Aftercooler For Diesel Generator | Turbo Charge Air Cooler CAC For Genset

Aftercooler (also called charge air cooler / CAC, intercooler) is a water-cooled heat exchanger installed between turbocharger outlet and engine intake manifold on turbocharged diesel generators.

- The turbo compresses intake air, which heats up sharply to 160–220°C.
- The aftercooler cools this hot compressed air down to 38–45°C before entering cylinders.

Two critical benefits:

1. Cooler air is denser, carries more oxygen → raise generator output power, reduce fuel consumption.
2. Lower combustion temperature → suppress NOx formation, meet Tier 3 / Tier 4 / IMO emission standards; reduce engine thermal load and extend component life.

Working Principle

1. Fresh air is compressed by turbocharger and becomes high-temperature charge air.
2. Hot charge air flows through the air side of the aftercooler finned tube core.
3. Engine glycol coolant (closed freshwater circuit) circulates inside tubes and absorbs heat from air.
4. Cooled dense air flows into engine cylinders for combustion.
5. Heated coolant flows back to radiator / remote air cooler to dissipate waste heat.

Marine diesel generator dual-circuit difference

On vessel gensets, aftercooler uses two separate loops:

- Inner closed loop: Antifreeze freshwater contacts tube bundles
- Outer loop: Seawater cools the freshwater loop; CuNi 90/10 tubes are adopted to resist seawater corrosion and marine fouling.

- 1:1 OEM direct replacement for Cummins, MTU, Perkins, MAN, Weichai, Yanmar diesel gensets
- Custom size, flange interface, mounting dimension based on customer drawings or measured data
- Marine-grade CuNi tube upgrade for offshore, coastal power equipment
- Full hydrostatic pressure test and air tightness test before delivery