Net-Zero Cooling to Power Technology
Power generation and industrial processes generate considerable heat loads, requiring cooling systems to reject the heat. This is not only a waste of energy but consumes additional power leading to increased costs and emissions.
The Active Cooler converts the heat from engine cooling circuits into clean electricity while eliminating parasitic cooling loads. This leads the system to act as a net-zero cooling solution with the added benefit of power generation when conditions are optimal.
During peak cooling demand, 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.
Model
Heat Rejected*
Hot Water Temp**
Hot Water Flow
Cold Water Temp
Cold Water Flow
Max (Gross) Output
AC800
380 kWth
158 – 240°F // 70 – 116°C
45 – 240 gpm // 3 – 15 l/s
40 – 150°F // 4 – 65°C
95 – 285 gpm // 6 – 18 l/s
75 kWe
Weight: 4,800 kg (skid option)
Dimensions: 2.4m x 9.5m x 1.75m (W*L*H)
*Loads larger than 800 kWth may require a custom design or secondary unit.
** Higher temperature heat sources require an additional heat exchanger.
Highlights
- Provides full-load cooling for the engine.
- Generates up to 75 kWe (gross).
- Zero emissions or fossil fuel requirements.
- Increases efficiency by offsetting the cooling load.
- Modular, scalable system that can be adjusted to fit changing needs.
- Closed-loop system minimizes water consumption.
- Induction generator allows for simple electrical connection and start up.
- Reduces engine derate due to insufficient cooling.
- A simple and reliable baseload power supply in remote areas.
- Serves as a radiator / cooling tower alternative offsetting capital costs.
- Easy installation with remote operation.
- Simple, robust design with minimal footprint.
- Short payback period (2 – 5 years).
- Qualifies for clean energy incentives.*
* Incentive eligibility varies based on region.
1.6 MW CAT 3530C
Example Application
- 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
- Total Savings: $98,250 per year at $0.15/kWh
- Efficiency Increase:4.8%
Typical Applications
The Active Cooler is an ideal fit for any business that implements commercial cooling to expel heat greater than 70°C (greater than 400 kWth). 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. 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.
