COOLING

Evaporative cooling is
energy efficient

“Transform the heat into cool

and refreshed air”
A world leader in air treatment
solutions
Munters is a global company with a world leading position in
climate control products, solutions and services. Customers
are served in a wide range of segments like insurance-,
utilities-, food-, pharma- and electronics- industries.
Manufacturing and sales are carried out via the Group’s own
companies in 30 countries. The Group has approx. 3,600
employees and net sales of SEK 5,712 million.

One of the main developed areas is the evaporative cooling

area where Munters through some 30 years has elaborated
on smart cooling techniques.
www.munters.com
Problems areas

• Hot indoor climate / Fug and still indoor air

- Lower productivity
- Unsatisfied staff / Hot and challenging working climate
- Increased number of errors and higher failure rate in production
- work safety decreases and accidents increases

• High cost for cooling facilities

- High installation cost
- High maintenance cost
- High running/electricity cost and environmental impact
- High life cycle cost

• Uneven temperature and humidity for balanced and efficient industrial

processes and storages places
 Typical temperature and humidity
cycle

Temperature [C] Relative humidity [%]

The temperature is in general higher day time and the humidity is

higher at night. The sun and machines generates heat that is
absorbed by the workers and they feel uncomfortable, sensible heat is
increasing. Often this also causes production quality problems.
Climate impact on working efficiency

• People are temperature and

humidity sensitive
• Dry air causes health problem
such as dry nose and throat
• Asthmatic and allergic people
require balanced climate
• Optimal humidity for people is in
between 40 % and 60% RH
Work safety – productivity
The heat generated in today’s industrial and commercial buildings can
quickly become unbearable when ambient temperatures increase.
Investigations made by independent institutes clearly show problems for
hot indoor climate. High workplace temperatures result in:
• Human productivity falling by 4% for every degree over 22°C
• Human errors increasing by up to 40% at 32°
Air renewals acquired for various
industries
Application Temp. °C Air renewals/hour Desired
RH%
Textile industry 20 - 24 25 - 29 50 - 70

Paper industry 21 – 26 19 - 24 45 - 65
Painting facilities 22 – 24 25 - 30 45 - 55
Plastic industry 22 – 25 30 - 35 40 - 50

Besides temperature, humidity and air renewals are important factors

for a number of different industrial processes in order to receive a
balance between humidity and temperature.
Energy cost trends
• Energy cost for industrial customers without taxes

Electricity cost in €/kWh

0,12

0,1

0,08 Italy
Germany
0,06 Spain
€

Brazil
0,04 USA

0,02

0
2000 2001 2002 2003 2004 2005 2006 2007
Year

*Source Swedish trade council

Worldwide energy supply in TW (2004)

A large portion of
consumed energy is from
fossil fuels, which is an
resource which will run dry.
This will also give an direct
impact on electricity cost
when switching from fossil
to other energy source.

Only 7% is renewable
energy sources
 Cost for cooling equipment

Life cycle cost

summary over 15
9%
27% Investment and years for a typical
Installation
cooling system in food
Energy consumption
processing industry
Maintenence application. Energy
64%
consumption is 2/3 of
the total cost

Source: Swedish energy agency

Calculations based on initial investment 80000€, Maintenance 2500€/year and electricity cost 0,035€/kWh
Problem area summary
• Saving in investments in cooling equipment may be expensive in
cost for faulty units, increased warranty cost and problems with
work staff

• Energy cost will steadily or even more aggressively increase and

will in the future be more important than unit cost. Focus will be on
life cycle cost rather then initial investments.
Munters solution
• Evaporative cooling based on air passing through a pad or
media
• The water evaporates with help of energy taken from the air
• The air will be chilled with only a fan and a water pump
• Old air is ventilated out and replaced with fresh cool air
• Noise level is kept low
The evaporative principle

1. Incoming warm air

2. Water pump
3. Water distribution
pipe
4. CELdek
evaporative cooling
pad
5. Centrifugal fan
6. Outgoing cool air
Definitions of heat

• The heat consists of two parts, latent and sensible, and the sum of the
heat energy is constant. This is called the enthalpy.
• Latent heat is the energy consumed when a material is changing
physical state, like water evaporates or ice melting.
• Sensible heat is when the temperature is changing without changing
physical state of the material, water gets warmer but not evaporating.
Transform from sensible heat to
latent heat
The water over the pads evaporates by using the energy in
the air. The sensible heat process when water becomes gas
transfer the sensible heat to latent.

