July 30 2025

How Chillers Help Capture CO₂ from the Air: A Real-World Case Featuring High-Precision DAC Systems

2,867,000,000 tons of CO₂ are emitted annually by the energy sector of MENA countries. Over 6,430 industrial facilities suffer from overheating — especially in the agriculture, food processing, plastics, and logistics sectors. Of these, 84% use water for cooling, but only 12.6% rely on modern centralized chiller systems. EVROPROM is changing this statistic by delivering high-precision solutions.

Direct Air Capture (DAC) is a technology where ambient air is passed through filters containing adsorbent materials that absorb CO₂. The captured CO₂ is then released and either sequestered or recycled. The process requires precise conditions: a stable temperature (±0.3 °C), humidity between 40–60%, and continuous cooling.

To ensure efficient DAC system operation, thermal load balancing is critical. According to IEA research, capturing one ton of CO₂ requires 400 to 800 kWh of energy for air cooling and dehumidification, depending on the climate and ambient humidity. For a Mammoth unit with a design capacity of 36,000 tons of CO₂ per year, the daily cooling demand reaches approximately 14.4 to 28.8 MWh. This is equivalent to the continuous operation of two chillers with a combined cooling capacity of about 230 kW, confirming the suitability of models like Climaveneta FX-W/H 0551 and FOCS-W/H 0501.

What Does a Chiller Actually Do — and How Does It Help Fight CO₂?

When calculating cooling loads, it’s essential to consider not only average values but also peak ambient temperatures. For example, at +35 °C outdoor temperature and water parameters of 12/7 °C, the Climaveneta FX-W/H 0551provides 124.3 kW of cooling with a Coefficient of Performance (COP) of 5.1. Similarly, the FOCS-W/H 0501delivers 106 kW under the same conditions, with a COP of approximately 4.8. These high COP values indicate excellent energy efficiency and optimized electricity use in real-world operation.

Maintaining cooling water temperature within ±0.3 °C is critical to prevent thermal fluctuations that can reduce DAC adsorbent efficiency by 8–12%. Air humidity maintained in the range of 40–60% enables maximum CO₂ absorption rates without over-saturation, which would otherwise increase dehumidification energy consumption by 15–20%.

Integration with BMS and SCADA systems allows automatic fine-tuning of chiller performance with a response time under 5 seconds, which is essential for adapting to rapidly changing environmental conditions.

In the Direct Air Capture (DAC) segment, precise control of temperature and humidity is vital. To provide the stable environmental conditions required for efficient CO₂ absorption, specialized chillers with integrated heating functionality are used.

DAC Technology Requirements: Key Features

Cooling water temperature stability must remain within ±0.3 °C to maintain high adsorbent efficiency;
Relative air humidity is maintained between 40–60%, as deviations significantly reduce the rate and volume of CO₂ capture;
Equipment operates 24/7 under continuous load, demanding exceptional reliability from chiller systems;
DAC facilities are powered by renewable energy, so chillers must offer maximum energy efficiency;
Integration with modern monitoring platforms (BMS, SCADA) is essential for responsive control and diagnostics.

Equipment Supplied by EVROPROM

To meet the cooling demands of DAC installations, Climaveneta water-cooled chillers were selected:

Climaveneta FX-W/H 0551 (2022)

Cooling Capacity: 124.3 kW at chilled water temperatures of 12/7 °C and an ambient temperature of +35 °C. These parameters comply with EN 14511 test conditions and ensure reliable operation under high thermal loads.
Compressor: Bitzer CSW6583-40CVY-40P screw compressor, equipped with an optimized oil injection system that reduces energy consumption by 8–12% compared to previous generations. Low vibration levels (< 3 mm/s)extend component life and minimize operational noise.
Refrigerant: R513A with a low Global Warming Potential (GWP ≈ 631), in compliance with modern EU F-Gas Regulation standards. It offers high specific heat capacity and improved thermodynamic performance.
Dimensions and Weight: 3.10 × 1.20 × 1.65 m; weight — 1,050 kg. The compact footprint delivers high capacity within constrained technical spaces.
Operating Hours & Lifecycle: Only 33 operating hours logged, with the compressor rated for up to 100,000 hours — equivalent to over 11 years of daily 8-hour operation. Proper routine maintenance extends service life.
Control Interfaces: Support for Modbus and BACnet protocols, full SCADA integration for centralized control, telemetry collection, remote diagnostics, and real-time adjustment of operational parameters.
Design Features: Dual shell-and-tube heat exchanger with copper tubing and aluminum fins, delivering high thermal transfer efficiency and corrosion resistance. The unit also features a variable frequency drive (VFD)-controlled fan speed system to reduce energy consumption.

