Primary Cooling Coil

PRIMARY COOLING COIL
FOR AIR HANDLING UNIT
Author:
Engr. K.H., Kong is Mechanic Engineer.
(IEM member, No: M21065)
Bachelor’s Degree with Honors with Distinction in Mechanical Engineering.
Primary Cooling Coil for Air Handling Unit
PRIMARY COOLING COIL FOR AIR HANDLING UNIT
ABSTRACT
In this write up, an energy-saving device is introduced into the air-handling
unit (AHU). Due to increases in energy costs, energy saving devices or systems have
become the new preferred trend in tropical countries. A primary cooling coil system
is incorporated into the AHU to recycle the condensate water in order to achieve
energy savings.
The warm outside fresh air is drawn through the primary cooling coil to
recover the latent heat of condensate water. The large temperature gradient between
the warm fresh air and condensate water enlarges the amount of energy recovered.
This system is well applicable to primary AHU which serves primary air to the air-
conditioning system. The cost of installing the device is negligible but in returning
long term saving. Furthermore, the de-cooled condensate water can be drained off
through non-insulated drain pipe.
The idea generation is discussed in the introduction. Chapters 2 and 3 describe
the preliminary calculation of the energy saving percentage. Chapter 4 shows the
detailed theoretical study of the development of the energy saving system. This shows
the viability of the idea. Chapter 5 will recommend the design of the primary cooling
coil configuration to achieve the desired cooling effect and energy saving strategy.
Lastly, the conclusion of the whole study is presented.
Copyright © 2008 by Kok-Haw Kong Page 2 of 23

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1.0 INTRODUCTION
In tropical countries such as the United Arabia Emirates (UAE) and Malaysia,
the climate is always hot and highly humid throughout the year. Lots of energy is
consumed for Air-Conditioning and Mechanical Ventilation (ACMV) systems.
For buildings such as hotels and hospitals, energy is used to cool down the
fresh air in the primary AHU and pumped into the building to achieve the internal air
quality required. Due to the high humid climate, lots of condensed water is drained
away as a by-product. However, the cooled condensate water actually consumes 2%
of the total cooling load of the system on average. Here, we are studying the recovery
of the condensed water in which the 2% energy can be saved. 2% of energy for a
system running 24 hours a day can make a significant reduction for the operating cost.
The condensed water is first collected by the condensate drain pan below the
main secondary cooling coil. Then, the collected condensed water is pumped into the
primary cooling coil for the de-cooling process.
In order to maximize the energy recovery, a primary cooling coil is
recommended to be installed at the fresh air intake opening of the AHU where the
temperature gradient between the air outside and condensate water is greater, rather
than at the side in which air returns or at the mixing plenum.

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2.0 PRELIMINARY THEORETICAL STUDY
In this study, we assume that the AHU is a chilled-water cooled type with a
modulating control valve. The percentage of energy saved is calculated by comparing
the AHU with and without the primary cooling coil.
Figure 2.1
Figure 2.1 shows a conventional AHU configuration without the primary
cooling coil. From the energy equation and psychometric chart, the cooling load per
unit of dry air is given as
•
Q1
•
= H1 − H 2 …(2.1)
ma

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From the mass balance equation, the condensed water per unit of dry air is
•
mw
•.
= (w1 − w2 ) … (2.2)
ma
For an AHU with a primary cooling coil, the cooling load of the condensate water per
unit of dry air is given as follows:
• • • •
Q2 mw Q2 ma
•
= •
C p , w ∆Tw on water side, or •
= •
C p ,a ∆Ta on air side … (2.3)
ma ma ma ma
Rearranging equation (2.3), we simplify it to
•
mw C p,w
•
(Tw,o − Tw,i ) = (Ta,i − Ta,o ) … (2.4)
m C p ,a
a
For the preliminary study, we first assume Ta ,o = Tw,o . This assumption and
condition depends on the coil length. In fact, Tw,o ≈ Ta ,i may be achieved if the coil is
long enough. The temperature difference is thus higher and higher energy saving is
possible.
We also assume 100% sensible heat transfer across the primary cooling coil
for equation (2.4). This is due to low heat transfer and high air velocity. This
assumption will be checked using a psychrometric chart and verified in chapter 3.

