Superior reliable performance

Niagara Wet Surface Air Coolers for fluid cooling and vapor condensing

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Designed for coldest process outlet temperatureAlfa 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 closed-loop 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

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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

ApplicationsThe 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 CO2

• Natural gas• Nitrogen

Vapor condensing

Up to 450°F max inlet temperature• Vacuum steam (1.4" HgA minimum)• Ammonia• Hydrocarbons – propane, ethane, propylene• Refrigerants

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WSAC® systems for fluid cooling and vapor condensingThe 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.

• 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

Packaged WSAC systems

Modular WSAC systems • Expand or contract based on

process requirements

• Direct drive fan system

• Heavy duty 10-12 gauge steel

• High flow, low pressure industrial pump system

• No plastic fill

• Nut and bolt assembly – no “zip” screws

• Access package available

• 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

Field erected WSAC systems

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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.

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)

Tube bundlesSerpentine

• Fully welded headers

• ASME, PED code designs

• Cost effective

• High pressure (3,500 PSI)

• Various metals (C.S., S.S.)

Electrical controls • 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

• Pump skids with available redundancy

• Water treatment skids

• Field commissioning and start-up

• Access packages (ladders, walkways, platforms)

• Complete pre-wired systems with controls

Ancillary components

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How it works

Warm process fluid flows through tube bundles which are sprayed with water . Air is drawn down over the tubes by fans , creating a cooling effect by evaporating the water. The water not evaporated is collected in a basin and pumped back to the top of the unit to begin the process again . The evaporated water and air are discharged from the top of the unit by the fan to the atmosphere .

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Evaporated water

Make up water

Blowdown

Cycles of concentration in a WSACEvaporation (GPM) = Heat Load (Btu/hr)/~500000 (same as CT)Blowdown = Evaporation / Cycles –1Total makeup = Evaporation + Blowdown

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Water usage

Water saving benefitsAs compared to cooling tower water costs, the WSAC system provides significant savings in operating expenses including:

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

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Technology comparison

Wet Surface Air Cooler (WSAC)

Cooling tower plus heat exchanger

Dry cooler

Thermal system

Latent Latent / sensible Sensible

Practical approach temp.

10F WB (5.5C)10F for CT WB (5.5C)

5F for HX (2.7C)15F DB (8.3C)

Coldest practical process temp.

89F (29.5C) 94F (34.4C) 115F (46.1C)

Water use /management

High cycles of concentration

Low cycles of concentration due to HX

Air only

Electrical consumption

Low Medium High

Total system plot space

Small Medium - Large Medium - Large

Water cost Low - Medium High Not applicable

Total system cost

Low - Medium High Medium - High

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)

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

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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.

Alfa Laval wet/dry hybrid auxiliary cooling

AdvantagesHaving 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

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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.

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Extending performanceAlfa 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 serviceAlfa 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.

Alfa Laval 360° service portfolio

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360° service portfolio

Start-upWe 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

MaintenanceWith 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

MonitoringStopping 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

ImprovementsPerformance 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

SupportAssistance 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: +1 800-426-5169

PEP00122 1610

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 NiagaraPhone: +1 716-875-2000Email: sales.niagara@alfalaval.comWeb: www.niagarablower.com

www.alfalaval.com/air

Contact details for all countries are continually updated on our website. Please visit www.alfalaval.com.