In this project, SPX Cooling Systems, formerly Marley Cooling Technologies, Inc., evaluates the performance of its patented Air2Air™ condensing technology in cooling tower applications at coal-fired electric power plants. Researchers quantify Air2Air™ water conservation capabilities with results segmented by season and time of day. They determine the pressure drop and energy use during operation. Additionally, SPX Cooling Systems develops a collection method for the recovered water, analyzes water quality, and identifies potential on-site processes capable of utilizing the recovered water.

Research conducted examines freezing condition operation and plume abatement. Cold weather application concerns are examined by determining if the Air2Air™ modules freeze to any extent and if freezing causes any structural damage to modules or supports. A wet/dry air mixing system is developed for plume abatement, and the dissipation of the plume discharged from the cooling tower fan is studied.

The project could demonstrate significant water savings due to recovery using the condensing technology. SPX Cooling Systems lists a design annual average water recovery rate of 20% for their Air2Air™ condenser and estimates that the cooling water savings in condensed evaporate for the U.S. to be 1.56 billion gallons per day if all power and industrial towers were outfitted with the condensing technology.