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3.0 CASE STUDY
The climate of Malaysia (Tropical Country) is selected for study. Generally,
three cases are studied for comparing the percentage of energy saved. The first two
cases are two extreme conditions while the last case is the normal average condition.
These are:
1) During the Afternoon, the Warmest Period of the Day
2) Under Extreme Conditions, a Hot Heavy Rainy Day, and
3) Under Normal Conditions, Average Weather.
3.1 During Afternoon, the Warmest Period of the Day
During the warmest period, where outside air condition is DB1/WB1 =
93.9/78.1°F, and the air off coil condition is DB2/WB2 = 55.4/53.6°F

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From the psychometric chart, we obtain H1 = 41.4 Btu/lbm, w1 = 0.017 lbv/lba
H2 = 22.3 Btu/lbm, w2 = 0.008 lbv/lba
The initial calculation is performed to find the overall cooling load of the
secondary cooling coil. From energy equation (2.1), the cooling load per unit of dry
air is
•
Q1
•
= H 1 − H 2 = 41.4 − 22.3 = 19.1 Btu / lbm … (3.1)
ma
From the mass balance equation (2.2), the condensed water per unit of dry air is
•
mw
•.
= (w1 − w2 ) = (0.017 − 0.008) = 0.009 lbv / lba … (3.2)
ma
From the energy equation (2.4) across the primary coil, the equilibrium temperature is
calculated as follows:
•
mw C p,w
•
(Tw,o − Tw,i ) = (Ta ,i − Ta,o ) … (3.3)
m C p , a
a
1
0.009 × (Tw,o − 55.4) = (93.9 − Ta,o ), assume Ta ,o = Tw,o
0.24
1.0375Tw,o = 93.9 + 2.0775
Tw,o = 92.5 oF … (3.4)
From energy equation (2.3), the cooling coad of condensate water per unit of dry air is

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• •
Q2 mw
•
= •
C p , w ∆Tw = 0.009 × 1 × (92.5 − 55.4 ) = 0.3339 Btu / lbm … (3.5)
ma ma
Hence, the actual cooling load required from chilled water is reduced to
• •
Q1 Q2
•
− •
= 19.1 − 0.3339 = 18.77 Btu / lbm … (3.6)
ma ma
Therefore, the percentage of cooling capacity reduction (the energy saving) is
•
Q2 0.3339
•
= = 1.75% … (3.7)
Q1 19.1
3.2 Case Study on the Additional Two Conditions
Similar studies such as those in chapter 3.1 are carried out for two additional
conditions. The computed results are tabulated as follows:
Item Description Warmest Hot Heavy Average

Period Rainy Day Weather
1) Outside air condition, DB1/WB1 (°F) 93.9/78.1 84.2/81.8 81.5/73.6
2) Air Off Coil Condition, DB2/WB2 (°F) 55.4/53.6 55.4/53.6 55.4/53.6
3) Energy Equation (2.1), (Btu/lbm) 19.1 23.3 14.8
4) Mass Balance Equation (2.2), (lbv/lba) 0.009 0.015 0.008
5) Equilibrium Temperature, Tw,o (°F) 92.5 82.5 80.7
6) Energy Equation (2.3), (Btu/lbm) 0.3339 0.4065 0.2024
7) Actualy Cooling Load, (Btu/lbm) 18.77 22.89 14.60
8) Energy Saving (%) 1.75 1.74 1.37
Referring to the psychometric chart, the cooling effect for the primary cooling
coil is plotted and checked. It is found that the off coil condition of fresh air across the
primary coil is far from the saturation curve. Due to high air flow, 100% of the

