Lowering the chiller’s load reduces the system’s carbon footprint

In this interview, Milind Mate, AVP (Sales & Marketing) of Zeco Aircon Limited talked about the products and concepts in air engineering, including Indoor Air Quality (IAQ), energy efficiency, and innovation.

Could you provide more details about your product range?
Zeco provides a comprehensive 360° overview of air engineering, encompassing Indoor Air Quality (IAQ), Energy Efficiency, and Innovation. While most HVAC ecosystems revolve around conventional Air Handling Units (AHUs), we now offer 4-5 new products that seamlessly integrate energy efficiency and IAQ features.

How does ZECO ensure its products suit the harsh environments often encountered in HVAC applications, such as extreme temperatures, humidity, and corrosive gases?
For over 35 years, Zeco Aircon has been dedicated to providing clients with filtered and conditioned air. We offer remarkable solutions that cater to every application, regardless of the temperature, humidity, or pollutants involved. Our latest product, the Dedicated Clean Air System (DCAS), is an exceptional solution designed specifically for air purification in commercial and industrial buildings. DCAS is a distinctive product designed for air purification in commercial and industrial buildings. Typically, outside air is introduced through an air handling unit, leading to increased energy consumption and chiller load capacity, which ultimately raises costs for building occupants. However, DCAS operates differently by reducing the requirement for outside air and effectively eliminating existing contaminants in the environment through its patented filter technology. This innovative product provides a sustainable solution for Indoor Air Quality (IAQ) while simultaneously minimizing CAPEX & OPEX.

Outside air may not be fresh. Typically, buildings require a lot of outside air to be introduced through an air handling unit, which is first filtered by multiple filters that results in increased energy consumption and chiller load capacity. The DCAS works on the principle of decontaminating contamination and requires minimal air input. The return air from the building environment is passed through a patented absorbent filter that decontaminates all gasses as per ASHRAE 62.1, resulting in clean air provided to the building envelope. This system has a two- to three-prong approach that eliminates the need for outside air, decontaminates formaldehyde and VOCs generated in the building, and provides cool, fresh air to the building. This solution is particularly useful in cities like Mumbai, where the outside air is as polluted as the inside air. Therefore, giving better energy savings, lesser carbon footprint of building and gaining LEED & WELL points.

What sets ZECO’s HVAC products apart from its competitors regarding product innovation, technology, and customer service?
ZECO is a leader in the air engineering industry, miles ahead of its peers, by providing innovative solutions. While most competitors rely on conventional recovery devices, such as heat recovery wheels, in their systems, ZECO’s Dedicated Clean Air System (DCAS) is a step ahead. Traditional air handling and treated pressure units often use heat recovery wheels to recover energy from exhaust air and reduce the chiller load by 20% – 30%. However, the DCAS system goes beyond that. Using the DCAS system reduces the chiller load, and its footprint is smaller than that of a heat recovery wheel.

For instance, a Treated Fresh Air (TFA) unit with a flow rate of 20,000 cubic feet per minute (CFM) is equivalent to 20,000 CFM in a heat recovery wheel or 12,333 CFM (7000 CFM outside + 6333 CFM return) in the DCAS unit. Consequently, the CFM footprint of the DCAS unit is smaller, leading to a reduction in the chiller load. The heat recovery wheel achieves a heat load reduction of approximately 75 tonnes of refrigeration, while the fan and cooling coil consume 116 tonnes of refrigeration. In comparison, the DCAS unit only requires 57 tonnes of refrigeration, resulting in nearly 50% savings. In summary, ZECO’s technology offers advanced solutions compared to conventional recovery devices, effectively reducing the chiller load and promoting energy efficiency.

Could you discuss some of the unique features or innovations of ZECO’s HVAC products and how they provide advantages over other solutions?
ZECO has taken a leadership role in introducing new products that can be broadly classified into three categories. Firstly, there are products that cater to Indoor Air Quality (IAQ). Secondly, there are products that provide energy efficiency. 

ZECO offers a range of innovative products designed to meet various air conditioning needs. One such product is the ZIDEC (Zeco Indirect Direct Evaporative Cooling), which utilizes sensible recovery technology and adiabatic cooling to provide refrigerant-free cooling for large spaces. This two-stage cooling system can effectively lower temperatures beyond the wet bulb temperature of the ambient air, resulting in significant market improvements.

The second product is the Zeco Outdoor Air System (ZOAS), which utilizes a two-wheel system incorporating enthalpy recovery and passive desiccant technology. This advanced system enables energy savings of up to 70%-80%. Additionally, the air supplied from this system can effectively address the internal latent load.

The third product, Dedicated Clean Air Module (DCAM) combines Indoor Air Quality (IAQ) with energy efficiency. It is an award-winning air cleaning module that uses Patented Filter Technology to remove CO2, VOCs, and other harmful contaminants (as per IAQP ASHRAE 62.1) from indoor air so that it can be safely recirculated. This solution reduces the requirement for fresh/outdoor air by 30%-40%, thus lowering the building’s carbon footprint and improving indoor air quality while generating LEED and WELL building credits.

DCAM integrates with a wide range of central or zone-based HVAC systems found in offices, schools, conditioned warehouses and distribution centres. The DCAM removes all the ASHRAE-defined contaminants of concern from indoor air without any regeneration, exhaust, or make-up air requirements. The DCAM unit is easily retrofitted in existing or new facilities to reduce the outside air requirements.

What are your views on sustainability?
Sustainability plays a crucial role in reducing carbon emissions, enhancing Indoor Air Quality (IAQ), and optimizing cost-effectiveness in air conditioning systems. By minimizing the load on the chiller, we can significantly reduce the system’s carbon footprint. Moreover, decontaminating the return air further enhances Indoor Air Quality (IAQ) and sustainability. For instance, power consumption for a 20,000 CFM unit can be reduced from 125 kilowatts to 64 kilowatts, resulting in a remarkable 50% power savings and a 50% to 60% percent decrease in operational costs. Overall, sustainability acts as a key factor in achieving a balance between Indoor Air Quality (IAQ) and energy efficiency, making it an essential consideration for any air conditioning system.

Zeco is confident that its innovative products will have a significant impact on the HVACR industry as they introduce new offerings to the market. The response from consultants and the expressed interest in these products indicate the potential for a new retrofit business. This is particularly relevant as many air handling units are already installed, yet new requirements continue to emerge. The company offers a dedicated linear module that can be retrofitted to existing AHUs, tapping into this retrofit market. While the size of the retrofit market is still being determined, the company believes its products are well-timed and poised to contribute to its growth in the coming years.

How is Zeco keeping itself in trend with the latest trends and technologies?
Zeco constantly seeks innovative products that promote energy efficiency, improve Indoor Air Quality (IAQ), and help earn carbon credits. The company can gain additional LEED and WELL points and credits by retrofitting existing products into AHUs and obtaining extra certifications. This approach is instrumental in driving sustainability and advancing energy efficiency. Zeco acknowledges the pressing challenges surrounding energy and efficiency in today’s world and remains dedicated to tackling them through its comprehensive range of products and services.

What is your focus on innovations?
Zeco strives to introduce new technologies and products to the market. The company has received positive feedback from consultants and influencers who visited their stall and appreciated the display of innovative technologies, particularly passive desiccant technology. As a market leader, Zeco consistently embraces and showcases new technologies at expos.