Cooling systems have been proven to reduce postharvest losses and improve the storage of fruits and vegetables [
1]. Several methods, including mechanical refrigeration, controlled atmospheres, adiabatic cooling, and evaporative cooling, can extend the shelf life of perishable produce [
2]. Nigeria’s tropical climate drives demand for cooling systems, as high temperatures necessitate cooling solutions. Furthermore, shifting consumer preferences for fresh produce in Sub-Saharan Africa have boosted the market potential of cooling systems in this region [
3,
4]. The literature shows that cold storage can increase agricultural profit margins by 40% through reduced postharvest losses [
5]. As a result, the cooling system market has vast potential in densely populated developing countries like Nigeria.
Table 1 highlights the potential for cold storage of various products in Nigeria, with an estimated cost-saving potential of NGN 111 billion.
In Nigeria, researchers and farmers have explored various temporary storage methods for freshly harvested fruits and vegetables in rural areas [
6]. However, power shortages and unreliable supply have hindered the use of conventional refrigerators, leading to chilling injuries due to excessive temperature reduction. This has prompted the search for cost-effective techniques to achieve suitable ambient conditions for preserving or cooling fruits and vegetables at optimal temperatures without chilling injuries. Evaporative cooling systems have emerged as a viable solution for removing field heat and preserving moderate-temperature produce. Evaporative cooling occurs when moisture is added to air with a relative humidity below 100%. The potential for evaporative cooling increases as relative humidity decreases, with the effectiveness of cooling dependent on the difference between air dry-bulb and wet-bulb temperatures. This technique reduces temperatures by absorbing energy from the surrounding environment as water evaporates. Evaporative cooling systems utilize mists, sprays, or wetted pads to lower air temperature, increasing relative humidity while cooling the air. The typical evaporative pad cooling system consists of a pad (wetting) medium, water supply line, water recirculation pump, water distribution header, fan or blower, gutter, sump tank, and bleed-off line (in some designs) [
6]. As air flows past the wet pad surfaces, moisture acquires heat, evaporates, and removes heat energy from the air. This results in exhaust air with a lower temperature and elevated moisture content. Water is continuously recirculated over and through the wetting medium capillaries during operation. Evaporative coolers have been developed and deployed for domestic, agricultural, and industrial applications in recent years, with various sizes and capacities available [
6]. For example, Dai and Sumathy investigated a cross-flow direct evaporative cooler using wet honeycomb paper and found an optimal air channel length for performance improvement [
7]. Bowman et al. [
8] studied passive downdraft evaporative cooling (PDEC) to reduce energy consumption in hot, dry climates. Jaber and Ajib [
9] designed indirect evaporative air conditioning to reduce energy consumption without negatively affecting thermal comfort, with the goal of lowering the imported oil bill on the national level and reducing the emission of harmful gases to the environment on the international level. Despite their increasing performance and high energy efficiency, these systems have high electrical energy consumption and cause peak electricity loads because they depend on energy from the grid. Thus, they are most of the time not suitable for rural areas due to low electricity penetration density and the need to power fans and pumps. Furthermore, the increasing cost of energy over the past few years has made the energy-saving concept one of the most important research areas in the energy industry. Moreover, energy consumption is directly related to the greenhouse gas effect and environmental pollution, which is responsible for increased global temperature or global warming. The aforementioned problems have increased the desire to adopt renewable energy systems in energy devices. In most countries, available evaporative coolers are those that depend on natural wind flow [
10], which is not reliable. A typical example is the pot-in-pot design or zeer pot design [
11]. These designs have been adopted in rural areas, especially for cooling and short-term preservation of vegetables and fruits. The performance of these coolers is limited by low air flow rates and the need to manually re-wet the pads, which increases operational drudgery. To mitigate this and constantly maintain a steady air flow rate and water recirculation at reduced energy consumption for increased performance, Schulz [
12] invented a new solar evaporative cooler retrofit kit to decrease the amount of electrical power supplied and the cost of operating such a common evaporative cooler. Solar energy is one form of renewable energy that is well distributed and available globally. In recent years, solar energy has been adopted as a cost-effective energy solution. It is clean, renewable, and environmentally friendly. Solar systems have been envisaged from an energy perspective for a sun-powered world [
13].
