Gas Cooler and Compressor Intercooler — online
Wet-gas coolers and intercoolers: dew point, condensate load, sensible and latent duty, U and fouling — and the extra compressor power a warm intercooler costs.
Yellow cells are inputs; orange cells are choices; blue cells choose the unit. Select or hover over an input to see its help in the box below the toolbar. The sheet is the same as the Excel tool (USD 49) — the Guide, method and references are in the Excel file.
What this gas cooler and compressor intercooler calculator does
Cool the gas, knock out the water, and see what a warm intercooler costs at the next stage. Wet-gas coolers and intercoolers: dew point, condensate load, sensible and latent duty, U and fouling — and the extra compressor power a warm intercooler costs.
- Wet gas done properly. Water content from dry, saturated, mol % or intake-air relative humidity; dew point, outlet humidity and condensate (knock-out) load.
- Sensible plus latent duty. Weighted MTD over the condensing curve, F factor, U, fouling resistance and cleanliness.
- Any gas. A pure gas or a mixture from the fluid library; flow as mass or Nm³/h, wet or dry.
- Next-stage power. Extra compressor power when suction is warmer than design, and its yearly cost.
- Clear checks. Approach, condensation and input warnings with ranked findings.
- Print-ready report. Inputs, results, findings and charts on A4.
What you enter
- Dry gas
- Water vapour in the gas
- Gas flow given as
- Gas mass flow (wet)
- Gas standard volume flow
- Gas inlet temperature
- Gas outlet temperature
- Gas inlet pressure (absolute or gauge – pick the unit)
- Gas outlet pressure
- Water content of the gas
- Ambient (intake) temperature
- Ambient relative humidity
- Ambient pressure at the intake
- Coolant
What you get
- Water vapour in the inlet gas (mol %)
- Dew point of the inlet gas (at the inlet pressure)
- Relative humidity of the outlet gas
- Dry gas flow
- Wet gas flow at the inlet
- Condensate to drain (knock-out load)
- Coolant flow used
- Gas-side duty (sensible + latent)
- of which latent (condensation)
- Coolant duty
- Heat balance error ÷ average
- Weighted MTD over the cooling / condensing curve
- F factor (from the end temperatures)
- Overall heat transfer coefficient — actual
How it was checked
Air intercooler case against humid-air reference data: dew point within 0.2 °C, duty within 0.3 %.
Related
- Free quick calculator — a simpler free version for a fast estimate.
- Calculation guide — the equations behind this tool, with a worked example.
- Gas Cooler and Compressor Intercooler Excel tool — USD 49, keep the workbook and its Guide.
- All 40 online tools
Questions
Is the gas cooler and compressor intercooler calculator free?
You can enter and check all your data free. The full results, findings and printable sheet are unlocked with a 3-run pack (USD 9), a monthly subscription to all 40 online tools (USD 15) or a yearly one (USD 99).
Are the results the same as the Excel tool?
Yes. The online tool runs the formulas of the Gas Cooler and Compressor Intercooler Excel workbook, checked cell by cell against the Excel file.
Which units can I use?
SI, US customary and British units — choose the unit next to each input.