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sensible heat transfer is achievable. No condensation occurs at the primary cooling
coil even during rainy days. Therefore, the assumption of energy equation (2.4) is
valid in this case.
In this study, we assume that Ta ,o = Tw,o and the average energy saving of the
primary cooling coil is 1.37%. In the actual case, a higher percentage of energy saved
can be achieved when the coil surface temperature is held constant and maintained at
Ta ,i . The constant coil surface temperature is due to high air flow across the primary
coil. The condition of Tw,o ≈ Ta ,i may be achieved due to the longer coil length.
Higher temperature differences between condened water inlet and the outlet produces
higher energy savings.
4.0 PRIMARY COOLING COIL CONFIGURATION
In this chapter, we study the configuration and the requirements of the primary
cooling coil in order to achieve the required cooling condition. We also study the
effect of the static loss in air across the primary cooling coil for fan selection.
•
4 mw
From the Reynold1,3 number, Re D = … (4.1)
πDµ
•
where D = diameter of coil, m w = water mass flow rate, µ = viscosity of fluid.
For a fully developed turbulent flow in a smooth circular tube, from the
Petukhov, Gnielinski1,4 correlation, the Nusselt1,4 number is given as follows

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( f 8)(Re D − 1000) Pr   D  2 3 
Nu D = 1 +    … (4.2)
1 + 12.7( f 8) (Pr 2 3 − 1)   L  
12
where the friction factor given by Petukhov1,4,
−2
f = (0.790 ln Re D − 1.64 ) … (4.3)
Pr = Prandtl Number
For cases of constant wall temperature and a fluid with Pr > 0.7, correlation
(4.2) for constant wall heat flux can be used with negligible error.4
For a preliminary study without knowing the pipe length, we first assume that
the pipe length is much longer than the pipe diameter, L>>D. Therefore, equation (4.2)
reduces to
Nu D =
( f 8)(Re D − 1000) Pr
… (4.4)
1 + 12.7( f 8) (Pr 2 3 − 1)
12
The error for the modified equation of (4.4) will be discussed at the end of this
chapter. For the preliminary assumption of the omitted item of equation (4.2), the
ratio of the pipe diameter in millimeters to the pipe length of meters is 1:1000. The
value of the ratio to the power of 2/3 is reduced to 1:100. Hence, the error is within a
1% range of the calculated value.
The Nusselt number also can be expressed as follows for a simplified application:
hD
Nu D = … (4.5)
k
where h = convection coefficient, D = pipe diameter, k = thermal conductivity of fluid.

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For the heat transfer equation in a circular tube1, we have

•
m w C p , w (T w ,o − T w ,i )
h= … (4.6)
π DL ∆ T lm
Combining equation (4.5) & (4.6) and rearranging, we obtain
•
m w C p , w (Tw,o − Tw,i )
L= … (4.7)
πkNu D ∆Tlm
where
∆Tw,o − ∆Tw,i
∆Tlm = … (4.8)
ln (∆Tw,o ∆Tw,i )
∆Tw,o = Ts − Tw,o , ∆Tw,i = Ts − Tw,i … (4.9)
From the above equations, our objectives are to generally determine the
following:
1) The required coil configuration to achieve the required cooling effect. The
parameters are coil diameter and length.
2) To check on the static loss in air across the primary cooling coil where higher
static loss in air requires a larger fan and a higher operating cost.
Again, three similar cases are studied to compare the percentage of energy saved. The
3 cases are:
1) During the Afternoon, the Warmest Period of the Day
2) Under Extreme Conditions, a Hot Heavy Rainy Day, and
3) Under Normal Conditions, Average Weather.

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4.1 During Afternoon the Warmest Period,
Taking DB1/WB1 = 34.4/25.6°C (93.9 /78.1°F), DB2/WB2 = 13/12°C (55.4/53.6°F),
Ts = 34.4°C (93.9°F), Tw,o = 33.6°C (92.5°F), and Tw,i = 13°C (55.4°F),
• •
m w ma = 0.009 kgv kga (0.009 lbv/lba)
Taking D = 12mm (1/2”), at the mean water temperature = (33.6+13)/2 = 23.3°C
(73.9°F), µ = 932 x 10-6 Ns/m2, Pr = 6.415
For an AHU serving 3000 l/s (6360 cfm) fresh air, the area of fresh air intake
is assumed to be 1300mm(W)x700mm(H). During the warmest period, the calculated
values are,
•
m w = 0.009 × 3 × 1.1614 = 0.0314 kg / s … (4.10)
•
4 mw 4 × 0.0314
Re D = = = 3570 , ∴ turbulent flow. … (4.11)
(
πDµ π (0.012) 932 × 10 −6 )
The friction factor,
= [0.790(ln 3570 ) − 1.64] = 0.043

