Cooling tower packing (or fill media) is a critical component that maximizes heat transfer by increasing the surface area for air-water contact. The right packing improves efficiency, reduces energy costs, and extends tower life.
1. Splash Packing (Splash Fill)
Design: Uses staggered PVC or PP bars to break water into droplets.
How It Works: Water cascades over multiple layers, creating splashes for better air mixing.
Best For:
Dirty or high-solids water (resists clogging).
Industrial applications (e.g., power plants, refineries).
Advantages Low clogging risk Easy maintenance
Disadvantages Less efficient than film fill
2. Film Packing (Film Fill)
Design: Thin, closely spaced PVC or PP sheets with corrugated patterns.
How It Works: Water spreads into a thin film, increasing evaporation surface area.
Best For:
Clean water applications (HVAC, chillers).
High-efficiency cooling (more surface area than splash fill).
Types:
Vertical Film Fill (Counterflow towers).
Horizontal Film Fill (Crossflow towers).
Advantages Highest heat transfer efficiency Compact design
Disadvantages Prone to clogging (requires clean water).
3. Grid Packing (Wood, Plastic, or Metal)
Design: Open-lattice structure made of plastic (PP), wood, or metal.
How It Works: Water flows over a grid-like structure, creating turbulence.
