For cooling towers handling high-contaminant water (high TDS, suspended solids, oils, or biological growth), selecting the right fill media is crucial to prevent clogging, fouling, and efficiency loss. Here are the best fill types for such conditions:
Fill Selection Guide Based on Contaminant Type
1. Splash Fill (Best for Dirty Water)
◉ Best for: Water with high suspended solids, oils, or scaling tendency.
◉ Why?
- No narrow passages → Less clogging.
- Self-cleaning due to large water droplets.
- Handles debris better than film fill.
◉ Materials: - PP (Polypropylene) – Chemical-resistant.
- PVC – For moderate conditions.
◉ Common Types: - Grid Bars (Robust, easy maintenance).
- Splash Grids (Vertical or staggered design).
2. Low-Fouling Film Fill (For Moderately Contaminated Water)
◉ Best for: Water with some dissolved solids but lower suspended particles.
◉ Why?
- Larger flute spacing (e.g., 30–40 mm) → Reduces clogging.
- Smooth surface → Minimizes deposits.
◉ Materials: - PVC (High-grade) – Resists scaling.
- CPVC (Chlorinated PVC) – Better for hot/chemically aggressive water.
◉ Designs: - Vertical Chevron Fill – Less prone to fouling.
- Cross-Fluted Fill – Self-cleaning design.
3. Hybrid Fill (Splash + Film Combination)
◉ Best for: Mixed contamination (solids + scaling).
◉ Why?
- Bottom: Splash fill (handles debris).
- Top: Film fill (improves efficiency).
◉ Applications: - Wastewater cooling.
- Industrial process cooling with variable water quality.
4. Anti-Microbial Fill (For Biofouling Control)
◉ Best for: Water with algae, bacteria, or organic growth.
◉ Why?
- Copper-infused PVC → Kills microbes.
- Bio-resistant coatings → Prevents biofilm.
◉ Used in: - Power plants.
- Petrochemical industries.
Fill Selection Guide Based on Contaminant Type
| Contaminant Type | Recommended Fill | Reason |
| High Suspended Solids | Splash Fill (Grid Bars) | No clogging, easy cleaning |
| High TDS/Scaling | Low-Fouling Film Fill (30mm+ spacing) | Resists scaling |
| Oily Water | Splash Fill (PP material) | Oil-resistant, self-cleaning |
| Biological Growth | Anti-Microbial Fill (Copper-PVC) | Prevents biofilm |
| Mixed Contaminants | Hybrid Fill (Splash + Film) | Balanced performance |
Maintenance Tips for High-Contaminant Water
◉ Regular Inspections – Clean fills if fouling exceeds 10% blockage.
◉ Side-Stream Filtration – Removes suspended solids before they enter fills.
◉ Chemical Treatment – Biocides (for microbes), dispersants (for scaling).
◉ High-Pressure Washing – For splash fills in heavy fouling conditions.
Final Recommendation
- For heavy solids/oils → Splash fill (PP Grid Bars).
- For scaling + moderate solids → Low-fouling film fill (30mm PVC).
- For biofouling → Anti-microbial copper-infused fill.