−2 −2
f = (0.790 ln Re D − 1.64 ) … (4.12)
Hence, the Nusselt number,

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Nu D =
( f 8)(Re D − 1000) Pr
1 + 12.7( f 8) (Pr 2 3 − 1)
12
Nu D =
(0.043 8)(3570 − 1000)6.415 = 88.615 = 27 … (4.13)
1 + 12.7(0.043 8) (6.415 2 3 − 1) 3.283
12
From equation (4.9), the temperature difference is
∆Tw,o = Ts − Tw,o , ∆Tw,i = Ts − Tw,i
∆Tw,o = 34.4 − 33.6 = 0.8 oC , ∆Tw,i = 34.4 − 13 = 21.4 oC … (4.14)
From equation (4.8), the log mean temperature difference is
∆Tw,o − ∆Tw,i 0.8 − 21.4

∆Tlm = = = 6.268 oC … (4.15)
ln (∆Tw,o ∆Tw,i ) ln(0.8 21.4)
At a water temperature of 23.3°C, the specific heat of water is Cp,w = 4180
J/kgK, the thermal conductivity is kw = 0.6078 W/mK. From equation (4.7), we obtain
the required pipe length,
•
mw C p , w (Tw,o − Tw,i ) 0.0314 × 4180 × (33.6 − 13)
L= = = 8.367 m … (4.16)
πkNu D ∆Tlm π × 0.6078 × 27 × 6.268
For a 12mm (1/2”) diameter primary cooling coil, the maximum coil length
required to achieve a cooling effect of 1.75% of energy is 8.367m (27.45ft). The net
effective primary cooling coil area perpendicular to the air flow direction is
Net Area = pipe length x pipe diameter
= 8.367 x 0.012 = 0.1m2 (1.08ft2) … (4.17)

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The total opening area for incoming fresh air, Af = 1.3m x 0.7m = 0.91 m2
Hence, the ratio of the effective primary cooling coil area to the fresh air
opening is 0.1/0.91 = 11%, where the pressure drop/static loss across the primary
cooling coil at the fresh air opening is negligible.
4.2 Under Extreme Condition, a Hot Heavy Rainy Day
Similar studies such as those in chapter 4.1 are carried out for a hot heavy
rainy day. The computed results are tabulated as follows:
Item Description Warmest Hot Heavy

Period Rainy Day
1) Outside air condition, DB1/WB1 (°C) 34.4/25.6 29/27.7
2) Air Off Coil Condition, DB2/WB2 (°C) 13/12 13/12
3) Coil Surface Temperature, Ts (°C) 34.4 29.0
4) Condensate Inlet Temperature, Tw,i (°C) 13.0 13.0
5) Equilibrium Temperature, Tw,o (°C) 33.6 28.06
6) Mass Balance Equation (2), (kgv/kga) 0.009 0.015
7) Cooling Coil Diameter, D (mm) 12 12
8) Mean Temperature (°C) 23.3 20.5
9) Viscosity of Fluid, µ (Ns/m2) 932 x 10-6 995 x 10-6
10) Prandtl Number, Pr 6.415 6.902
11) Air Intake Volume Flowrate, ma (l/s) 3000 3000
12) Condensate Water Flowrate, mw (kg/s) 0.0314 0.0523
13) Reynold number, ReD 3570 5577
14) Type of Flow Turbulent Turbulent
15) Pipe Friction Factor, f 0.043 0.03734
16) Nusselt Number, NuD 27 45
17) Log Mean Temperature Difference, ∆Tlm (°C) 6.268 5.313
18) Specific Heat of Condensate Water, Cp,w (J/kg.K) 4180 4182
19) Thermal Conductivity of Condensate Water, kw 0.6078 0.6036
(W/m.K)
20) Length of Cooling Coil, L (m) 8.367 7.265
21) Net Effective Obstructed Area, Ac (m2) 0.1 0.0944

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22) Percentage of obstructed area (%) 11 10