You feel 36°C You feel 26°C

and 30% HR and 70% HR

Latent 1/3
heat Latent 2/3
heat
Sensible
heat Sensible
2/3 heat 1/3
Temperature and humidity cycle
The Munters evaporative cooler range is levelling out fluctuations
in temperature and humidity, cutting the peaks, creating a stabile
environment for humans and processes.

Relative humidity [%]

Temperature [C]
Munters Evaporative Coolers
Munters cooling products summary
Munters has a broad range of cooling products for various
problems and applications. We produce and sell both light weight
polymeric coolers as well as rigid steel coolers for heavier
industry. Installation is simple and flexible.

ESAC™ line FCA 5 – mobile and

FCX 15-35 T & B stationary light weight cooler
Stationary factory cooler with FCA 5F+ – mobile unit with
top and bottom air outlet extended tank
• FCX 15T & B
• FCX 22T & B FCA 15 T & B – stationary
• FCX 30T & B factory
• FCX 35T & B
cooler, light weighted for roof
Polymer cooler line and wall installation
CCX 1,5F & 2,5F – mobile
smart
light weight cooler
CCX 2.5F+ – stationary cooler
with extended tank
 Feature overview of all coolers
External Cooling /
Cooler Air volume Voltage/ Fan speed Outlet Installation Water Control sensor ventilation
name m3/h cfm Frequency steps versions options connections options connections choice Ionizer
Wheels,
ESAC FCX 400V 3ph floor, roof, Wall Humidistat,
15 15000 8824 50Hz 1 Top/ Bottom wall Fixed mounted termostat No No
Wheels,
ESAC FCX 400V 3ph floor, roof, Wall Humidistat,
22 22000 12942 50Hz 1 Top/ Bottom wall Fixed mounted termostat No No
ESAC FCX 400V 3ph Floor, roof, Wall Humidistat,
30 30000 17647 50Hz 1 Top/ Bottom wall Fixed mounted termostat No No
ESAC FCX 400V 3ph Floor, roof, Wall Humidistat,
35 35000 20588 50Hz 1 Top/ Bottom wall Fixed mounted termostat No No
230V 1ph
ESAC FCX 3 3300 1942 50Hz 7 Top Floor Fixed / Tank 45l On unit front No No No
230V 1ph
ESAC PC 4T 4000 2353 50Hz 7 Top Floor Fixed / Tank 60l On unit front No No No

Floor, stand
with wheels,
230V 1ph ventillation Remote / On
FCA 5 5000 2942 50Hz 3 Front inlet Tank 23-30l unit front No Yes Yes

230V 1ph Floor, on Remote / On

FCA 5+ 5000 2942 50Hz 4 Front wheels Tank 190l unit front No Yes Yes
400V 3ph
50Hz, 230V Floor, roof, Wall
FCA 15 15000 8824 3ph 60Hz 1 Top/ Bottom wall Fixed mounted No Yes Yes

230V 1ph Remote / On

CCX 1.5 1500 883 50Hz 3 Front Wheels Tank 30l unit front No Yes Yes

230V 1ph Remote / On

CCX 2.5 2500 1471 50Hz 3 Front Wheels Tank 35l unit front No Yes Yes

230V 1ph Remote / On

CCX 2.5+ 2500 1471 50Hz 3 Front Floor Tank 80l unit front No Yes Yes
ESAC™ FCX15-35 T & B
• Rigid steel casing for industrial
purpose
• High performance centrifugal fan
for long distance ducting
• Varity of installation options and
sizes
• Top and bottom outlet of air
for maximum usability
• ESAC rage is suitable for
heavier industry applications
 CCX 1.5 , 2.5 & 2.5+
Light weight mobile coolers
• Attractive compact design
• Low installation, running and
maintenance cost
• Remote control for easy
operation
• Different settings and running
features CCX 2,5 Suitable for CCX 1,5 Suitable for
rooms in between 20 rooms in between 15
• Handles to easily carry the unit to 30 m² to 20 m²
• Wheeled units with integrated
water
tank for multiple applications.
• CCX 2.5+ is a floor standing
stationary unit
• Long uninterrupted running time
without need of water refilling
• CCX 2.5+ has an extended tank
for uninterrupted running a full
day
• Low noise
• Environmentally friendly with no
chemicals
CCX 1,5 & 2,5
Features, design and display functions

