Most designs take advantage of the fact that water has one of the highest known
enthalpy of vaporization (latent heat of vaporization) values of any common substance. Because of this, evaporative coolers use only a fraction of the energy of vapor-compression or absorption air conditioning systems. Except in very dry climates, the single-stage (direct) cooler can increase
relative humidity (RH) to a level that makes occupants uncomfortable. Indirect and two-stage evaporative coolers keep the RH lower.
Direct evaporative cooling Direct evaporative cooling (open circuit) is used to lower the temperature and increase the humidity of air by using latent heat of evaporation, changing liquid water to water vapor. In this process, the energy in the air does not change. Warm dry air is changed to cool moist air. The heat of the outside air is used to evaporate water. The RH increases to 70 to 90% which reduces the cooling effect of human perspiration. The moist air has to be continually released to outside or else the air becomes saturated and evaporation stops. A
mechanical direct evaporative cooler unit uses a fan to draw air through a wetted membrane, or pad, which provides a large surface area for the evaporation of water into the air. Water is sprayed at the top of the pad so it can drip down into the membrane and continually keep the membrane saturated. Any excess water that drips out from the bottom of the membrane is collected in a pan and recirculated to the top. Single-stage direct evaporative coolers are typically small in size as they only consist of the membrane, water pump, and centrifugal fan. The mineral content of the municipal water supply will cause scaling on the membrane, which will lead to clogging over the life of the membrane. Depending on this mineral content and the evaporation rate, regular cleaning and maintenance are required to ensure optimal performance. Generally, supply air from the single-stage evaporative cooler will need to be exhausted directly (one-through flow) as with direct evaporative cooling. A few design solutions have been conceived to utilize the energy in the air, like directing the exhaust air through two sheets of double glazed windows, thus reducing the solar energy absorbed through the glazing. Compared to energy required to achieve the equivalent cooling load with a compressor, single stage evaporative coolers consume less energy. Energy savings from using a passive direct evaporating cooling strategy depends on the climate and heat load. For arid climates with a great wet-bulb depression, cooling towers can provide enough cooling during summer design conditions to be net zero. For example, a 371 m2 (4,000 ft2) retail store in Tucson, Arizona with a sensible heat gain of 29.3 kJ/h (100,000 Btu/h) can be cooled entirely by two passive cooling towers providing 11890 m3/h (7,000 cfm) each. For the Zion National Park visitors' center, which uses two passive cooling towers, the cooling energy intensity was 14.5 MJ/m2 (1.28 kBtu/ft2;), which was 77% less than a typical building in the western United States that uses 62.5 MJ/m2 (5.5 kBtu/ft2). A study of field performance results in Kuwait revealed that power requirements for an evaporative cooler are approximately 75% less than the power requirements for a conventional packaged unit air-conditioner.
Indirect evaporative cooling Indirect evaporative cooling (closed circuit) is a cooling process that uses direct evaporative cooling in addition to some
heat exchanger to transfer the cool energy to the supply air. It is a method of cooling air without adding moisture to the air supplied to a building. The cooled moist air from the direct evaporative cooling process never comes in direct contact with the conditioned supply air. The moist air stream is released outside or used to cool other external devices such as solar cells which are more efficient if kept cool. This is done to avoid excess humidity in enclosed spaces, which is not appropriate for residential systems.
How it works Indirect evaporative cooling uses two separate air streams and an
air-to-air heat exchanger. Water evaporates into a secondary air stream. Heat moves through the heat exchanger from the primary air stream to the secondary air stream. Direct evaporative cooling adds moisture directly to the supply air. Indirect evaporative cooling is used in commercial, industrial, and residential buildings. It is also used in data centers and ventilation systems.
