperature recordings taken during the when the unit was running in 100%
fresh air mode
Temperature recordings taken during the when the unit was running in air-
conditioning mode

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Markets served
Auto/auto ancillaries Commercial Engineering FMCG
Print & Packaging Rubber & mouldingPharmaceuticalFood & Beverages

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Applications

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SO FAR…
Organizations using and recommending
these sustainable technologies

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Why is Middle East one of the largest
HVAC market?
• Extreme climatic conditions of the desert
• Ongoing drive towards diversified businesses away from the
traditional petro based economy
• Growing capital investment in infrastructure development
• Rising population with high standards of living
Moving ahead, smart buildings and environmentally
sustainable HVAC systems across commercial, residential,
hospitality and retail user segments in this region will aid in
further driving the HVAC market

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Cooling performance: Supply Air Temp profile
IDEC supply air temperatures spread for a complete year
(8760 Hrs) for Abu Dhabi
VENTILATION DIRECT INDIRECT - DIRECT
No of Hrs in % No of Hrs in % No of Hrs in %
S A Temp ≤ 20 1655 19% 3374 39% 4609 53%
S A Temp 20.01 - 22.00 724 8% 1315 15% 1416 16%
S A Temp 22.01 - 24.00 812 9% 1234 14% 904 10%
S A Temp 24.01 - 26.00 719 8% 1102 13% 805 9%
S A Temp 26.01 - 28.00 827 9% 1059 12% 701 8%
S A Temp 28.01 - 30.00 864 10% 605 7% 314 4%
S A Temp 30.01 - 32.00 812 9% 71 1% 11 0%
S A Temp 32.01 - 34.00 644 7% 0% 0%
S A Temp 34.01 - 36.00 557 6% 0% 0%
S A Temp 36.01 - 38.00 469 5% 0% 0%
S A Temp≥ 38.01 677 8% 0% 0%
8760 8760 8760

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Questions?

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THANK YOU
Contact:
Mail: s_a_tiwari@hmx.co.in / svs@gessuae.ae
Web: www.hmx.co.in / www.gessuae.ae