23) Pressure Drop Across Primary Cooling Coil Negligible Negligible
4.3 Hourly Simulation for Average Weather
An hourly simulation is carried out to study the hourly energy savings
throughout a day. A day in July is selected. The primary cooling coil diameter is taken
to be 8mm (3/8”). For an AHU serving 3000 l/s (6360 cfm) fresh air, the opening area
of fresh air intake is taken to be 1300mm (4.27 ft) (W) x 700mm (2.3 ft) (H), which is
equal to 0.91m2 (9.8ft2). Intake air velocity is 3.3m/s (650fpm).
From table 4.1 shown below, for an installed 8mm (3/8”) diameter primary
cooling coil, the maximum coil length required is 6.847 meters (22.466 ft), which able
to achieve 1.42% of energy saved, happened at the hour of 23. The ratio of the
primary cooling coil area to the fresh air opening is 6.77%, where the pressure drop
across primary cooling coil is negligible. The supply fan capacity can remain as is
without additional power to drive the fan.
With the designed length of the primary cooling coil as 8m (26.2 ft), the
primary cooling coil can achieve a higher energy saving level at any time compared to
the calculated value, which is tabulated in table 4.1. The energy saved can be higher
than the average value of 1.51%. Furthermore, , the coil surface temperature is higher

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than the calculated value in actual cases where Tw,o ≈ Ta ,i . This is due to the high
convection coefficient of the high velocity of fresh air across the primary cooling coil.
A higher temperature difference between the inlet and outlet for condensed water
contributed to higher energy savings.
Moreover, the energy saved can achieve a higher percentage because more
condensed water is collected on a rainy day.
From equation (4.4), the corrective error is very small. The ratio between a
pipe diameter of 8mm to the pipe length of 8000mm is 1:1000. Hence, the corrective
error is 1% of the calculated value. The energy saved is 1.51%±0.015%.

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Table 4.1
An hourly simulation of the average weather to obtain the desired design configuration
Outdoor Original Cooling Primary Cooling Energy Saving Coil Effective Obstructed
Temperature, °F Load, Q1/ma Load, Q2/ma Percentage Reynold Length Coil Area Area Ratio
Hour Jul DB Jul WB Btu/lbm Btu/lbm (%) Re (ft) (ft2) (%)
0 80.78 74.48 15.700 0.220 1.40% 4930 18.935 0.5591 5.71%
1 79.88 74.30 15.500 0.212 1.37% 4902 19.019 0.5616 5.73%
2 79.16 74.12 15.300 0.206 1.35% 4879 19.087 0.5636 5.75%
3 78.44 73.94 15.200 0.200 1.31% 4857 19.154 0.5656 5.77%
4 77.90 73.76 15.000 0.195 1.30% 4841 19.205 0.5671 5.79%
5 77.72 73.76 15.000 0.194 1.29% 4835 19.222 0.5676 5.79%
6 78.08 73.76 15.000 0.197 1.31% 4846 19.188 0.5666 5.78%
7 78.98 74.12 15.300 0.205 1.34% 4874 19.104 0.5641 5.76%
8 80.42 74.48 15.700 0.217 1.38% 4919 18.968 0.5601 5.72%
9 82.58 75.02 16.200 0.236 1.46% 4987 18.767 0.5542 5.66%
10 84.92 75.74 16.800 0.256 1.52% 5064 18.550 0.5478 5.59%
11 87.62 76.46 17.500 0.279 1.60% 5156 18.302 0.5404 5.52%
12 90.32 77.00 18.000 0.303 1.68% 5244 18.071 0.5336 5.45%
13 92.30 77.54 18.500 0.320 1.73% 5305 17.915 0.5290 5.40%
14 93.56 77.90 18.900 0.331 1.75% 5345 17.816 0.5261 5.37%
15 93.92 78.08 19.100 0.334 1.75% 5357 17.788 0.5253 5.36%
16 93.56 77.90 18.900 0.331 1.75% 5345 17.816 0.5261 5.37%
17 92.30 77.54 18.500 0.320 1.73% 5305 17.915 0.5290 5.40%
18 90.68 77.18 18.200 0.306 1.68% 5255 18.043 0.5328 5.44%
19 88.52 76.64 17.700 0.287 1.62% 5187 18.220 0.5380 5.49%
20 86.36 76.10 17.200 0.269 1.56% 5112 21.540 0.6361 6.49%
21 84.56 75.56 16.700 0.253 1.51% 5052 21.881 0.6461 6.60%
22 82.94 75.20 16.300 0.239 1.47% 4999 22.204 0.6557 6.69%
23 81.68 74.84 16.000 0.228 1.42% 4958 22.466 0.6634 6.77%
AVERAGE 16.758 0.256 1.51% MAX 22.466 0.6634 6.77%

