HXV Hybrid Coolers

BAC’s patented HXV design combines the advantages of evaporative and dry cooling technologies to deliver a highly efficient, compact, and water-saving solution. This hybrid operation concept has earned multiple patents and innovation awards in North America and Europe.
HXV is engineered to meet the demanding requirements of critical projects.

Eliminate Visible Plume

Visible water vapor discharge caused by saturated air leaving conventional cooling towers can create safety concerns, especially in sensitive areas like airports and traffic zones. The HXV operates in a hybrid mode that combines sensible, adiabatic, and evaporative heat transfer, significantly reducing or even eliminating visible plume formation.
During the coldest periods of the year—when plume potential is highest—the HXV can run in 100% dry mode, completely eliminating visible vapor emissions.

Maximize Water Savings

The HXV can operate in three different modes throughout the year to reduce water consumption. Under peak thermal load or extreme weather conditions, much of the heat is removed through sensible cooling in the dry section, greatly reducing evaporation losses compared to traditional evaporative systems.
As thermal load or ambient temperature decreases, water consumption further drops—especially during adiabatic mode—and eventually ceases entirely in dry mode. Compared to conventional evaporative coolers, water savings can reach up to 70%, all while maintaining efficient fluid cooling. In many regions, the water savings alone can offset the equipment investment within two years.
For projects with limited water supply, the HXV is an ideal solution.

High-Temperature Fluid Cooling Capability

For fluid temperatures above 82°C (180°F), pre-cooling is achieved in the dry section before reaching the evaporative coil. Even under peak summer conditions, HXV systems deliver lower fluid temperatures with minimal fan energy, thanks to the synergy between dry and evaporative heat transfer—all within a compact footprint.

Superior Economic Value

Reduced Capital Investment
Heat exchanger selection is typically based on peak dry bulb conditions, which often result in larger and more expensive dry cooling systems. In contrast, evaporative systems like the HXV are selected based on wet bulb conditions, providing greater temperature driving force and allowing for lower system design temperatures.
This advantage translates into smaller heat exchange surfaces and lower equipment costs.
During peak loads, HXV uses evaporative cooling, enabling reduced unit size, lower fan horsepower, and minimized structural and cabling costs.
Unlike dry coolers that require water spray during extreme days—causing corrosion and scaling—the HXV’s hybrid design avoids these risks.
Its low scaling tendency allows for lower fluid temperatures and reduces the size and cost of downstream equipment (e.g., chillers, compressors). It also eliminates the need for plume abatement accessories.

Lower Operating Costs
Thanks to its hybrid cooling concept and water-saving design, the HXV offers clear operational cost advantages.
In peak summer, a significant portion of the heat is removed via the dry coil, reducing evaporation, blowdown, and chemical treatment costs. In adiabatic mode, only a small amount of water is evaporated to pre-cool the air, minimizing blowdown.
In low ambient conditions, dry mode eliminates both water and pump energy consumption.
Depending on local water costs and availability, the HXV can reduce water consumption by up to 70% or more, delivering ROI through savings on water, treatment chemicals, blowdown disposal, and improved energy efficiency—often within two years.

In addition, the HXV’s closed-loop system and advanced coil design prevent fouling and scaling common in open-circuit cooling towers, ensuring long-term efficient operation. The entire product line exceeds ASHRAE 90.1 energy efficiency requirements.
Axial fan designs also consume less power than centrifugal fans used in conventional systems.

Low Installation & Maintenance Costs

The HXV is modularized into three sections to reduce hoisting weight and overall unit size. Fewer interconnecting pipes are required, enabling the use of smaller and more affordable lifting equipment.

Maintenance-Friendly Design
The hinged access doors are integrated into the casing and allow direct entry into the internal space, which includes a standard internal walkway. The spacious interior enables easy inspection of the cold water basin, drift eliminators, fan drive system, and coil surfaces.
Air and spray water flow in the same direction, and the spray system is located above the coil section, allowing for maintenance of the coil top even during operation.