Transcript Document

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CREATING INNOVATIVE MISTING SOLUTIONS SINCE 1994
“HARNESSING THE POWER OF MIST”
To Increase Efficiency of Industrial Air Cooled Systems
Presentation Outline
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Introduction
Cloudburst® Key Milestones
How Misting Works
Misting System Components
Cloudburst® High Pressure Cooling Systems
Chill-N-Save Pre-Cooling Systems
Open Discussions
Introduction (CLOUDBURST®)
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CLOUDBURST® is a leading manufacturer of misting systems
in the U.S – main focus is on commercial & industrial application but we also have several
patented retail products sold through our Mist & Cool Line or private license agreements
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A global leader in the mist industry since 1994
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Number one in experience, quality and services
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A reputation for innovation and new product development
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Hundreds of dealers worldwide
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Thousands of industrial and commercial installs
Cloudburst is a privately held and self financed California Corporation. Cloudburst has been
consistently profitable with sales derived from commercial and industrial equipment sales, retail
product sales and product licensing.
CLOUDBURST Factory in Oxnard, California
Key Milestones of
®
Cloudburst
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1994: founded by Steve Wright, a former NFL Raider player
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1996: provided cooling equipment to 1996 Atlanta Olympics
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1996-2009: manufactured Mist&Cool retail line of products
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2004: launched Cool&Save AC pre-cooling products
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2007: set up Authorized Dealer Program, expanding
overseas (Mexico, Saudi Arabia, Australia, south Asia,
and 40+ countries)
2007: established Chill-N-Save Division, focusing on
industrial pre-cooling applications (AC/refrigeration,
dry cooling towers, turbines)
2009-2010: launching sanitizer, WindChiller®, and
other new products
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How Misting Works
Evaporative cooling
• Dry bulb, wet bulb temperatures and dew point
• Cooling potential
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Evaporative Cooling
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One gallon of water has ~8,000 BTU of cooling potential (heat of
vaporization)
 The more efficiently water is evaporated, the more of its full
cooling potential can be realized
 The greater the surface area, the quicker it evaporates
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Misting system uses ultra low flow atomization nozzles to form a
mist of fine water droplets in µm sizes (~1/10 of a strain of hair)
– 1 gal of water has a surface area greater than a Soccer Field
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Once released into air, water droplets quickly absorb heat in the
ambient and evaporate, thus cooling the air
1 Gallon =
Water Phase Change Diagram
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Heat of vaporization = 540 cal/g = 2,260 kJ/kg
1 gal of water = 3.785 kg, 1 BTU = 1.055 kJ
Heat of vaporization for 1 gal of water = 2,260 kJ/kg x 3.785 kg x
(1BTU/1.055 kJ) = 8,109 BTU
AC vs. Misting System
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A 1-ton (12,000-BTU/hr)
window AC uses 7 amps:
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Cooling Capacity = 12,000 BTU/hr =
3,517 W
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Energy Consumption = 7 amp x 220 V
= 1,560 W
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A 1.18-gpm misting pump uses
6.3 amps:
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Cooling Capacity = 8,000 BTU/gal x
60 min/hr x 1.18 gal/min = 566,400
BTU/hr = 166,000 W (or 47 tons)
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Energy consumption = 6.3 amp x 220
V = 1,386 W
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Equivalent COP = 166,000 W/(1,386
W) = 120
COP = 3,517 W/(1,556 W) = 2.3
Evaporative Cooling Under Typical
Humid Climate Conditions
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Example Evaporative Cooling Potential For
Hot & Humid Climates
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Shanghai Temperature and Humidity Plot - August 15, 2010
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100%
90%
Temperature (℃)
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80%
70%
30
60%
50%
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Temp
40%
Dew Point
30%
RH
Source: www.wunderground.com
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20%
Time
Potential Cooling Chart
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Starting Air Temperatures (℃/℉)
Humidity
30/86
35/95
41/106
10%
13/55
16/61
19/66
30%
19/64
22/71
26/78
50%
23/70
26/79
30/86
70%
26/77
30/86
34/93
90%
28/83
33/91
37/99
The highest temperature reduction we’ve
ever achieved was 53 ℉ (29.6 ℃) at a
copper smelting plant
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Misting System Components
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Nozzles
Pumps
Fans
Misting Lines, Fittings, and Controls
Nozzle Characteristics
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Spray Characteristics: Produces a
high percentage of < 10 µm droplets
at medium to high pressure ranges
Spray Pattern: Cone-shaped fog
Spray Angle: 45-120 degree
Flowrate: 0.006-0.045 gpm (1.4 -10
LPH)
Droplet Size Distribution
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100%
50%
80%
40%
60%
30%
1000 psi
800 psi
650 psi
500 psi
350 psi
250 psi
1000 psi
40%
20%
20%
10%
0%
0%
0
5
10
15
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Droplet Size (microns)
Flow Rate (gpm) = K √PSI
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30
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Volume Frequency (%)
