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ENEXIO
ENEXIO
About Enexio
ENEXIO is a reflection of what we do and what we have accomplished as pioneer in the field of industry-, process-, and power plant cooling as well as process industry cooling over decades. At the same time, our name is a promise to our customers and business partners – ENEXIO stands for Energy. Engineering. Excellence. With our experience and pioneering spirit in engineering, manufacturing and service, we deliver state of the art solutions for power plants, water and wastewater applications – always inspired by our profound sense of responsibility for the overall management of resources and a clean environment. We deliver excellence and achieve customer satisfaction everywhere in the world. Our global network of employees work with an unceasing commitment to high quality, ecology and cost effective products and services.
DRY COOLING SYSTEMS
AIR COOLED CONDENSERS (ACC)
ENEXIO – as the inventor of the Air Cooled Condenser – has played a leading role
in the evolution of this dry cooling technology. We are known for our comprehensive
expertise in the field of cooling technology for the power generating industry and
we offer the whole range of services for dry cooling systems.
In 1935, Otto Happel, in co-operation with the engineer Dr. Kurt Lang, began
developing Air Cooled Condensers for stationary steam turbines. The start-up of the
first ACC serving a steam turbine at the Prosper mine in Essen, Germany was in 1939.
A PROUD PART OF OUR HERITAGE IS BEING THE EXPERTS FOR AIR COOLED CONDENSERS
The leading market position of ENEXIO in the field of power plant cooling is partly
due to its expertise in both cooling processes: Wet Cooling Towers and Dry Cooling
Solutions. It is a well-known fact that experience pays off. For decades, ENEXIO
has been building cooling systems all over the world, covering everything – from the
construction of new systems to the enhancement, maintenance and optimisation of
existing systems – always to the highest quality standards and incorporating the
latest findings from its own research and development programmes.
CLASSIC AIR COOLED CONDENSERS (ACC)
A proud part of our heritage of innovation in cooling technology is in being the inventor of the Air Cooled Condenser (ACC). The ENEXIO Air Cooled Condenser is a direct dry cooling system wherein steam is condensed inside fin tubes.
Typically, the aluminum-plated fin tubes are single-row condensing tubes that are brazed with aluminum fins and are air cooled. Since they are air cooled, no water is required for main cooling of the power plant.
DRAFT AIR COOLING CONDENSER
From the company who invented the Air Cooled Condenser, comes the next generation
of innovative and intelligent design.
The InAIR combines proven components and technologies to yield the next
generation in dry cooling: an Air Cooled Condenser featuring induced draft fans.
Induced draft fans have been used reliably in the majority of power plant main
cooling systems worldwide, such as in wet cooling tower applications.
Now, through innovative engineering and utilization of ENEXIO’s self-supporting
ALEX bundles, we can offer the InAIR — an Air Cooled Condenser that delivers
superior operational performance.
ALUMINIUM FINNED STEEL TUBE SYSTEM
The ALEX system of ENEXIO consists of an aluminium-coated steel flat duct.
Aluminium finnings between the flat ducts are hard-soldered to the aluminium
coating of the flat duct. The solder fills the gap completely between the fin
root and the core tube to achieve excellent heat transfer properties.
Conventional fin tube bundles require A-supports to carry the weight of the
tube bundles, but the patented ENEXIO self-supporting fin tube bundle with
integrated headers needs no support. Only separation walls and hoist beams
are required — resulting in significant material savings and extremely low
erection time.
Key Advantages:
• Own heat exchanger bundle production
• Bundle preassembly at ground level
• Only one small crane needed (1 big lift = 2 bundles)
Hybrid Cooling Deluge ACC
The Deluge Air cooled condenser is the latest technological achievement in hybrid cooling, where the primary interest is in dry cooling, but where limited water resources are available for use during certain periods of the year.
ENEXIO is one of the leading consortium partners of the EU-funded Horizon 2020 Research and Innovation programme called “MinWaterCSP” with the aim to develop advanced cooling technologies as well as integrated water management plans to reduce cooling system water consumption by up to 95% relative to wet only cooling systems. The increase in scarcity of water resources worldwide is one of the main drivers towards the use of dry-cooling (cooling with air) for power plant cooling purposes instead of the more conventional wet-cooling (cooling with water) approach. However, even though dry-cooling methods allow an order of magnitude reduction in cooling water consumption, the overall power cycle efficiency is generally lower compared to cases where wet-cooling is implemented.
WET COOLING TOWERS
We design, manufacture, and service cooling towers for the energy and
processing industries. With nearly three decades of experience and numerous
successful installations worldwide, we have become a major global player in
the planning and implementation of wet cooling tower solutions.
Our Competence Center for Wet Cooling Towers offers advanced counter-flow cooling
tower designs with a wide range of technologies and concepts. The extensive
portfolio of ENEXIO cooling tower designs ensures that all cost, environmental,
operational, and service requirements are optimized and minimized.
