Case Study of Condensate Recovery
and Its Reuse at The University of
Alabama at Birmingham
Presented by
Atul Kajale
Dr. Robert W. Peters, Ph.D., P.E.
Mr. Matt Winslett
Alabama Water Resources Conference 2013
Orange Beach, AL
September 5-6, 2013
Overview
1. Introduction
2. Condensate recovery
3. Chilled water usage
4. Results
5. Discussion and Conclusions
Introduction
 Condensate Recovery: Recovery of the condensate
water produced from the air handling units (AHUs)
and its reuse in processes where non-potable
water is required.
 Condensate Recovery Systems (CRS) in new
constructions and in existing buildings.
 Uses of condensate water- for irrigation, flushing
toilets, reuse in chilled water plants
 Southeastern states have potential of capturing
more than 15 gallons per cfm of air [Lawrence
and Perry, 2010].
Introduction
 Research done in co-operation with the Energy
Management Division of the Facilities Management
Department at the University of Alabama at
Birmingham (UAB)
 CRSs in seven campus buildings
 Laboratories, and research buildings use- 100%
outside air
 Pipes, joints/connectors, water storage tanks
(100-500 gallons), pumps, floating devices,
filters, and water - meters.
Condensate Recovery
Figure 1. Condensate Collection Potential in United States.
[Lawrence and Perry, (2010)]
Drought Condition
August, 2012
December, 2012
August, 2013
Condensate Recovery at UAB
Figure 2. Schematic of the Condensate Collection System at
UAB.
Condensate Recovery at UAB
Figure 3. Condensate Recovery System at UAB: Small storage
tank, 500-gallon storage tank
Condensate Recovery at UAB
 Condensate from each 500-gallon storage tanks is
measured by a water - meter
 Condensate production in 4 AHUs is continuously
monitored and recorded in real-time using HOBOU20 water level dataloggers
 Change in water level, temperature, and pressure.
 Condensate is fed to the chilled water return pipe
 Temperature of condensate (53⁰F-73⁰F)
Condensate Recovery at UAB
 Main objectives of the study:
Develop a multiple regression model to analyze
the effect of indoor and outdoor operating
conditions.
Model validation, hypothesis testing
Sensitivity analysis and uncertainty analysis
Projection for other campus buildings
Feasibility analysis and applicability for other
locations in Alabama.
Condensate Recovery at UAB
Building Name
Installation Cost
McCallum Building
$
25,000
Kaul Building
$
16,000
Zeigler Building
$
5,500
Tinsley Harrison Tower
$
2,500
Bevill Building
$
30,000
Resreach Support Building
$
25,500
Volker Hall Tower
$
24,000
Wallace Tumor Institute
$
20,000
Total
$
150,000
Table 1. Detailed Cost of Condensate Recovery System at UAB
Results
 3 chilled water plants serve 52 campus buildings.
 Make-up water demand and cost
Figure 4. Water demand of UAB Central Chilled Water Plant
Results
Year
Water in gallons
Figure 5. Condensate volume
2012 (12 months)
3,232,962
recovered at McCallum and
Tinsley Harrison Tower
2013 (7 months)
2,128,719
Results
Figure 6. Condensate volume recovered from six condensate
recovery systems
Results
 In 2011, total water demand was 311,00 CCF
and the cost $2,170,000.
 In 2012, total water demand was 310,199 CCF
and the cost $1,960,075.
 More than 7 million gallons of water was
captured and reused in 2012.
 5.7 million gallons of condensate is captured in
2013 till the end of July.
 12.7 millions gallons accounts for $54,500.
 This accounts for 5% of water demand and
2.7% of associated cost
Results
 The peak condensate recovery during summer
was 4.38 gph/1000 ft2.
 Average condensate was is 6 times higher than
predicted by Guz’s study (2005).
 The minimum and maximum hourly condensate
volumes ranged from 0 to 230 gph.
 12.7 millions gallons of condensate recovery
accounts for $54,500 of savings.
 Average payback period of 3 years for the entire
project.
Discussion
 Advantages of reuse of condensate water in chilled
water plants:
 Lowers the water demand of the chilled water plant.
 Efficient use of potable water.
 Temperature of condensate varies between 53 ⁰F
and 74 ⁰F whereas the temperature of municipal
water is 81 ⁰F.
 Feasibility: water savings, energy savings, and
sewer cost
Discussion
 Majority of the southeastern United States is prone
to drought condition and hence conservation of
water is very important.
 Hot and humid weather is favorable for successful
condensate recovery.
 There is great potential for water conservation in
commercial, industrial, and institutional buildings.
 CRS at UAB have shown significant collection of
condensate
 Indicating opportunity to install more systems
across the campus buildings.
Acknowledgement
 Energy Management Division of Facilities
Management Department at UAB
 Sigma Xi Scientific Research Society
 Department of Civil, Construction, and
Environmental Engineering at University of
Alabama at Birmingham
Thank You!!!