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5.0 THE DESIGN OF PRIMARY COOLING COIL
Figure 5.1 shows the recommended configuration of the primary cooling coil
for the AHU and Figure 5.2 shows the recommended detailed design of the primary
cooling coil.
Figure 5.1

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Figure 5.2
Let us take an example for an AHU serving 3000 l/s (6360 cfm) fresh air
across a 0.91 m2 (9.8 ft2) (1.3m x 0.7m) fresh air intake opening with the primary
cooling coil installed as shown in Figures 5.1 and 5.2. Outside air is entering the AHU
at temperature DB/WB = 32.2°C/30°C (90°F/86°F). Air face velocity = 3.3 m/s (650
fpm).
On the water side, condensate water is entering coil at 13°C (55.4°F). The
primary cooling coil diameter = 8mm (3/8”). Condensate water flow rate = 0.0314 l/s
(0.414 igpm), and condensate water velocity = 0.625 m/s (123 fpm).

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5.1 Operating Methodology of Primary Cooling Coil
Referring to Figure 5.2, condensate water is periodically pumped to the
balancing tray. Then, the flow of the condensate water is adjusted by the control valve.
When the balancing tray is filled with water, the fresh condensate water is fed into the
tube by gravity and the de-cooled condensate water will discharge to the nearest floor
trap or scupper drain. When balancing tray is empty, condensate water stays in the
coil until the balancing tray is refilled with fresh condensate water.
When water is flowing through the cooling coil, the heat transfer rate is as per
designed performance. When the balancing tray is empty, the water stays in the
primary cooling coil and maximum heat transfer occurs. The energy saved is higher
than the calculated value.
5.2 Operating Cost of Pump
The condensate pump is used to pump the condensate water from the
condensate drain pan to the balancing tray. For example, when the water level in the
drain pan achieves 3 liters (0.66 igallons), a condensate water pump with a capacity of
1.0 l/s (13.2 igpm) is used to pump away the condensate water within 3 seconds.

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For a 1.0 l/s pump, the power consumption is 120W. The worst case is taken
to calculate the total power consumption of the condensate pump. During extreme
conditions, the total condensate water generated is 222 liters per day.
Pumping time is 222/3 = 74 times per day.
Pumping period is 222 seconds = 0.0617 hrs
Round up to 0.1 hrs. Total electricity consumption required is,
0.12kW x 0.1 hrs = 0.012 kWhr
0.012 kWhr x RM 0.294 (USD 0.077) = RM 0.0035 (USD 0.001) per day
The heat generated from the pump is roughly 42W. By adding the primary
cooling coil to AHU, the de-cooled condensate water can be discharged to the nearest
floor trap or scupper drain without condensation on the drainage pipe.
5.3 Maintenance
The primary cooling coil only requires simple maintenance. A suitable
cleaning chemical is poured into the condensate drain pan. Then, pump it to the
balancing tray, to the primary cooling coil and let it drain out. For the external coil
surface, clean it with a suitable cleaning chemical. The condensate pump may need to
be replaced yearly.

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6.0 CONCLUSION
For a modulating control valve chilled-water cooled type AHU, when the
primary cooling coil is placed at the fresh air side of the AHU, it can achieve
1.5%±0.015% of energy savings compare to a conventional AHU. In the actual case,
the energy saved is higher than the calculated value due to the following reasons,
a) higher coil surface temperature,
b) longer coil length,
c) higher condensate water outlet temperature,
d) more condensate water collected during rainy days.
For a direct expansion refrigerant type AHU, the compressor cuts in and out
from time to time according to the cooling load. For this type of AHU, the cooling
load profile demonstrates zigzag fluctuating behavior. The condensate water collected
will not achieve 100% as per a modulating chilled water type AHU. Experiments
found that the amount of condensate water collected for this type of AHU is around
65% as compared to a modulating type chilled water AHU. Therefore, the total
energy saved for the direct expansion refrigerant type AHU is 1%±0.01%.
The energy saving of 1% to 2% is attractive in air-conditioning system. In
simple theory, as long as heat is transferred between the cooled condensate water and
the warm fresh air, energy is saved. The operating cost is negligible compare to the
energy saved and the capital cost is negligible compare to the AHU construction cost.