Maisotsenko cycle Indirect cooler manufacturer uses the Maisotsenko cycle (M-Cycle), named after inventor and Professor Dr. Valeriy Maisotsenko, employs an iterative (multi-step) heat exchanger made of a thin recyclable membrane that can reduce the temperature of product air to below the wet-bulb temperature, and can approach the
dew point. Testing by the US Department of Energy found that a hybrid M-Cycle combined with a standard compression refrigeration system significantly improved efficiency by between 150 and 400% but was only capable of doing so in the dry western half of the US, and did not recommend being used in the much more humid eastern half of the US. The evaluation found that the system water consumption of 2–3 gallons per cooling ton (12,000 BTUs) was roughly equal in efficiency to the water consumption of new high efficiency power plants. This means the higher efficiency can be utilized to reduce load on the grid without requiring any additional water, and may actually reduce water usage if the source of the power does not have a high efficiency cooling system. An M-Cycle based system built by Coolerado is currently being used to cool the Data Center for NASA's National Snow and Ice Data Center (NSIDC). The facility is air cooled below 70 degrees Fahrenheit and uses the Coolerado system above that temperature. This is possible because the air handler for the system uses fresh outside air, which allows it to automatically use cool outside ambient air when conditions allow. This avoids running the refrigeration system when unnecessary. It is powered by a solar panel array which also serves as secondary power in case of main power loss. The system has very high efficiency but, like other evaporative cooling systems, is constrained by the ambient humidity levels, which has limited its adoption for residential use. It may be used as supplementary cooling during times of extreme heat without placing significant additional burden on electrical infrastructure. If a location has excess water supplies or excess desalination capacity it can be used to reduce excessive electrical demand by utilizing water in affordable M-Cycle units. Due to high costs of conventional air conditioning units and extreme limitations of many electrical utility systems, M-Cycle units may be the only appropriate cooling systems suitable for impoverished areas during times of extremely high temperature and high electrical demand. In developed areas, they may serve as supplemental backup systems in case of electrical overload, and can be used to boost efficiency of existing conventional systems. The M-Cycle is not limited to cooling systems and can be applied to various technologies from
Stirling engines to
Atmospheric water generators. For cooling applications it can be used in both cross flow and counterflow configurations. Counterflow was found to obtain lower temperatures more suitable for home cooling, but cross flow was found to have a higher
coefficient of performance (COP), and is therefore better for large industrial installations. Unlike traditional refrigeration techniques, the COP of small systems remains high, as they do not require lift pumps or other equipment required for cooling towers. A 1.5 ton/4.4 kW cooling system requires just 200 watts for operation of the fan, giving a COP of 26.4 and an EER rating of 90. This does not take into account the energy required to purify or deliver the water, and is strictly the power required to run the device once water is supplied. Though desalination of water also presents a cost, the latent heat of vaporization of water is nearly 100 times higher than the energy required to purify the water itself. Furthermore, the device has a maximum efficiency of 55%, so its actual COP is much lower than this calculated value. However, regardless of these losses, the effective COP is still significantly higher than a conventional cooling system, even if water must first be purified by desalination. In areas where water is not available in any form, it can be used with a
desiccant to recover water using available heat sources, such as
solar thermal energy.
Theoretical designs In the newer but yet-to-be-commercialized "cold-SNAP" design from Harvard's Wyss Institute, a 3D-printed ceramic conducts heat but is half-coated with a hydrophobic material that serves as a moisture barrier. While no moisture is added to the incoming air the relative humidity (RH) does rise a little according to the Temperature-RH formula. Still, the relatively dry air resulting from indirect evaporative cooling allows inhabitants' perspiration to evaporate more easily, increasing the relative effectiveness of this technique. Indirect Cooling is an effective strategy for hot-humid climates that cannot afford to increase the moisture content of the supply air due to indoor air quality and human thermal comfort concerns.
Passive indirect evaporative cooling strategies are rare because this strategy involves an architectural element to act as a heat exchanger (for example a roof). This element can be sprayed with water and cooled through the evaporation of the water on this element. These strategies are rare due to the high use of water, which also introduces the risk of water intrusion and compromising building structure.
Hybrid designs Two-stage evaporative cooling, or indirect-direct In the first stage of a two-stage cooler, warm air is pre-cooled indirectly without adding humidity (by passing inside a heat exchanger that is cooled by evaporation on the outside). In the direct stage, the pre-cooled air passes through a water-soaked pad and picks up humidity as it cools. Since the air supply is pre-cooled in the first stage, less humidity is transferred in the direct stage, to reach the desired cooling temperatures. The result, according to manufacturers, is cooler air with a RH between 50 and 70%, depending on the climate, compared to a traditional system that produces about 70–80% relative humidity in the conditioned air.