Display functions

Unit design and

features
FCA 5 & 5+
Mobile and stationary coolers

• Low installation and maintenance cost

• Remote control for uncomplicated
setting and possibility to run units
in parallel
• Light weight polymer casing
FCA 5: On stand, wall mounted or
through wall ventilator installation options
FCA 5+: Floor standing or on wheels
• FCA5+ has an 190l big tank for extended
uninterrupted running
• Suitable for a wide range of applications
• Simple and flexible installation
• Low noise FCA5 Suitable for rooms
• Environmentally friendly in between 30 to 50 m²
FCA 5 control functions
ON/OFF pushbutton: pressing the ON/OFF
button, the cooling and ionizing functions are
enabled, the air cooler works and the side
movement of air outlet ("SWING") is also
enabled. Pressing the ON/OFF button during
operation the unit will stop and go to stand-by
mode.
COOLING button: press the cooling button,
to enable or disable the cooling and air
ionizing function
FAN SPEED button: Press the fan speed
button to control the fan speed, there are
three levels available: High /Middle/ Low,
the display indicator will light accordingly.
SWING button: pressing the swing button
and start or stop the side movement of air
diffuser.
FCA 15
Stationary light weight cooler

• Low installation, running and FCA 15 Suitable for

maintenance cost rooms in between
100 to 150 m²
• Remote control for uncomplicated
setting and possibility to run units
in parallel
• Light weight polymer casing
• High performance axial fan for
ducting options
• Suitable for a wide range of
applications
• Simple and flexible installation
• Environmentally friendly
Dimensioning of coolers

•Which model shall be used?

•How many units are necessary?
•What will be their performance?
•How much water will they consume?
 Climate input data
• Local weather data
• Temperature Max/Min
• Relative Humidity Max/Min
• Yearly and daily variations of temperature and relative
humidity

• Available data sources

• Weather websites/services/archives
(ex. www.wunderground.com)
• Direct information
Design input data
• Building information
• Type of application (factory, warehouse, …)
• Main dimensions (L x W x H)
• Building layout
• Location and distribution of machinery, production
lines, workstations, stored goods, people…
• Internal heat sources (kW?)
• Possible installation solutions
• Walls
• Roof
• Floor
• Outdoor/Indoor
 Installation of factory cooling
Free standing Roof mounted unit
unit on floor

Wall mounted unit

Exhaust fans
Ground mounted unit
Air volume calculation

• Calculate the air volume to be treated

V = L × W × H [m³]

• If the actual height is > 4 m, assume H = 4 m

• Select the appropriate number of hourly changes required based

on the application

• Calculate the required airflow rating

q = V × N [m³/h]

V = air volume to be treated [m³]

N = number of required hourly changes
Air changes chart
Application No. of air changes per hour
Textile industries 25 – 29
Manufacturing industries 18 – 22
Plastic materials industries 30 – 35
Paint work room 25 – 30
Foundries 25 – 30
Workshop 22 – 25
Engine rooms 18 – 22
Ovens 20 – 25
Restaurants 18 - 22
Bars and cafés 18 - 22
Wineries 18 - 22
Wine bars 30 – 40
Discos or pubs 25 – 29
Cinemas and theatres 14 – 18
Selection of units

• Select the type and number of coolers to be used based on:

– AIRFLOW requirements (air changes)
– INSTALLATION requirements
– AIR DISTRIBUTION requirements

Ex.: if the required airflow is 60000 m³/h you can use 2 FCX30 units or
4 FCX15 units depending on the installation and distribution
conditions
Efficiency and temperature
calculations
The psychrometric chart

It is a basic tool for the analysis

of humid air properties and for
the design of cooling systems.
Point A represents humid air at
36°C dry bulb temperature and
30% RH, a typical condition of
the air at the cooler inlet
You can read the other relevant
properties at point A directly from
the diagram:
Humidity ratio: ~ 11 g/kg
Wet bulb temperature: ~ 22°C
Specific enthalpy: ~ 65 kJ/kg
Air temperature at cooler outlet
η(TD1 − TW1 )
TD2 = TD1 −
100
TD1 dry bulb air temperature at inlet
TW1 wet bulb air temperature at inlet
TD2 dry bulb air temperature at outlet
η evaporation efficiency
approx 82% for ESAC and 85% for
FCA and CCX coolers

The outlet air temperature is ~ 24.5°C in

our case

Point B is then identified by TD2 ~ 25°C

and hB ~ 65 kJ/kg

RH% at point B is ~ 82%

ESAC FCX cooling capacity
Ambient relative humidity
20% 25% 30% 35% 40% 45% 50% 55% 60%
Ambient
temp Temperature °C after Evaporative cooling
30 18,4 19,3 19,9 20,8 21,8 22,5 23,4 24,2 24,9
35 21,8 22,4 23,7 24,8 25,8 26,8 27,8 28,5 29,5
40 25,4 26,1 27,4 28,7 29,8 31 32 32,9 33,9

