Energy costs continue to rise across all industries, and sustainability is the competitive advantage. This means the right temperature control strategy can help you significantly cut energy usage without compromising process reliability.
For many industrial applications, a dry cooling system is a smart way to achieve both goals. When used under the right conditions, dry coolers (free coolers) can dramatically reduce operating costs and extend the life of your cooling equipment.
For Quick Background:
A dry cooler is an air-cooled heat exchanger that removes heat from process water using ambient air, eliminating the need for evaporative cooling. Dry coolers have a straightforward and sustainable principle:
- The hot process fluid, typically water or a water-glycol mixture, is pumped through a heat exchanger, also called a “coil, ” located outdoors.
- As the process fluid flows through the coil, a fan blows ambient air across the coil. This causes the heat from the process fluid to transfer to the air. Usually, a minimum difference of 10°F (~5°C) is enough.
- The process fluid is then pumped back into the facility to cool the equipment or process it is intended to cool.
Important to note:
Dry coolers still require water in the process loop, but unlike evaporative cooling towers, they don’t lose water to evaporation.
Compared to chillers or cooling towers, dry coolers are simpler, cleaner, and more energy-efficient in the right environment.
Learn more about: What is a Dry Cooler (Free Cooler) & How Does It Work?
The Energy-Savings Advantage of Dry Coolers
Dry cooling systems help reduce energy costs in several ways:
- Reduced Compressor Usage:
When outdoor temperatures are low enough, a dry cooler can replace or supplement chiller operation, reducing high-energy compressor usage. - Lower Pumping Costs with VFD-Controlled Centrifugal Pumps:
At Delta T Systems, we combine centrifugal pumps with variable frequency drives (VFDs) to precisely match flow to process demand — minimizing wasted energy. - Dry Cooling Opportunities:
“Dry cooling mode” takes advantage of cool outdoor air to remove heat from the process water without mechanical refrigeration, reducing power draw to just fans and pumps.
Learn more about: Common Industries That Benefit From Dry Cooling Technology.
Dry Cooling Integration with Chiller Systems
Dry cooling doesn’t have to be an all-or-nothing choice. Our Dry Cooler/Chiller Combo Unit is purpose-built for many facilities to benefit from hybrid cooling solutions:
- In cooler months, the dry cooler handles most or all of the heat load.
- In warmer months, the chiller takes over, or both work together in series for improved efficiency.
Automated switchover controls make it seamless, ensuring the system always runs in the most energy-efficient mode possible. Using a Delta T Systems Dry Cooler System gives you a year-round, optimized temperature control solution for your industrial process.
ROI for Dry Cooling Systems
Dry cooling systems are engineered to minimize or eliminate evaporative water consumption by using air instead of water as the cooling medium. While ROI varies by site, climate, and process, industry data reveals consistent trends that make dry cooling especially attractive in the right conditions.
Key ROI Insights
- Water & Cost Savings:
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- Studies show dry cooling can reduce water usage by 75-95% compared to wet-cooled systems.
- Savings can be seen as $1,000-$2,000 per acre-foot of water conserved annually, depending on local rates.
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- Energy & Operating Cost Impact:
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- In cooler climates, hybrid cooling can cut chiller energy use by up to 70% during colder months, dramatically lowering annual electricity spend.
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- Performance Considerations:
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- Direct dry cooling is most efficient when process temperatures are above ambient air temperature for significant parts of the year.
- Hybrid systems mitigate efficiency drops in warmer months, keeping ROI strong year-round.
Smart Industrial Cooling for a Sustainable Future
Dry cooling systems deliver measurable water savings, significant seasonal energy reductions, and reduced maintenance — especially in climates where dry cooling is viable for much of the year.
At Delta T Systems, we custom-design each system for your specific process and environment. Need more information? Check out our Dry Cooler Systems and Dry Cooler/Chiller Combo Units.