We select the most suitable solution from a broad set of configuration options,
including natural draft cooling towers and induced draft cooling towers, available
in engineered composites or concrete structures. Standardized design solutions for
both power and industrial markets are customized based on application needs, ambient
conditions, and performance requirements.
We deliver solutions for all aspects of cooling tower operation—from maximum cooling
capacities to exceptional operating reliability.
Cooling Tower Types:
• Natural Draft Cooling Towers
• Induced Draft Cooling Towers
• Cooling Tower Components
NATURAL DRAFT COOLING TOWER
ENEXIO’s Natural Draft Cooling Towers are designed using our in-house thermal
design software, developed through continuous research and more than 25 years of
expertise in designing and constructing natural draft cooling towers.
We take utmost care in the thermal design to ensure that the plant operates with
maximum efficiency and reliability. This is achieved through correct selection of
heat transfer media and a fully optimized hydraulic system. With our technical
know-how and wide range of tower designs, we deliver solutions that meet all cost
and environmental requirements while maintaining optimal operational and service costs.
The nearly complete absence of moving parts results in high operational reliability
and minimal maintenance needs—providing long-term performance stability that our
customers rely on.
ENEXIO has deep core competence in this field, enabling customers to benefit from
specialist knowledge and proven high-quality products.
When designing Natural Draft Cooling Towers, lifecycle cost optimization is essential.
This requires an optimized hydraulic design that ensures uniform water distribution
across the entire plan area. Each tower is therefore custom-engineered to meet the
client’s specific requirements, considering factors such as water quality and local
meteorological conditions.
ENEXIO proudly designed the 2nd tallest Natural Draft Cooling Tower in the world
for M/s. RRVUNL, with a total height of 202 meters. The tower has been in successful
operation since 2015.
INDUCED DRAFT COOLING TOWER
ENEXIO is one of the leading manufacturers of Induced draft cooling towers, catering to Industries and for all applications.
Enexio ensures that the cooling tower is designed as per the client’s requirement, based on a wide range of factors, starting from the circulating water quality to other local meteorological conditions. The cooling towers are optimised based on the foot print area, power consumption & pumping head requirement. The designs are optimised not only with respect to the Capex but with respect to Opex also. We, at Enexio, take utmost care in determining the aspect ratio, the velocities at critical points viz., air inlet, fill & fan stack exit. These parameters ensures that the re-circulation is minimized to a larger extent. Enexio also follows the recommendations given in the specified literature for citing and orientation, so as to prevent interference in performance from adjacent cooling towers. Cooling towers are tested in conformity to CTI ATC 105. We have different types of fill manufactured depending upon the water quality, from clarified water to seawater. We have in our manufacturing range, modular splash / trickle fill, ideally suited for brackish / seawater applications. Fills are manufactured with high precision moulding machines at our state-of-the-art manufacturing facility.
COOLING TOWER COMPONENTS
NF 20/NET 150 MODULAR SPLASH FILL
NF 20 / NET 150 (Next Gen modular splash fill) is a state-of-art innovation in splash cooling technology.
Water droplets fall from web to web and offer a self-cleaning characteristic thereby ideally suited for brackish / seawater & dirty water applications.
It increases the residence time distribution of air and water droplets.
Due to the fact that this fill is of splash type, the droplets in the air between the webs give additional exchange surface thereby enhancing overall heat & mass transfer capability of the fill.
These fills are freely rested and supported on concrete / FRP beams thereby eliminates the cumbersome stainless steel wires and accessories, which are required for supporting the conventional splash bars / grids.
Excellent temperature gradient in terms of heat and mass transfer with efficient cooling resulting in relatively lower pressure drop across the fill zone as well as the static pumping head.
FILM FILL - CROSS - FLUTED TYPE
The foils are reinforced at the outer edges and are therefore very stable.
Excellent heat and mass transfer established due to the higher residence time distribution between air and water with the help of cross-fluted structure.
Due to their high specific surface area and higher heat and mass transfer area, also which results in lower pressure drop across the fill cross sections.
Longer durability due to chemical, bacterial and UV resistance of PVC, subject to maintaining the defined water quality.
Self-supporting structure – High bearing capacity achieved by large number of connecting points.
Less downtime for installation.
DRIFT ELIMINATOR
TAP 160 reduce water loss and emissions.
The chemical and UV resistance of PVC material ensures a long service life.
TAP 160 remains stable and maintains its shape even under high temperatures.
Quick and easy installation.
SPRAY NOZZLES
Three layers downward spray nozzle ensures uniform distribution over the entire fill area.
These nozzles are made of Polypropylene and can withstand upto a maximum of 60⁰C.
Nozzles are of non-clogging design.
Replacement of nozzle does not demand any downtime.