Cumulative Volume Frequency (%)
Droplet Size Distribution of CB108 Nozzle with 0.008 inch (0.15 mm) Orifice
Droplet Size Distribution
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External impaction-pin type nozzle with 0.006” orifice @2000 psi
Flowrate vs. Pressure
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4.00
Flowrate, gph
3.50
3.00
2.50
0.006"
2.00
0.008"
1.50
0.012"
0.015"
1.00
0.020"
0.50
0.00
0
500
1000
Pressure, psi
1500
Flowrate vs. Orifice Size
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Fog vs. Pressure
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~200 psi
~500 psi
~1,000 psi
Triplex Piston vs. Wobbler-Plate
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Standard Pump Modules
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Flow Range: 0.25 to 2.2 gpm
Complete with Balder motor, pressure switch, solenoid valve,
and water filtration
Powder-coated or stainless steel enclosures with pressure
gauge and water-proof switches for outdoor applications
Custom-Made Pump Assemblies
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Flow Range: 2.2 to 72 gpm
Steel stand equipped with pump control box, multi-stage water
filtration, reverse osmosis (optional), and UV disinfection
(optional)
Misting System Controls
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Cloudburst® provides a wide variety of controls for specific
applications, from proven commercial controls to customfabricated solutions with varieties of control parameters, such as
temperature, humidity, time, etc.
Our philosophy is to use the finest components and integrate only
the controls needed for each application
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High Pressure Misting Systems
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Applications
Case Studies
Applications
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Cloudburst® misting systems are a cost-effective solution to cooling a
wide array of applications:
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Industrial/Process Cooling
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Commercial/Residential Cooling
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Humidity Control
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Animal Cooling/Dust and Odor Control
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Special Effects
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Case Studies
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Jamarat Bridge, Saudi Arabia (2010-11)
Reflection Pond, Mexico (2010-11)
Mexico City Subway, Mexico (2009-10)
Stairmaster Factory (1997)
1996 Atlanta Olympics (1996)
Jamarat Bridge, Saudi Arabia (2010)
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“Reflection Pond” in Mexico 2010-11
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Mexico City Subway, Mexico (2009)
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Installed 30 cooling stations in the
subway, reducing the temperature from
36 to 26-27 ºC
Train movement found to help spread
the mists and cool the air
Stairmaster Factory
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Space to be Cooled: 3,000,000 ft3, area = 110,000 ft2
Fan Used: Nine, 24 to 52”
Cooling Effect: Temperature reduced from 41 to 29 ºC
Summer 1996 Atlanta Olympics
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Cloudburst® was the sole
supplier of cooling equipment
to 1996 Atlanta Olympics
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Chill-N-Save™ (a division of Axess1 Group, LLC)
“HARNESSING THE POWER OF MIST””
To Increase Efficiency of Industrial Air Cooled Systems
The Challenge
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Air conditioning (AC) can consume up to 75% of a typical
building’s energy usage
As outdoor temperature rises, performance of AC condensers
decrease, thus increasing energy usage
Excessive cooling loads on a condenser shorten its life
expectancy and even cause AC to shut down
Thermostat Setting (°F)
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75
72
% of Electric Bill Consumed by AC
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74
95
The Solution – Chill-N-Save™ AC Pre-Cooling
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The system works by cooling the air around the AC unit with a super
fine mist. This mist evaporates instantly, significantly cooling the
ambient air temperature around the unit (up to 30oF). This allows
the condenser and AC coils to transfer heat much more efficiently:
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Head pressure and amperage draw are reduced
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Output temperature is reduced
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“Time-on” cycles are reduced
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Energy consumption is reduced
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Coefficient of performance (COP) is increased
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Life of condenser is extended
Chill-N-Save™ Applications
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Can be used on any air-cooled AC/refrigeration, Cooling Towers
and other equipment
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Chill-N-Save™ Components
Smart Pumps
• Smart Arrays
• Smart Release Technology (SRT)
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Smart Pumps
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A medium pressure, low amp
booster pump with built-in
proprietary electrical control
system
Senses condenser activation
through a low voltage relay
sensor and releases just enough
treated water to each nozzle
Adapts modular design with four
outlets capable of handling up
to four individual condensers
with cooling capacity up to
~100 tons
Custom High Pressure Models
used for larger equipment such
as Cooling Towers
Smart Arrays
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Arrays of customized misting arms and nozzles designed to
meet specific HVAC equipment specifications and environmental
conditions. They safely attach to the outside of coils. Once
installed, each nozzle is positioned and field calibrated to
produce the best mist pattern for optimal performance.