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7.0 REFERENCE
1. Incropera, F.P. and Dewitt, D.P. “Fundamentals of heat and mass transfer”.
(5th ed.). John Wiley & Sons. New York, 2002.
2. ASHRAE. (2001). “Climate Design Information”.
3. Street, R.L., Watters, G.Z. and Vennard, J.K. “Elementary Fluid Mechanics”.
(7th ed.). John Wiley & Sons. New York, 1996.
4. Spang, B. “Correlations for Convective Heat Transfer”. The Chemical
Engineers’ Resource Page. http://www.cheresources.com/convection.pdf

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PRIMARY COOLING COIL

FOR AIR HANDLING UNIT

PRIMARY COOLING COIL FOR AIR HANDLING UNIT

In this write up, an energy-saving device is introduced into the air-handling

through non-insulated drain pipe.

The idea generation is discussed in the introduction. Chapters 2 and 3 describe

Lastly, the conclusion of the whole study is presented.

Copyright © 2008 by Kok-Haw Kong Page 2 of 23

consumed for Air-Conditioning and Mechanical Ventilation (ACMV) systems.

away as a by-product. However, the cooled condensate water actually consumes 2%

primary cooling coil for the de-cooling process.

In order to maximize the energy recovery, a primary cooling coil is

than at the side in which air returns or at the mixing plenum.

Copyright © 2008 by Kok-Haw Kong Page 3 of 23

2.0 PRELIMINARY THEORETICAL STUDY

modulating control valve. The percentage of energy saved is calculated by comparing

the AHU with and without the primary cooling coil.

Figure 2.1 shows a conventional AHU configuration without the primary

unit of dry air is given as

Copyright © 2008 by Kok-Haw Kong Page 4 of 23

unit of dry air is given as follows:

Rearranging equation (2.3), we simplify it to

assumption will be checked using a psychrometric chart and verified in chapter 3.

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3.0 CASE STUDY

The climate of Malaysia (Tropical Country) is selected for study. Generally,

1) During the Afternoon, the Warmest Period of the Day

2) Under Extreme Conditions, a Hot Heavy Rainy Day, and

3) Under Normal Conditions, Average Weather.

3.1 During Afternoon, the Warmest Period of the Day

During the warmest period, where outside air condition is DB1/WB1 =

93.9/78.1°F, and the air off coil condition is DB2/WB2 = 55.4/53.6°F

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From the psychometric chart, we obtain H1 = 41.4 Btu/lbm, w1 = 0.017 lbv/lba

H2 = 22.3 Btu/lbm, w2 = 0.008 lbv/lba

1.0375Tw,o = 93.9 + 2.0775

Tw,o = 92.5 oF … (3.4)

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Therefore, the percentage of cooling capacity reduction (the energy saving) is

3.2 Case Study on the Additional Two Conditions

conditions. The computed results are tabulated as follows:

Item Description Warmest Hot Heavy Average

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sensible heat transfer is achievable. No condensation occurs at the primary cooling

valid in this case.

higher energy savings.

4.0 PRIMARY COOLING COIL CONFIGURATION

Petukhov, Gnielinski1,4 correlation, the Nusselt1,4 number is given as follows

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where the friction factor given by Petukhov1,4,

1% range of the calculated value.

where h = convection coefficient, D = pipe diameter, k = thermal conductivity of fluid.

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For the heat transfer equation in a circular tube1, we have

Combining equation (4.5) & (4.6) and rearranging, we obtain

∆Tw,o = Ts − Tw,o , ∆Tw,i = Ts − Tw,i … (4.9)

parameters are coil diameter and length.

1) During the Afternoon, the Warmest Period of the Day

2) Under Extreme Conditions, a Hot Heavy Rainy Day, and

3) Under Normal Conditions, Average Weather.

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4.1 During Afternoon the Warmest Period,