Cooling capacity

40

35
Temperature after cooler

30

25
Ambient temp 30 degree C
20 Ambient temp 35 degree C
Ambient temp 40 degree C
15

10

0
20% 25% 30% 35% 40% 45% 50% 55% 60%
Humidity in %
Cooling/thermal power
Dry air
P = ρ x cp x Δt x q

Wet air
P = ρ x Δh x q

• P = power in kW
• ρ = 1,2 kg/m3 at 20°C at sea level
• cp = 1,0 KJ/kg, °C
• Δt = temp difference in °C
• Δh = enthalpy difference i KJ/kg
• q = airflow i m3/s
Cooling power calculation

• Dry air
P = ρ x cp x Δt x q

• Wet air
P = ρ x Δh x q

• P = power in kW
• ρ = 1,2 kg/m3 at 20°C at sea level
• cp = 1,0 KJ/kg, °C
• Δt = temp difference in °C
• Δh = enthalpy difference i KJ/kg
• q = airflow i m3/s
Water usage calculation

The water usage rate W per 1000

m³/h of airflow is given by

W = ρ (x2 – x1) 1000 l/h

where
ρ air density, 1.2 kg/m³
x2 – x1 absolute humidity
difference between outlet
and inlet
In our case:

W ~ 5.8 l/h per 1000 m³/h

Bleeding rate should also be

considered when applicable.
 Water usage per 1000 m³/h airflow

30% RH 40% RH 50% RH

30°C 5.0 litres/h 4.1 litres/h 3.3 litres/h

35°C 5.6 litres/h 4.6 litres/h 3.7 litres/h

40°C 6.1 litres/h 5.0 litres/h 3.9 litres/h

based on 82% evaporation efficiency

Air extraction

• Air extraction is always recommended as it improves the air quality

as a whole (removes bad smells, emissions, fumes, etc.)

• Air extractors should have the same airflow rating as the coolers
ΣQcoolers ~ ΣQextractors
Exhaust fans

Exhaust fan Power [W] Airflow [m3/h] Airflow [m3/h]

at 0 Pa at 20 Pa
ED24 370 10600 9780
EM30 550 14550 13410

EM36 550 19880 17930

EM50 1100 42125 38048

Dimensioning chart
Area Volume Required hourly Units Extractor Opening
(H = 4m) airflow (22 Area
renewals per
hour)

[m2] [m3] [m3/h] [m2]

150 600 13200 FCX 15 EM30 1.70
200 800 17600 FCX 22 EM36 2.50
250 1000 22000 FCX22 ED24 2.50
300 1200 26400 FCX30 2 x EM30 3.40
350 1400 30800 FCX 30 EM50 3.40
400 1600 35200 FCX 35 EM50 4.00
450 1800 39600 2 x FCX 22 2 x EM36 5.00
500 2000 44000 2 x FCX 22 3 x EM30 5.00
550 2200 48400 1 x FCX 35 + 1 x FCX 22 4 x EM30 6.50
600 2400 52800 1 x FCX 35 + 1 x FCX 22 3 x EM30 6.50
650 2600 57200 1 x FCX 35 + 1 x FCX 22 2 x EM50 6.50
700 2800 61600 2 x FCX 35 2 x EM50 8.00
750 3000 66000 2 x FCX 35 2 x EM50 8.00
800 3200 70400 2 x FCX 35 4 x EM36 8.00
850 3400 74800 2 x FCX 30 + 1 x FCX 22 2 x EM50 9.00
900 3600 79200 3 x FCX 30 4 x EM36 10.00
950 3800 83600 3 x FCX 30 5 x EM36 10.00
1000 4000 88000 3 x FCX 30 3 x EM50 10.00
Dimensioning program – FCX
DAILY PERFORMANCE MODEL