Evaporative + conventional backup In another
hybrid design, direct or indirect cooling has been combined with vapor-compression or absorption air conditioning to increase the overall efficiency and/or to reduce the temperature below the wet-bulb limit.
Evaporative + passive daytime radiative + thermal insulation Evaporative cooling can be combined with
passive daytime radiative cooling and
thermal insulation to enhance cooling power with
zero energy use, albeit with an occasional water "re-charge" depending on the
climatic zone of the installation. The system, developed by Lu et al. "consists of a solar reflector, a water-rich and IR-emitting evaporative layer, and a vapor-permeable, IR-transparent, and solar-reflecting insulation layer," with the top layer enabling "heat removal through both evaporation and radiation while resisting environmental heating." The system demonstrated 300% higher ambient cooling power than stand-alone passive daytime radiative cooling and could extend the shelf life of food by 40% in cool humid climates and 200% in dry climates without
refrigeration.
Membrane dehumidification and evaporative cooling Conventional evaporative cooling only works with dry air, e.g. when the humidity ratio is below ~0.02 kgwater/kgair. They also require substantial water inputs. To remove these limitations, dewpoint evaporative cooling can be hybridized with
membrane dehumidification, using membranes that pass water vapor but block air. Another material which is sometimes used is corrugated cardboard.
Design considerations Water use In arid and semi-arid climates, the scarcity of water makes water consumption a concern in cooling system design. From the installed water meters, 420938 L (111,200 gal) of water were consumed during 2002 for the two passive cooling towers at the Zion National Park visitors' center. However, such concerns are addressed by experts who note that
baseload electricity generation usually requires a large amount of water in their
cooling towers. Evaporative coolers use far less electricity than A/C, thus comparable water usage overall might be less, and cost less overall compared to
chillers.
Shading Allowing direct solar exposure to any surface which can transfer the extra heat to any part of the air flow through the unit will raise the temperature of the air. If the heat is transferred to the air prior to flowing through the pads, or if the sunlight warms the pads themselves, evaporation will increase, but the additional energy required to achieve this will not come from the energy contained in the ambient air, but will be supplied by the sun, and this will result not only in higher temperatures, but higher humidity as well, just as raising the inlet air temperature by any means, and heating the water prior to distribution over the pad by any means, would do. In a worst-case scenario, placing the cooler on a sunny roof where temperatures might be 30+ degrees more than a shaded area off the roof, could result in negated exhaust air temperatures being unchanged or even hotter from a well-functioning cooler producing a delta of -30 degrees. In addition, sunlight may degrade some media, and other components of the cooler. Therefore, shading is advisable in all circumstances, though the vertical aspect of the pads, and insulation between the exterior and interior horizontal (upwards facing) surfaces to minimise heat transfer will suffice.
Mechanical systems Apart from fans used in mechanical evaporative cooling, pumps are the only other piece of mechanical equipment required for the evaporative cooling process in both mechanical and passive applications. Pumps can be used for either recirculating the water to the wet media pad or providing water at very high pressure to a mister system for a passive cooling tower. Pump specifications will vary depending on evaporation rates and media pad area. The Zion National Park visitors' center uses a 250 W (1/3 HP) pump.
Exhaust For optimal cooling exhaust ducts and/or open windows must be sufficient in size to allow for several
air exchanges per hour to pass through the air-conditioned area. Otherwise, a positive pressure might develop, lowering air exchanges, and the fan or blower in the system is unable to draw enough air through the cooling media resulting in less evaporation and lowering efficiency. The evaporative system cannot function effectively without exhausting a continuous supply of air from the air-conditioned area to the outside. By optimizing the placement of the cooled-air inlet, along with the layout of the house passages, related doors, and room windows, the system can be used most effectively to direct the cooled air to the required areas. A well-designed layout can effectively scavenge and expel the hot air from desired areas without the need for an above-ceiling ducted venting system. Continuous airflow is essential, so the exhaust windows or vents must not restrict the volume and passage of air being introduced by the evaporative cooling machine. One must also be mindful of the outside wind direction, as, for example, a strong hot southerly wind will slow or restrict the exhausted air from a south-facing window. It is always best to have the downwind windows open, while the upwind windows are closed. ==Different types of installations==