Indirect charge air cooler (CCFC)

In the last years the indirect charge air cooler is more and more used in the field of cooling down the charge air of vehicles.  Disadvantages like an additional low temperature cooling circuit, a higher complexity of the cooling system, an additional pump or an additional low temperature cooler are more and more outweighed by the advantages:

One advantage is that the indirect charge air cooler requires only a small additional low temperature cooler (~32mm) in comparison to a large direct CAC, which reduces the size of the cooling package. Furthermore the integration into the engine packaging becomes more flexible (due to the reduced size and possible positioning closer to engine). Indirect charge air cooling also leads to reduced pressure drop in the charge air tubing (down to 80%), a higher thermal inertia for high performance circles and the low-T-circuit can be used for cooling down of electrical components of hybrid cars (Battery, power electronics). Finally even the implementation of the cooler directly into the suction tube of engine is possible (no additional tubing necessary).

Figure 1: Indirect charge air cooler


The typical indirect charge air cooler is a cross counter flow cooler (CCFC). Starting with KULI 10 we are providing this component for the simulation in cooling systems. The CCFC can be used for the cooling down of charge air or all other single phase media.

Figure 2: CCFC Component in KULI


For the definition of the component properties KULI provides an input sheet, the component data are stored in the KULI project library and can be used by different users.  Based on an open configuration of passes on the charge air and coolant side, the component is open for existing and future different real world applications. In cooperation with our customers it was possible to verify the component with measurement data.


Figure 3: CCFC Input data in KULI


More information regarding the input data can be found in the new KULI online help. 


Figure 4: Indirect charge air cooler in combination with a low temperature circuit