Inlet Air Conditions Input Parameters

Temperature RH % Efficiency ? 82%
Max ? 32 °C Min ? 55% Bleed Rate ? 0%
Min ? 15 °C Max ? 94%
Airflow Rate 100000 m³/h
Time Air Inlet Relative Air Outlet Water
Temp (°C) Humidity ∆t °C Temp (°C) Usage Daily Performance Chart
01:00 16,1 91,4% -0,8 15,4 37,6
02:00 15,3 93,3% -0,6 14,6 28,2 35,0 100,0%
03:00 15,0 94,0% -0,6 14,4 28,2
04:00 15,3 93,3% -0,6 14,6 28,2 90,0%
05:00 16,1 91,4% -0,8 15,4 37,6 30,0
06:00 17,5 88,3% -1,1 16,4 51,7 80,0%
07:00 19,3 84,3% -1,5 17,7 70,5
21,3 79,5% -2,1 98,7 25,0
08:00 19,3 70,0%
09:00 23,5 74,5% -2,7 20,8 131,6

Temperature (°C)
10:00 25,7 69,5% -3,5 22,2 164,5 60,0%
20,0
11:00 27,8 64,8% -4,2 23,5 197,5

RH%
12:00 29,5 60,7% -4,9 24,6 235,1 50,0%
13:00 30,9 57,6% -5,5 25,3 258,6 15,0
14:00 31,7 55,7% -5,9 25,8 282,1 40,0%

15:00 32,0 55,0% -6,0 26,0 282,1

31,7 55,7% -5,9 282,1 30,0%
16:00 25,8 10,0
17:00 30,9 57,6% -5,5 25,3 258,6
20,0%
18:00 29,5 60,7% -4,9 24,6 235,1
19:00 27,8 64,8% -4,2 23,5 197,5 5,0
10,0%
20:00 25,7 69,5% -3,5 22,2 164,5
21:00 23,5 74,5% -2,7 20,8 131,6
0,0 0,0%
22:00 21,3 79,5% -2,1 19,3 98,7 0

0
23:00 19,3 84,3% -1,5 17,7 70,5
:0

:0

:0

:0

:0

:0

:0

:0

:0

:0

:0

:0
01

03

05

07

09

11

13

15

17

19

21

23
00:00 17,5 88,3% -1,1 16,4 51,7 Time
avg ∆t °C -3,0 Total 3423
Inlet Temperature Cooled Air Inlet RH
avg P kW -100,68 Avg 143
Coefficient of performance (COP)
comparison

A typical comparison in between

evaporative and traditional AC coolers.
COP for the evap. cooler is 6-8 times
higher

CCX 1.5

Airflow 1500 m³/h

Voltage 230 V 50 Hz
Power 170 W
Current 0.75 A
Water consumption 1.8-2.5 l/h
Tank capacity (with draining 30 l
valve)
Overall Dimensions (l×w×h) 540×410×1115 mm
Weight w/o water 17 kg
Cooled area 10-20 m²
Coefficient of performance (COP) 19,52
Life cycle cost for Evaporative
cooling vs. air condition
Comparison of evaporative cooling to phase-change air conditioning:

Advantages

- Less expensive to install

Estimated cost for installation is 1/8 to 1/2 that of refrigerated air
conditioning

- Less expensive to operate

Estimated cost of operation is 1/4 that of refrigerated air.
Power consumption is limited to the fan and water pump vs.
compressors, pumps and blowers.
Flexible installations of coolers

Nice design that doesn’t interfere with

the external design of the structure.
Ground mounted Munters cooler with
top outlet of air, directed in a extra
supplyed duct system.
Installation options
• Mounted on the wall or standing
beside a facility connected to a duct
or a diffuser.

• Installed on the roof of a building

connected to ventilation ducts. One
or several units can be used.

• Free standing unit with a diffuser

spreading air

• The smaller units can be placed on

a wheeled unit for temporary cooling of
for example event tents
Installation options
Cooler installed inside a boat
factory. The cold air is directed
via tubes inside the boat.

Cooler installed in parallell on a factory roof.

ESAC range accessories
• Double outlet diffuser
• 90 degree single outlet diffuser
• 360 degree outlet diffuser
• Connection duct
• Connection duct 90 degree
• Noise reduction kit
• Wall mounting kit
• Portability kit
• Thermostat
• Winter protection/cover
Light cooler accessories

FCA 5
• Wheeled unit on high stand
• Wall mounting kit

FCA 5+
• Wheeled unit
Summary - Benefits with Munters
evaporative coolers
• Coolers from 1500 to 35000 m3/h for a wide range of customer
needs and applications

• Low life cycle cost. Lower investments, maintenance and

running cost in comparison with alternative systems. Higher
COP value.

• Environmental friendly cooling with no refrigerants

• Replaces old re-circulated with cool and fresh air

• Low noise level

• Boosting the productivity and reduces errors