Two-Stage Evaporative Cooling Air Handling Unit (AHU)

Sustainable, Ultra-Low Energy Cooling for Industrial & High-Ventilation Applications

By: RAJENDRA SAGAR, SHYAM V NAMBIAR, TOM JOBY & Dr. SUDARSHAN. B

Overview

Designed for demanding environments like industrial engine test laboratories, our Two-Stage Evaporative Cooling AHU integrates Indirect Evaporative Cooling (IDEC) and Direct Evaporative Cooling (DEC) to deliver precise thermal control without relying on traditional compressor-driven chillers. The system uses ambient adiabatic cooling to deliver massive energy savings and high ventilation rates for fresh-air applications. 

System Architecture & Core Components

• Stage 1 (IDEC Section): Lightweight, porous polypropylene heat exchanger featuring natural fiber wicking sheets. Pre-cools primary air without adding moisture.  

• Stage 2 (DEC Section): High-efficiency wetted Celdek media pads. Provides secondary sensible heat reduction through controlled evaporation.  

• Axial-EC Plus Fans: Direct-drive permanent-magnet motors eliminating belt transmission losses. Coupled with Variable Frequency Drives (VFD) for precision airflow control.  

• Water Management & Quality: Dual-pump arrangement (Duty/Standby) with an integrated UV-C purification system to prevent biological fouling, algae, and media clogging.  

• Automated Control: Fully integrated PLC automation regulating VFD speed, water circulation, and auto shut-off based on multi-point temperature/humidity inputs. 

Recommended Applications

• Automotive & Industrial Reliability Laboratories  

• High-Heat Equipment & Machinery Facilities  

• Manufacturing Plants Requiring Once-Through Fresh Air  

• Commercial spaces needing large ventilation volumes at low operating costs

  
  

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