Ways to Inhibit Scaling on Coils
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Uses proprietary formulation of scale and corrosion
inhibiting agents commonly used in boilers and cooling
towers
All materials are USDA food grade and safe to the
environment
Use Smart Release Technology (SRT) to dispense agents to
water
In areas with extreme hardness, other techniques such as RO
and proprietary polyester membranes, can be used
Research and Testing
• Tulane University
• Hong Kong Polytechnic University
• Plan B Logistics
• Average Test Results
Research & Testing
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A Study by Tulane University (05/20/2005):
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Both evaporative cooling of air and evaporation of water on fins of a
condenser reduce temperature of fins, thereby increasing heat transfer from
condensing refrigerant
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At 20% RH, CNS lowered fin temperature by 14.1°K and increased heat flux
by 170%
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At 70% RH, fin temperature lowered by 6.1°K and heat flux increased by
76.8%
Under ideal conditions, savings can be > 30%
20% Humidity
70% Humidity
Heat Flux
(W/m2)
Fin Temp
(ºK)
Heat Flux
(W/m2)
Fin Temp
(ºK)
Without CoolNSave™
400.4
301.0
400.4
301.0
With Evaporative Cooling Effects
616.6
296.9
565.9
297.9
With Evaporative Cooling and
Water Evaporation Effects
1080.5
286.9
708.2
294.9
Source: “ Improvement on the Efficiency of Condensing Units: - Analysis of the CoolNSave™” (Chodak and Murphy, 2005)
Research & Testing
Hong Kong Polytechnic University and Logistics Engineering
University in Chongqing, China (2009):
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A simulation analysis on an air-cooled chiller equipped with a water mist
pre-cooling system under head pressure control was used to examine
effects of pre-cooling on COP
Results indicated that “the application of water mist pre-cooling could
increase the COP… by up to 30%”
Paper presented at Glasgow, Scotland in July 2009
Research & Testing
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Independent Study by Plan B Logistics (08/19/2007)
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Current w/Mist Cooling Off: 9.5 Amps
Current w/Mist Cooling On: 7.5 Amps
Watts ( Line Voltage x Power Factor x Amp) w/Mist Cooling Off : 994 (100%)
Watts ( Line Voltage x Power Factor x Amp) w/Mist Cooling On: 784 (79%)
21% Reduction in energy consumption (dose not include decreased cycle times)
Nearly instant reduction in energy consumption
Room temp stabled at 80 °F, AC exhaust stabled at 65 °F. Stable cooling performance
Test Study #2 - International Rubber Products’ Compton Facility
Test completed on 9/15/07 by Plan B Logistics
Test illustrates different mist configurations during the test phase. Ultimately reaching a 24.6% reduction in energy consumption*
Test start at 10:00 am SLC, UT Time
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Steady State reached @ 11:30 Compressor Base Current 8.14 Amps 100.0 % of Base
Mist on at 11:30 1st mist configuration Current 7.465 Amps 91.7 % of BasMist on at 12:34 3rd mist configuration
Current 6.573 Amps 80.7% of Basee
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Mist on at 12:08 2nd mist configuration Current 7.172 Amps 88.1% of Base
Mist on at 13:01 4th mist configuration Current 6.195 Amps 75.4 % of Base
*Does not include
decreased cycle time
Research & Testing
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Average Test Results
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Compressor head pressure reduction – 25%
Amperage draw reduction – 21%
Condenser ambient temperature reduction – 28 °F
Exhaust air temperature reduction – 12 °F
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Case Studies
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AC/Refrigeration Pre-Cooling
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Soriana - City Club Store in Mexico (Initial pilot April 2008)
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International Rubber Products (June 2007)
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Arco AM/PM Gas Station - Moreno Valley, CA (January 2009)
Dry Cooling Towers Pre-Cooling
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Enterprise Products Houston- Propane Transfer
