Forced Draft Horizontal Air Cooler With Finned Tube API Forced Draught
A Forced Draft Horizontal Air Cooler (FDAC) is a specialized heat exchanger designed to cool process fluids using air, commonly employed in industries where water scarcity or efficiency is a concern. Here's a detailed overview:
Key Components and Design
- Finned Tube Bundles: Horizontal tubes with fins to maximize surface area for heat transfer. Fins can be helical or longitudinal, enhancing thermal efficiency.
- Forced Draft Fans: Axial or centrifugal fans positioned below the tube bundle to push air through the system, ensuring controlled airflow.
- Plenum Chamber: Directs airflow evenly over the tubes, optimizing cooling efficiency.
- Support Structure: Elevates the unit to facilitate airflow and provide maintenance access.
- Louvers/Shutters: Adjustable to regulate airflow and adapt to environmental or operational changes.
Working Principle
Process Fluid Flow: Hot fluid (e.g., hydrocarbons, water, or gases) circulates through horizontal finned tubes.
Airflow: Fans force ambient air over the tubes, absorbing heat from the fluid. The heated air is then expelled into the atmosphere.
Cross-Flow Configuration: Air moves perpendicular to the tubes, maximizing heat exchange efficiency.
Advantages
Energy Efficiency: Effective cooling with lower water usage, ideal for arid regions.
Low Maintenance: Fans are ground-level, simplifying access for servicing.
Adjustable Cooling: Louvers and variable fan speeds (via VFDs) allow precise temperature control.
Space-Saving: Horizontal layout suits compact industrial setups.
Challenges
Energy Consumption: Fans require significant power, especially in high-temperature environments.
Ambient Sensitivity: Performance dips in hot climates; supplemental cooling (e.g., misting) may be needed.
Noise: Fan operation can generate noise, necessitating acoustic mitigation.
Space Requirements: Adequate clearance around the unit is critical for airflow.
FDACs are a robust solution for industrial cooling, balancing efficiency with operational flexibility. While they require careful planning around energy use and environmental factors, their adaptability makes them indispensable in sectors prioritizing water conservation and reliability.
Normal Air Cooler type is Forced-draft Horizontal Air Cooler,Induced-draft Horizontal Air Cooler,Sloped-top Air Cooler.
Air Cooler Applications
Oil & Gas: Cooling refinery process fluids or condensing gases.
Power Plants: Auxiliary system cooling (e.g., turbine lube oil).
HVAC: Large-scale air conditioning in commercial buildings.
Chemical Plants: Temperature control for reactors or storage.
Air Cooer Maintenance Troubleshooting
| Issue | Cause | Solution |
| Reduced Cooling Efficiency | Fouled fins, fan failure | Clean tubes, check fan belts |
| Vibration | Unbalanced fan, resonance | Rebalance fan, check supports |
| Leakage | Corrosion, gasket failure | Pressure test, replace gaskets |
| High Power Consumption | Dirty fins, misaligned fan | Clean, adjust fan pitch |
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