Climaveneta FOCS-W/H 0501 (2020)

Cooling Capacity: 106 kW under standard operating conditions (chilled water at 12/7 °C, ambient air at +35 °C). Performance values are confirmed by ISO 9614 test protocols.
Compressor: Bitzer CSH6583-50CVY-40P screw compressor — an optimized model with an advanced oil system and reduced mechanical losses, delivering COP up to 6.5 at nominal load.
Refrigerant: R134a, a widely used refrigerant with a GWP of ~1430, still commonly applied due to its thermal stability and proven operational safety.
Dimensions and Weight: 2.9 × 1.2 × 1.7 m; weight — 840 kg. Its modular construction simplifies installation and service, minimizing system downtime.
Runtime and Lifespan: Only 48 operating hours logged, with a design lifespan of up to 100,000 hours. Built-in diagnostics support proactive compressor health monitoring and timely preventive maintenance.
Installation and Integration: The modular design supports seamless integration into existing process lines and allows easy scalability without major investments in time or infrastructure.
Control Systems: Full BMS and SCADA compatibility with remote monitoring support enables energy consumption tracking, real-time load management, and fast incident response.
Heat Exchangers: High-efficiency shell-and-tube exchangers with internal anti-corrosion coatings ensure extended service life and minimal thermal losses.

Key Technical Advantages of Both Chillers:

High Energy Efficiency Ratio (EER) — up to 6.5 under nominal conditions, significantly reducing operational energy costs;
Flexible Power Modulation — integrated VFDs (Variable Frequency Drives) enable smooth capacity adjustment from 30% to 100%, ideal for dynamic thermal loads in DAC systems;
Low Noise Levels — sound pressure below 65 dB at 1 m, suitable for urban or industrial zones with noise restrictions;
Environmental Compliance — use of low-GWP refrigerants and full adherence to EU F-Gas and ISOenvironmental standards;
Reliability and Durability — factory-assembled and tested, up to 2-year manufacturer warranty, plus EVROPROM’s maintenance recommendations for long-term performance.

Total Cooling Capacity: approx. 230 kW, ensuring precise temperature control across critical zones in DAC process modules.

Thermal Load Assessment & Energy Efficiency

On average, removing 1 ton of CO₂ via DAC requires 400–800 kWh, of which about 30–35% is attributed to air cooling and dehumidification.
For every 1,000 tons of CO₂ per year, cooling systems must dissipate roughly 1.2 MW of thermal load.
For large-scale DAC plants rated at 36,000 tons of CO₂ annually, the total daily thermal load reaches 43–45 MWh.
The installed chillers are engineered to locally offset thermal emissions and maintain stable cooling parametersunder 24/7 continuous operation.

Technical Advantages of EVROPROM Solutions

Direct Air Capture (DAC) technology demands ultra-precise cooling and strictly controlled climate conditions — water temperature stability of ±0.3 °C, humidity maintained within 40–60%, and continuous 24/7 operation. EVROPROM provides a comprehensive engineering approach for such critical projects:

Accurate cooling capacity calculation based on real DAC thermal loads — ensuring optimal system sizing and stable performance;
Up to 40% budget savings through our loyalty program and configuration optimization;
Full compliance with ISO 50001 and EU F-Gas regulations for maximum environmental responsibility;
Energy savings of up to 15% achieved through high-efficiency Bitzer compressors and intelligent load modulation;
Full BMS and SCADA integration for remote monitoring, real-time control, and rapid fault response;
Fast installation and commissioning — completed within 5 business days, backed by EVROPROM’s warranty and service support.

EVROPROM doesn’t just supply chillers — we engineer and tailor solutions specifically for DAC, delivering the reliability, precision, and energy efficiency required for successful CO₂ capture from ambient air.

Article by:
Sviatoslav Ovcharenko, Sales Manager
30.07.2025