When using low-temperature cooling and air conditioning systems in cold storage facilities, food processing plants, and industrial freezers, productivity at very low temperatures is a top priority. These systems must maintain stable, often sub-zero temperatures with high humidity, frost, and frequent defrosting. The traditional coil design may not work as optimally under these conditions, resulting in inefficiency, increased maintenance, and shortened equipment life. However, microchannel heat exchangers are a promising alternative, combining improved heat transfer, reduced frost formation, and greater durability.
The biggest advantage of microchannel technology for use at low temperatures is its ability to maintain efficient heat transfer at very low evaporation temperatures. Unlike copper-aluminum coils, which are prone to poor refrigerant distribution and the appearance of hot spots, microchannel coils use flat aluminum tubes with multiple internal channels. This design ensures a uniform flow of refrigerant, which results in a more uniform coil surface temperature. This means that such coils are more efficient both during defrosting and cooling, consume less energy and respond faster to the needs of the system. Learn more.
In addition, the compactness of the microchannel coils provides greater flexibility in the system design. In conditions of limited space in cold storage rooms, lighter coils of smaller sizes can be placed in more cramped rooms without reducing productivity. Their lower weight also reduces the complexity of installation, especially in hard-to-reach areas often used in industrial freezers.
Increased frost resistance and corrosion protection
Perhaps one of the main problems when used in low-temperature installations is the formation of frost on the surface of coils. The formation of frost insulates the coil, reducing the efficiency of heat transfer and increasing the frequency and duration of defrosting cycles. Traditional heat exchangers freeze unevenly, which leads to the formation of ice plugs between the fins and the restriction of air flow. Microchannel heat exchangers solve this problem by optimizing the distance between the fins and improving the temperature distribution on the surface, which allows frost to form more evenly and more easily separate during defrosting.
In addition, most microchannel coils have a hydrophilic coating that improves condensate drainage and reduces water retention, two factors of primary importance for reducing frost formation. Coatings are equally good at fighting corrosion, which is another constant danger in areas with high humidity and low temperatures, where moisture is constantly present. Unlike standard coils, which are susceptible to formic corrosion, especially in humid areas where gases are released when using insulation or cleaning products, microchannel coils made of aluminum are more resistant to chemical destruction.
For plant operators servicing Carrier-based refrigeration units, switching to a new generation of microchannel replacement coils is a practical solution that increases reliability and productivity. Some legacy Carrier installations initially used heavier and less efficient coil configurations, which are more susceptible to inefficiency due to freezing. Updating them with microchannel versions optimized for low temperature operation ensures a longer service life, lower maintenance requirements, and improved overall system efficiency.
Conclusion: A reliable and efficient solution for use in extreme cooling conditions
As industrial cooling strives to increase energy efficiency and environmental sustainability, microchannel heat exchangers are becoming the best option for low temperature applications. Their ability to provide stable thermal performance, prevent frost formation, and withstand harsh operating conditions makes them ideal for high-performance applications such as cold storage, food processing, and pharmaceutical refrigeration.
Whether in a new installation or expansion of an existing carrier system, microchannel technology provides tangible benefits in energy efficiency, downtime prevention, and increased reliability. For those who are exploring available alternatives and choosing suitable replacement options for microchannel coils that are most suitable for their system, detailed product information and technical support can be found here.
By using microchannel technology for low-temperature processes, plant owners and engineers not only maximize productivity, but also protect their heat transfer processes from rising energy costs and changing environmental requirements.