Vaphtek™ Environmental Control Unit
What is the vaphtek™ ECU
The Vaphtek™ ECU is an option on ACT’s Tekgard® brand of Environmental Control Units (ECUs) and chillers where we combine traditional vapor compression (DX) cooling with pumped two-phase (P2P) cooling, creating a hybrid system and efficient cooling technology. Combining these two systems allows for a lower pumping capacity during ideal times which cuts carbon emissions, gasoline consumption and power usage.
How the Vaphtek™ ECU Works
Standard Vapor Compression Mode: In medium to high ambient temperatures, the unit operates like a conventional ECU, providing robust cooling through a compressor-driven refrigerant cycle.
Pumped Two-Phase Mode: The game-changer comes into play when ambient temperatures drop below the desired indoor temperature. The system automatically switches to this mode, utilizing a pump instead of a compressor to circulate refrigerant. This transition can result in up to a 70% decrease in electrical power consumption under certain conditions.
Meeting the military’s environmental challenge
In an era where environmental concerns and operational efficiency are paramount, the U.S. Department of Defense faces a significant challenge. With an annual consumption of 4.6 billion gallons of diesel fuel and a carbon footprint of approximately 50 million metric tons of CO2, the need for innovative solutions in military operations has never been more pressing.
Modern military operations span diverse, often hostile environments – from scorching deserts to humid jungles. In these settings, reliable climate control isn’t just about comfort; it’s a critical factor in protecting high-value electronic assets and ensuring optimal personnel performance. Traditional cooling systems, while effective, often come with a heavy price tag in terms of fuel consumption and emissions. ACT’s new Vaphtek™ Environmental Control Units can offer an alternative solution and provide savings that will benefit the military’s budget.
Vaphtek™ ECU Benefits
Significant Energy Savings: Operational analyses have shown substantial reductions in fuel consumption, costs, and emissions, with an estimated payback period of less than two years under standard operation.
Enhanced Durability: The dual-mode operation extends compressor life and overall system durability.
Environmental Protection: The refrigerant-side economization in pumped two-phase mode shields the conditioned space from external contaminants.
Intelligent Control: A state-of-the-art automatic control system ensures seamless transitions between modes, maximizing efficiency and performance.Versatility: the hybrid Vaphtek™ unit can be retrofitted into existing ECUs or chillers or designed as part of the customer requirements.
Vaphtek™ ECU Performance in the Northern United States
Vaphtek™ Hybrid ECUs have shown substantial power savings throughout extensive experimental testing. But how will a Vaphtek™ ECU perform in a given location? Let’s look at the annual operation of a Vaphtek™ ECU in the northern United States. At 45° north of the equator cities such as Portland, Fargo, Minneapolis, Toronto and Montreal experience similar climates. Along with the climate there are several other factors that affect Vaphtek™ operation. A summary of these parameters and the assumptions used for this case study is found below.
| Location | Power Source: | Shelter: |
|---|---|---|
| Northern USA | 30-kW diesel generator | 80°F indoor temperature |
| 45°N, 93°W | 1-3 gal/hr operation | 70% load capacity |
| 40% P2P operation | $15/gal diesel fuel | Standard ECU operation |
The selected power source for this analysis is a 30-kW diesel generator that would power the Vaphtek™ ECU, along with the other electronics in the shelter. The shelter generates a heat load of 70% rated capacity via electronics and personnel while requiring 80°F room temperature. Since ambient temperatures remain low for multiple months of the year, the Vaphtek™ ECU can operate in P2P mode for over 3,500 hours per year, which is around 40% of the time. Based on the size of the unit, the fuel savings vary. If a Vaphtek™ ECU with a 68,000 Btu/hr (20kW) cooling capacity is utilized, the annual fuel savings are estimated to be 1,161 gallons which exceeds $17,000 in cost savings. Due to the efficiency of the Vaphtek™ ECU compared to a standard Tekgard™ ECU, the energy usage was reduced by 30% over a year of operation.
The Vaphtek™ ECU operates at its fullest potential when the enclosure max inside air temperature is higher than the ambient temperature. So, climates with large temperature ranges, but a considerable amount of time in the lower ambient temperature ranges, see significant benefit. In Fargo’s continental climate, the average summer high is 81°F and the average winter low is 5°F. That lower temperature range allows the Vaphtek™ ECU to spend the majority of its operating hours in the efficient P2P mode, maximizing fuel and cost savings.
Cooling Innovation
As the military continues to grapple with the challenges of climate change and resource scarcity, innovations like the Vaphtek™ ECU play a crucial role. Although DX and pumped two-phase cooling are not novel technologies, they have never been combined into a seamless technology for ruggedized cooling, until now. The control system of Vaphtek™ ECUs has also been overhauled to include state-of-the-art controllers and PID logic that utilizes both real-time data and stored experimental data to ensure reliable operation. Vaphtek™ ECUs are the first of their kind with versatile capabilities to meet any cooling requirement of the customer while providing industry-leading energy savings.
The Vaphtek™ ECU, leveraging ACT’s expertise in thermal management, stands as a testament to the power of innovative engineering in solving complex, real-world challenges. As we move forward, such advancements will be key in balancing operational readiness with environmental responsibility.