Therefore, solar energy can be harnessed to various degrees to power the energy world, especially in rural areas with no electricity. This has been applied in the literature to power evaporative cooling systems. For example, Olosunde et al. [
14] developed a solar-powered evaporative cooling system for preserving tomatoes, mangoes, bananas, and carrots in rural areas of Nigeria. The aim was to overcome the irregular power supply prevalent in rural areas. The designed evaporative cooling system had a capacity of about 0.39 m
3 and delivered an exhaust temperature range of 7.8 to 15.4 °C and a relative humidity range of 44 to 96.8%, capable of preserving the products for 14 to 28 days. Saleh et al. [
15] evaluated solar evaporative coolers for storing citrus and tomatoes for rural farmers in Nigeria, using charcoal as the wetting medium. They obtained an average temperature depression of 7 °C and achieved a storage life of 14 days with a saturation efficiency of 41%. Mekonen et al. [
16] presented a two-stage solar-powered active evaporative cooling system in Ethiopia using activated carbon as the cooling pad. The cooler provided a temperature drop of about 9 to 15 °C under various operating conditions, with a relative humidity of up to 88% and a COP of 52.2 at a cooling capacity of 3653 W. Mansuri et al. [
17] developed a solar-powered evaporative cooling system for storing fresh fruits and vegetables in India, using wet wool, khas, and CELdek as cooling pads. Under various operating conditions, they achieved a maximum relative humidity increase of 59% and a temperature drop of 14.6 °C. However, CELdek outperformed other cooling pads, with a cooling efficiency of 78.67%. Despite the above studies, research on evaporative cooling is ongoing. Various local materials, including biomass materials, have been tested as cooling pads due to the high cost of exotic pads [
18,
19]. The above assertions informed the design of the present solar evaporative cooler for cooling fruits and vegetables. Furthermore, noticing that fruits and vegetables require different cooling rates, the current research attempted to develop a novel evaporative cooler with dual cooling chambers capable of cooling concurrently at different temperatures. This was conceived by using different types of cooling pads or wetting media with different moisture absorption capacities, affecting the exhaust temperature range as shown in several studies in the literature [
20]. Research has shown that different wetting materials can produce different cooling efficiency [
21]. However, apart from energy demand, another challenge in adopting this cooler in most rural areas is the lack of techno-economic feasibility data on solar evaporative coolers, as the initial investment cost might seem high for farmers. This study will present a trade-off between the evaporative cooling system to be adopted and the energy sources for different countries [
22]. This kind of study is lacking in Nigeria. Additionally, the energy pay-back time of PV-powered systems is a major concern, as it is a good CO
2 emission indicator [
23]. Furthermore, although a solar evaporative cooler is renewable, the energy used in manufacturing most of the components represented in the embodied energy is not renewable, coming from electricity or fossil-based fuels. Thus, there is a need to study the impact of the embodied energy in the CO
2 emission, which will assist in reducing CO
2 emissions into the environment. Therefore, the present research aims to (1) develop and test a solar PV-powered evaporative cooling system with dual cooling chambers and biomass pads, (2) evaluate the system’s cooling performance, energy efficiency, and environmental impact, (3) assess the techno-economic feasibility of the system for smallholder farmers in tropical regions, and (4) compare the performance of different biomass pads (wood shavings and polyurethane foam) in the evaporative cooling system. However, the novelty of this research lies in developing a solar PV-powered evaporative cooling system with dual cooling chambers, utilizing biomass pads (wood shavings and polyurethane foam) as a sustainable and locally available solution and conducting comprehensive energy analysis and economic evaluation to assess its techno-economic feasibility and environmental impact in the tropical environment of Nigeria, where postharvest losses are significant and energy access is limited, making it an innovative solution for reducing postharvest losses and improving the cooling of fruits and vegetables while promoting sustainable energy and reducing environmental impact.