Active Cooler

Net-Zero Cooling To Power Technology

Power generation and industrial processes generate considerable heat loads. This heat is a waste of energy and requires cooling systems to reject it – further wasting energy and contributing to global emissions. The Active Cooler serves as a net-zero cooling to power solution, using an Organic Rankine Cycle (ORC) to generate electricity while reducing the cooling load 70-100%. This allows the cooling to power system to prioritize the production of electricity asides for periods of high ambient temperature and peak cooling demand. During peak loads, the ORC expander is bypassed and the system prioritizes cooling, fulfilling cooling requirements regardless of power generation. This is the only time, other than initial startup, that the Active Cooler will consume power that is not its own.

Typical Applications

The Active Cooler is an ideal fit for any business that implements commercial cooling to expel heat greater than 70°C. Common industries that could benefit from net-zero cooling to power include manufacturing, air / gas compression, wastewater treatment, biogas production as well as sectors that generate power such as power plants, landfills, well pads, and other micro-grids. These industries produce large amounts of heat and require cooling.

The ElectraTherm Active Cooler is currently available in the 800kWth and 1800kW sizes. Designed with flexibility in mind, the Active Cooler is easily integrated into existing systems and scalable to multiple megawatt heat loads.

Numerous Benefits

Not only is engine cooling an unavoidable operating expense, but all radiators must be replaced eventually. By installing an Active Cooler as a radiator alternative, you benefit from the offset cooling load in addition to increased efficiency through either reduced fuel consumption or increased power output – with no additional fuel consumption or emissions.

For remote applications, such as oil and gas operations, the ability to serve as a net-zero cooling system as well as a micro-grid providing a baseload power supply allows operators to implement processes that rely on electricity, a commodity previously not provided.

Seasonal Graphic

Fulfill 100% of your system’s cooling needs while generating clean power

Historically, radiators are fully utilized during the summer and grossly underutilized during the winter, providing little to no benefit.

With the Active Cooler, maximum capital utilization can still be achieved with varying operating conditions such as ambient temperature differentials throughout the year. The Active Cooler eliminates power usage from the cooling process during the summer as well as generates extra power and income during times of underutilized capacity such as the winter.

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Pilot Installation - Biogas Production

At a biogas plant in Poland, the first ever Active Cooler sits humming away - cooling the site's 800 kW engine while generating emission-free electricity. The Active Cooler displaces the previous radiator's demand of 8 kW while providing an additional 35 kW. The total newly available electricity from waste heat is 43 kW, amounting to a 5.5% increase in efficiency.

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Pilot Installation - Gas Compression

At a natural gas compression site in Oklahoma the Active Cooler provides net-zero cooling while generating clean electricity - serving as a radiator alternative with a payback. For remote projects ElectraTherm offers micro-grid functionality, allowing operators to generate and store power onsite for a variety of uses. In these instances, the value provided is far greater than the fiscal value associated with the electricity.

Example Application – 1.6 MW CAT 3520C

// Average Annual Temperature: 65°F
// 8,500 operating hours per year
// Hot Water Inlet: 230°F @ 220 gpm
// Radiator Demand: 10 kW

// Parasitic Cooling Load: 85 MWh per year
// 
Parasitic Cooling Cost: -$8,500 per year at $0.10/kWh
// AC800 Production: 570 MWh per year

// Newly Available Electricity: 655 MWh per year
// Total Savings: $65,500 per year at $0.10/kWh
// Efficiency Increase: 4.8%

CAT 3520C Engine

FACTORS THAT MAKE A SUCCESSFUL APPLICATION

HEAT

The amount of heat available is the largest factor in determining if a heat source is viable for ORC heat recovery. While heat sources as low as 70°C can be used, heat sources above 100°C are considered ideal. Other variables that play a role in determining output are the flow rate and hot/cold water temperature differential.

RUN HOURS

The more time an application is operational, the more heat there is available to convert into electricity. There are 8760 hours in a year and suitable applications will experience 80% up-time, however applications with 90% up-time offer the best economics.

COST OF POWER

Installing an ElectraTherm ORC heat recovery system comes with several benefits, from reduced carbon footprint to increased efficiency. However the most tangible benefit realized is the value of electricity produced. Ideal projects have electrical costs greater than $0.10/kWh.

Good for business

Simple. Reliable. Profitable. Sustainable.

Simple

The simple and flexible nature of our ORC solutions allows them to be adjusted to fit the needs of any application. A robust, modular, and scalable design allows the system to be easily integrated into existing processes while allowing for future adjustments. Able to successfully operate at partial loads with varying conditions also means that they will produce electricity even when your processes are not at capacity.

Reliable

Every ElectraTherm product goes through a rigorous testing process at our world-class R&D test cell to ensure absolute reliability. With a global fleet of over 100 units clocking over 2,000,000 operating hours with 24/7 access to our team as well as dedicated partners, you can have peace of mind knowing that we confidently stand behind our products.

Profitable

Our systems use existing heat as fuel, keeping operating costs minimal. ElectraTherm converts this heat into clean electricity, ready immediately. The Active Cooler is a net-zero cooling to power solution that provides cooling as well as power – making the Active Cooler the perfect radiator alternative. This increases energy efficiency – up to 10% – while substantially reducing energy consumption. ElectraTherm’s ORC solutions may also qualify for local sustainability incentives as well as enabling micro-grid functionality in remote regions. With an impressive 20-year design life and a payback period of 2-3 years, the economics amount to an attractive return on investment.

Sustainable

The Active Cooler is the ultimate radiator replacement not only due to the ability to generate power for cooling and profit but since it reduces the emissions and energy usage associated with standard radiators.

Cooling to power means no more compromising efficiency or power output for cooling. Cooling to power means replacing a power-hungry radiator with a power-producing Active Cooler. Cooling to power means improving your bottom line and the environment.

Questions?

Contact us and we will be happy to help.

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