How ecobrid works
The ecobrid dry cooler is a next-generation closed-loop air-cooled cooling tower that eliminates water evaporation and component condensation.
With its low water consumption, it offers water-saving benefits, as well as effective maintenance of the circulating water quality.
Features
1. Leverages the advantages of a closed-loop air-cooling system to solve all the challenges of conventional primary cooling water systems
💡No evaporation or dispersion of circulating water means minimal water usage is more than enough
Unlike traditional cooling towers, ecobrid eliminates concerns about water evaporation or dispersion.
While it does require water for spraying into the adiabatic chamber, this is only necessary when outdoor temperatures exceed 30°C during the summer. This allows for efficient heat exchange with minimal water costs.
*For more details on water-saving benefits, please refer to the "Water Saving Effect Simulation" below.
💡No concentration of water means no scale risk
When water evaporates, it becomes concentrated, and minerals such as calcium and magnesium solidify, leading to the formation of scale. This scale can clog pipes, hindering heat exchange and making it difficult to maintain proper cooling and temperature control. Such heat exchange issues can lead to variations in mold temperature, causing molding defects such as warping and deformation, increased cooling times, as well as maintenance and downtime due to equipment malfunctions.
Since ecobrid uses a closed-loop air-cooling system, there is no water concentration, significantly reducing the risk of scale buildup. This results in improved productivity and cost reduction.
💡With closed-loop air cooling, no need for traditional water quality management or maintenance
Thanks to the closed-loop air cooling system, ecobrid eliminates the need for typical water quality management, blowdowns, and maintenance related to scale buildup on cooling towers. Additionally, there is no need for chemicals, so there’s no concern about handling or disposal.
Since ecobrid requires minimal maintenance and no time-consuming management, it enables significant cost reductions, including maintenance costs.
💡No risk of bacteria spreading from the fan, ensuring excellent consideration for human health and the environment
Legionella bacteria thrive in natural environments such as soil and rivers within a temperature range of 20°C to 50°C.
In traditional cooling towers, these conditions are ideal for bacteria to grow, and water droplets can carry bacteria that are dispersed by the fan.
Since ecobrid is a closed-loop system, there is no risk of bacterial dispersion, eliminating any potential impact on human health or the environment.
2. Free-Cooling System Reduces Chiller Operating Hours and Cuts Electricity Costs by Up to 54%
Free cooling is a system that stops the chiller during cooler periods, such as winter or when the required cooling water temperature isn’t very low, and uses the water supplied by the cooling tower directly as cooling water. By controlling the chiller's operating hours, unnecessary energy consumption can be reduced.
3. Maximized space-saving with modular components
By integrating control panels, tanks, valves, and other unit components, ecobrid achieves a highly compact design.
The integration of the components allows for faster on-site installation.
Additionally, the pump unit and cooling water tank are made of stainless steel, ensuring excellent durability.
Performance Impact Simulation
Water saving effect simulation
This simulation analyzes the water savings and reduction in water utility costs when operating a cooling system at 100 cooling tons with a circulation water flow rate of 1,300 L/min for 20 days (24 hours per day).
[Simulation Environmental conditions]
◆General cooling tower
Condition 1: 0.8% of the factory circulating water evaporates.
Condition 2: 0.05% of the factory circulating water is lost due to carryover.
Condition 3: 0.4% of the water is used for blowdown to dilute the concentrated water.
◆ Factory water rates
Condition 4: The basic fee is 39.1 yen per cubic meter.
Condition 5: The usage fee is 5.6 yen per cubic meter。
General cooling tower
Based on conditions 1–3, it is found that 1.25% of the circulating water is consumed or lost.
1300 (L/min) x 1.25 (%) x 60 (min ⇒ Hr) x 24 (Hr ⇒ day) x 20 (day ⇒ month) = 468㎥ evaporation/month
A total of 468 m³ of circulating water evaporates per month (wasted)
Basic water usage ▲ 468 (m³) x 39.1 (yen) + usage fee 468 (m³) x 5.6 (yen) = 20,919 yen
Annually, the water cost totals 5,616 m³ = 251,028 yen
Closed-loop Air-cooled Systeme cobrid
Unlike cooling towers, ecobrid eliminates circulating water evaporation and water loss, resulting in nearly no water fees.
Note: Only during the summer, when the outside temperature exceeds 30°C, will there be spraying on the filter.
Annual water costs for the cooling tower are 251,028 yen
The total amount of spray used by ecobrid in summer is 45 m³ annually (assuming a 22.5 m³ monthly contract).
5,616m³ - 45m³ = 5,571m³ water savings
The water cost is 251,028 yen - 10,809 yen = a cost reduction of 240,219 yen
ROI (return on investment) effect simulation
Simulation with the closed-loop air-cooling system in the following conditions:
① Extension of recycling (cooling) time prevention: 22 sec ⇒ 20 sec
② Reduction in product defect rate: 11% ⇒ 10%, assuming 15 units in a UK-based factory
[Simulation Environmental conditions]
Condition 1: 180 tons
Condition 2: Material: PP, 1 shot of 95g (16 pieces)
Condition 3: Cycle time 22 sec
Condition 4: Monthly production of 100,000 units
Annual reduction: 168,485 (yen) x 15 units = 2,527,275
When calculated with the difference in cost between the new system and the open cooling tower:
ROI (return on investment) = 63.1% (payback period: 1.6 years)
Investment amount: 6,000,000 yen
When replacing an existing open cooling tower:
ROI (return on investment) = 25.2% (payback period: 4.0 years)
Investment amount: 10,000,000 yen
Note: The calculation above does not include reductions in water and electricity costs. Annual running cost reductions of approximately 500,000 yen are included, which further increases the ROI.
Case Studies
The ecobrid has a proven track record across a wide range of industries, ensuring a reliable and effective solution for your needs.
Examples include: PET preforms and caps, automotive, home appliances, healthcare, daily goods, electrical components, pharmaceuticals, and more.
