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Stay Ahead of the Heat: Industrial and Commercial Refrigeration System Cooling

A walk-in cooler turns into an oasis during the summer months. While this may bring you relief, it adds stress to your commercial or industrial refrigeration system. The efficiency of any refrigeration system drops as the ambient temperature increases. Pressure within the system also increases, putting strain on the entire system. For areas with warmer climates, this happens for a longer period of time during the year. There are many ways to mitigate stress and heat in your system, but which one works best for your application?

Condenser Cooling Methods

For every refrigeration system, the condenser is generally the same. The difference between systems can vary in how the coils are cooled. The cooling methods are water, air, cascade, and evaporative. Each has its benefits and drawbacks, depending on the system type and location.

Water-Cooled

Water is efficient at conducting heat, making water-cooled condensers more efficient than other types. The water-cooled system does not vent the heat from the system into the ambient air but carries the heat away with the water leaving the coils. These condensers do require a continuous supply of water and regular maintenance to prevent the buildup of waterborne contamination.

Air-Cooled

Air-cooled condensers blow ambient air over the coils containing the high-temperature refrigerant. The fans on the air-cooled condenser are typically easy to access for maintenance. Without the requirement of running water, air cooled condensers are more environmentally friendly and cost-effective in places where water is scarce.

The performance of air-cooled condensers is dependent on ambient air temperatures. The warmer the ambient air temperature, the less efficiently air-cooled condensers will operate.

Cascade Systems

Cascade systems use a secondary refrigerant to cool the primary. This method is more efficient than traditional refrigeration systems because cascade systems use less energy per ton of refrigeration while operating at full load. A cascade system is more efficient at producing colder temperatures, and a colder temperature freezes your product faster.

Evaporative Cooling

Evaporative cooling removes heat from the condenser coils by spraying water directly on the surface and blowing air over them. The heat is carried away with the evaporated water. This results in the system operating more efficiently due to the decreased pressure within the coils.

Adiabatic Cooling

Similar to evaporative cooling, adiabatic cooling draws air through water-soaked pads, typically at high ambient temperatures and higher cooling loads. This type of cooling combines the ease of owning an air-cooled condenser with the efficiency of a water-cooled condenser. With a lower water requirement, adiabatic cooling also saves on water consumption.

Charge Saver

A charge saver is refrigeration equipment specifically designed for CO₂ systems. It is an auxiliary condensing unit that helps prevent an unwanted partial or complete loss of refrigerant during downtime caused by a power outage, an emergency shutdown, or maintenance. During downtime, the system cannot cool itself, thereby increasing its overall temperature. As the temperature in the system increases, so does the pressure. Powered by a generator, the charge saver automatically starts to cool the CO₂ during downtime and makes the flash tank the lowest pressure point in the system. This will cause the CO₂ to migrate to the flash tank, which can hold a large volume of refrigerant. This also keeps the flash tank pressure below the design pressure, preventing the charge from venting through safety relief valves. Charge savers are not only for new systems, but they can also be retrofitted to existing CO2 systems.

Find Your Method for Peak Efficiency

The type of condenser cooling required and the use of a charge saver vary depending on the refrigeration system’s application and location. Some methods, like adiabatic cooling, provide greater flexibility in their application. To get more information on condensers, charge savers, or what is right for your system, visit our products page or contact a sales rep