Optimization and Control of Regeneration Drier Air Inlet Temperature using PEC Chiller (Pre-evaporative Cooling Chiller at JSW Vijayanagar Metallics Limited)

Ratna Rohini Bolisetti; Rajeswari P; Gondela Rakesh

Optimization and Control of Regeneration Drier Air Inlet Temperature using PEC Chiller (Pre-evaporative Cooling Chiller at JSW Vijayanagar Metallics Limited)

Author(s)	Ratna Rohini Bolisetti, Prof. Rajeswari P, Gondela Rakesh
Country	India
Abstract	Cryogenic Air Separation Plants (ASUs) require reliable temperature control to ensure efficient air purification and uninterrupted production of industrial gases. During summer operation, an increase in cooling-tower water temperature can raise the regeneration drier inlet air temperature beyond the permissible operating limit, resulting in poor moisture removal and a potential ASU shutdown. The present work proposes the optimization and control of regeneration drier air inlet temperature using a Pre-Evaporative Cooling Chiller (PEC Chiller) integrated with the existing cooling-water system. The proposed modification replaces approximately 25 °C cooling-tower water with PEC-chiller-cooled water at about 12 °C and increases the E07 cooling-water flow rate from 40 to 45 m³/h. Design calculations based on a water flow rate of 50 m³/h and an evaporator temperature reduction from 22.1 °C to 10.8 °C indicate a cooling capacity of approximately 656.8 kW (187 TR). With an assumed coefficient of performance of 5.0, the corresponding compressor power is approximately 131.4 kW, while the condenser heat rejection is approximately 788.2 kW. Further modified cooling-duty analysis indicates approximately 163 kW cooling duty in E60 and 395.6 kW total cooling duty for the proposed lower-temperature cooling arrangement. A DN100 chilled-water pipeline with suitable insulation and aluminium cladding is proposed for reliable water delivery. The preliminary execution cost, including a 10% contingency, is estimated at approximately ₹62.48 lakh, excluding pipe procurement cost. The proposed system is expected to maintain the regeneration drier inlet temperature below the critical operating limit, improve summer operating stability, reduce the probability of ASU trips, and enhance overall plant reliability. The results provide a practical engineering approach for improving thermal control and operational continuity in cryogenic air separation systems.
Keywords	Cryogenic Air Separation Unit (ASU), Regeneration Drier, Pre-Evaporative Cooling Chiller (PEC Chiller), Regeneration Air Cooling, Cooling Water System, Chilled Water Pipeline, E07 Cooler, Thermal Performance, Energy Optimization, Process Reliability, Industrial Gas Production, Air Separation Plant.
Field	Engineering
Published In	Volume 8, Issue 5, September-October 2026
Published On	2026-09-07

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Optimization and Control of Regeneration Drier Air Inlet Temperature using PEC Chiller (Pre-evaporative Cooling Chiller at JSW Vijayanagar Metallics Limited)

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