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AHMSA Steel – Steel Production
Soriana - City Club Store in Mexico
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Type of Business: Mexican Sam's Club (equivalent)
The Challenge: Several isles of walk-in coolers and freezers being opened
and closed constantly, difficult to keep them at required temperature during
hottest part of day, high energy costs
Water Quality: Hard
The Solution: Installed a Chill-N-Save™ pilot system on one 8-fan
refrigeration unit with use of SRT for water treatment
The Results:
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Before – Energy consumption at 8,802 kWh/wk
After – Reduced to 6,523 kWh/wk (> 25% reduction)
Achieved a net savings of $1,435/mon/unit
Decided to install Chill-N-Save™ on more than
1,000 identical units in 400 stores nationwide
Estimated Payback: 5 months
International Rubber Products
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Type of Business: Light industrial
The Challenge: Equipment manufacturing that generated heat adding to the high
cooling cost for this 40,000 sq/ft manufacturing plant
Water Quality: Hard
The Solution: Installed a Pre-Cooling system on 4 large AC units
The Results: Summer electricity bills (July through October) prior to installation
averaged $22,608/mon, which was reduced to $18,659 after installation (an average
savings of ~$4K/mon). Savings continued through subsequent years and achieved a
30% reduction in AC electric costs. Coils are as clean if not cleaner than before
Payback: 3 months
*Note: The above saving percentages are based on total electric usage.
This customer estimates the AC electric use in the summer accounts for
about 50% of total use. Therefore, the real AC electric use savings is
approximately twice what is shown above.
**August 2008 had other factors contributing to savings.
Arco AM/PM Gas Station - Moreno Valley, CA
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Type of Business: Mini Mart/Gas Station
(part of BP)
The Challenge: Full glass front, many walkin coolers that are opened several times per
hour, and constant in/out traffic created high
cooling costs in the summer
Water Quality: Extremely hard
The Solution: Installed a CNS system on
two 10-ton AC units and 2 smaller
refrigeration units
The Results: Reduced 2009 electric costs
by an average of ~$400/mon as compared
to 2008’s. Coils are as clean if not cleaner
than before (one end of year cleaning
required)
Payback: 11 months
Enterprise Products Houston, TX
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Type of business: Propane Transfer
The Problem: The company owns and operates
boat loading facilities in Houston, TX for oil,
natural gas and propane. Historically, propane
had been loaded onto tankers during the winter
to minimize heat expansion and facilitate faster
transfer from land to ships. World demand has
grown and changed; now ships must be loaded
in the summer months too. But because the dry
cooling tower could not keep the propane cool
enough during the hot summer days, the transfer
rates would stop or be so slow that tankers
would start lining up in the harbor.
The Solution: Install a 1400-nozzle CNS system
under the dry cooling tower to lower
temperatures. The cooling capacity was
improved by approximately 30% so that even
on the hottest days, the propane transfer rates
were as good as the middle of winter.
Payback: 1 Day!
AHMSA Steel (www.ahmsa.com)
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Type of Business: Steel Production (5th
largest in the world)
The Problem: During the summer months,
cooling towers could not keep up with
material cooling needs during the steel
manufacturing process, so the entire process
was slowed up to 30%, costing millions of
dollars of production.
The Solution: Install 3 - 900 nozzle CNS HP
pre-cooling mist systems under the dry
cooling towers to lower temperatures.
The Results: Cooled the intake air as much
as 38 degrees F. Heat transfer rates went
up so significantly, that even on the hottest
days, steel production was kept at maximum
capacity.
Payback: 1 1/2 shifts!
Dal-Tile Testimonial
Since this letter more then 80 stores have
installed the Chill-N-Save™ System wit
same results.
IRP Testimonial
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