EcoShield Adiabatic Cooling System Gerab Energy Systems

Overview

EcoShield is an adiabatic cooling solution designed to improve the operating efficiency of air-cooled condenser systems, particularly under high ambient temperature conditions. The system pre-cools the ambient air before it reaches the condenser by passing it through wetted evaporative pads.

EcoShield creates a controlled evaporative cooling barrier around the condenser air intake. Ambient air is drawn through specially designed wet cellulose pads where heat is absorbed through the adiabatic evaporation process. The resulting cooler air is then supplied to the condenser.

In addition to lowering incoming air temperature, the evaporative pads act as a protective barrier against dust and sand, helping reduce contamination of condenser coils. This can reduce condenser coil cleaning requirements, lower preventive-maintenance needs and contribute to longer condenser life.

The system incorporates an intelligent multi-stage controller that adjusts operation according to ambient temperature and humidity conditions, helping ensure that water is used only when conditions are suitable for effective evaporative cooling.

Adiabatic pre-cooling: Reduces condenser inlet/suction air temperature by up to 18°C.
Four-stage intelligent control: Uses a programmed Siemens LOGO controller to regulate system operation according to temperature and humidity.
Ambient and wet-wall humidity sensing: Monitors operating conditions for optimized control.
Automatic cut-off: Stops operation when temperature or humidity conditions are not suitable for optimum performance.
Automatic bleed system: Helps prevent accumulation of dust and minerals within the water circuit.
Tailor-made evaporative pads: Pad dimensions can be adapted to the available height to maximize airflow.
High-absorbency cellulose media: Manufactured from special cellulose craft paper saturated with resins for high water absorption and mechanical strength.
PVC pad option: Full PVC evaporative pads are also available.
Protective pad treatment: Protection against shrinkage and deterioration caused by UV exposure, fungi, bacteria and algae.
UV water sterilization: UV sterilizer installed in the water line to help prevent the growth of Legionella bacteria and algae.
Automated tank bleed and chemical dosing: Tank bleeding is programmed after accumulated pump operation, with settings adjustable during commissioning according to site water quality.
Maintenance accessibility: Designed with adequate space between the evaporative pads and condenser to allow maintenance activities.

The four-stage temperature, humidity and timer settings above are taken directly from the operating logic in the presentation.

Cooling Principle	Adiabatic / evaporative pre-cooling
Cooling Medium	Wetted evaporative pads
Condenser Inlet Air Reduction	Up to 18°C
Pad Material	Resin-treated, high-absorbency cellulose media
Alternative Pad Material	Full PVC option
Pad Configuration	Tailor-made according to available installation height
Pad Protection	Treatment/protection against UV, fungi, bacteria, algae and deterioration
Controller	Siemens LOGO programmable logic controller
Control System	4-stage operation
Sensors	Ambient humidity, ambient temperature and wet-wall humidity
High Humidity Cut-Off	System OFF at ambient humidity of 75% and above
Low Temperature Cut-Off	System OFF below 24°C ambient temperature
Stage 1 Timer	ON 150 sec / OFF 90 sec
Stage 2 Timer	ON 120 sec / OFF 120 sec
Stage 3 Timer	ON 60 sec / OFF 180 sec
Stage 4 Timer	ON 180 sec / OFF 60 sec
Stage 4 Activation	Wet-wall humidity below 60% and ambient temperature above 40°C
Water Hygiene	UV sterilization
Water Management	Automatic bleed and periodic chemical dosing
Tank Bleed Reference Setting	After 12 accumulated pump-running hours; adjustable during commissioning