Evaporative Condenser Counter Flow
High-performance evaporative condensers engineered for industrial ammonia refrigeration — maximum heat rejection with minimum power consumption and long, corrosion-free service life.
High-performance evaporative condensers engineered for industrial ammonia refrigeration — maximum heat rejection with minimum power consumption and long, corrosion-free service life.
Prime Coil’s counter flow evaporative condensers are the workhorses of industrial ammonia refrigeration — engineered to reject large heat loads efficiently, reliably, and over decades of continuous duty.
The counter-flow design routes rising air against downward-cascading water, exposing the refrigerant coil to the coldest air and water at the same point. That combination delivers the lowest possible condensing temperature, which in turn cuts compressor power draw and lowers the plant’s energy bill every single hour of operation.
Every condenser we ship is built around an SS-304 tube coil and stainless steel basin — the two components that determine service life in a wet, corrosive environment. Combined with high-efficiency drift eliminators, PVC fills and axial-flow fans with weatherproof motors, the machine is designed for continuous outdoor duty across Indian ambient conditions from Ludhiana winters to Chennai summers.
Available from 100 kW to 1,600 kW single-unit capacity, with multiple units combined in parallel for larger installations.
Built to run, season after season.
SS-304 coil block
Stainless steel construction where it matters most — the coil that carries refrigerant and sees continuous water contact. Minimises corrosion, extends service life, reduces long-term maintenance versus galvanised alternatives.
Counter-flow heat transfer
Air flows upward against downward-cascading water, exposing the coil to the coldest media at the same point. Delivers the lowest achievable condensing temperature and the highest efficiency of any wet-condenser configuration.
Stainless steel basin & structure
SS water sump and structural elements resist the corrosion that eventually kills galvanised units. What you save on cheaper carbon-steel construction you lose ten times over in early replacement.
High-efficiency drift eliminators
Multi-pass PVC drift eliminators reduce water loss from the expelled air stream to under 0.001% of circulation rate. Less water lost means lower make-up requirement and reduced downstream fouling.
Axial-flow fan system
Weatherproof motors with SIS fan hubs deliver high air volume at low static pressure — the right physics for evaporative duty. Optional VFDs available for floating head-pressure control and further energy savings.
Multi-section design
Larger capacities ship as bolted modular sections, allowing standard road transport and simple site assembly. No crane-heavy monolithic units that get stuck at gates or under bridges.
Low-noise spray system
Low-pressure-drop spray nozzles distribute water evenly across the coil with minimum noise — suitable for plants adjacent to processing areas or residential zones.
Compatible with NH₃ and HFCs
Single equipment platform serves both ammonia and Freon systems. Same coil metallurgy, same basin construction, same service parts — simplifies your maintenance inventory across a mixed-refrigerant plant.
Specifications
| Refrigerants | Ammonia (R-717), Freon (HFC) variants |
|---|---|
| Heat rejection capacity | 100 kW to 1,600 kW per unit, parallel modules for higher |
| Coil material | SS-304 stainless steel |
| Basin material | Stainless steel |
| Structure | SS structure with SS fasteners |
| Fan type | Axial-flow, low-noise, weatherproof motor |
| Fan hub | SIS (Stainless Iron Steel) construction |
| Drift eliminator | PVC multi-pass, <0.001% drift |
| PVC fill | Cross-fluted, high-efficiency |
| Water circulation | Bottom sump, recirculation pump |
| Make-up water | Automatic float valve |
| Bleed line | Adjustable, conductivity-controlled optional |
| Ambient design | 27°C wet bulb standard; site-specific on request |
| Approvals | ARI compliant design methodology |
| Assembly | Multi-section modular for road transport |
Where it's used.
- Cold chain & cold storage
- Food processing
- Dairies
- Breweries
- Sea food processing
- Chemical & pharma
- Ice manufacturing
- Beverage production
- Meat & poultry processing
Product questions, answered.
What's the advantage of counter flow versus cross flow?
Counter flow moves air against the direction of water descent, exposing the coil to the coldest available media at each point. This delivers a lower condensing temperature than cross flow (where air moves horizontally through the water curtain), which reduces compressor work. On typical ammonia plants, this translates to 5-8% lower running cost versus equivalent cross flow units.
Why SS-304 coil instead of galvanised?
Galvanised coils are cheaper upfront but corrode in the wet, cyclic environment inside an evaporative condenser. Typical galvanised service life is 8-12 years in Indian conditions before pinholes appear. SS-304 routinely delivers 20+ years. When you factor in the plant downtime, refrigerant loss, and replacement labour of a mid-life coil failure, SS-304 pays back many times over.
How much water does the condenser consume?
Roughly 1.5-2% of the water circulation rate is lost to evaporation (that's the process doing its job), plus a small controlled bleed to prevent scale buildup. On a 500 kW unit that's approximately 800-1,200 litres per hour of make-up water at peak load. Actual consumption depends on your wet bulb temperature and water quality — softer water needs less bleed.
Can I run this with a VFD on the fan?
Yes, and we recommend it for any plant running continuously. VFDs on the condenser fans let you modulate speed with load, delivering 20-30% energy savings on fan power over the year. They also enable floating head-pressure control, which cuts compressor energy by another 15-25%. The additional capital cost pays back in under 2 years on continuous-duty plants.
What about noise levels?
Standard units produce approximately 75-80 dB(A) at 1 metre from the fan discharge. For sites near residential zones or offices, we offer low-noise variants with sound attenuators and slower-speed fans that bring readings down to 60-65 dB(A). Choose based on site conditions during specification.
Is on-site assembly straightforward?
Yes. Units above 600 kW ship as bolted sections small enough for standard road transport (no over-dimensional permits needed for most). Site assembly typically takes 2-4 days for a two-person crew. Prime Coil provides assembly drawings, torque specifications, and phone/on-site commissioning support included in the supply.
Winter operation — freeze protection?
For cold-climate sites, we supply optional basin heaters and pan freeze protection to keep the sump above freezing during winter shutdowns. VFD-controlled fans also help by modulating airflow to prevent overcooling of the water at low ambient conditions. Discuss your minimum design ambient with our engineers during selection.
Every Prime Coil evaporative condenser is selected against your site's design wet bulb and load profile — not against a generic catalogue figure. Send us the numbers and we'll come back within a working day with the model, the footprint, and the delivered price.
Tell us your daily requirement.
Share your output target, product and ambient conditions — we'll specify the machine and the plant around it.