Tags: Shell and tube heat exchanger

KEY MATERIALS FOR FILLS Material Max Temp Properties Typical Use PVC (Polyvinyl Chloride) ~50-60°C (122-140°F) Low cost, good corrosion resistance, flammable. Standard for most film & splash fills in HVAC and general industry. PP (Polypropylene) ~70-80°C (158-176°F) Higher temp tolerance, good chemical resistance. Hot water processes,...

Double Cross flow vs. Other Types Feature Double Cross flow Single Cross flow Induced Draft Counter flow Air Inlets Two opposite sides One side All around the bottom perimeter Plan Area (Footprint) Wider for same capacity Wider (one-sided) More compact Pump Head Required Low (gravity basin) Low Higher (pressurized nozzles) Fill...

COOLING TOWER WATER TREATMENT Purpose & Importance Water treatment is critical to: Untreated water leads to reduced heat transfer, increased energy consumption, equipment damage, downtime, and health hazards. . COMMON PROBLEMS IN COOLING SYSTEMS A. Scaling B. Corrosion C. Biological Fouling & Growth D. Fouling (Suspended...

SIZING A COOLING TOWER Core Concept Sizing a cooling tower involves determining its required thermal capacity (heat rejection rate) and physical dimensions to meet specific process cooling needs under design ambient conditions, while balancing capital and operating costs. 1. KEY INPUTS FOR SIZING (Design Parameters) A. Thermal...

Typical Applications Comparison: Single-Flow Cross flow vs. Counter flow Parameter Induced Draft, Single-Flow Cross flow Induced Draft Counter flow Air/Water Flow Path Perpendicular (Crossing) Opposite (Parallel) Water Distribution Open Gravity Basin Pressurized Nozzle System Pump Head Required Lower Higher Clogging Susceptibility Lower (larger...

COOLING TOWER Purpose: Basic Principle: Main Types: Key Components: Applications: Advantages: Disadvantages: Key Terms:

Advanced Fill Technologies High-Efficiency/Low-Clog Film Fill Zero Drift Fills Fire-Retardant Fills Installation Considerations Economic Impact Fill represents 15-25% of tower cost but determines 60-80% of cooling performance Industry Trends

A Vertical Spray Tower (also called a Spray Pond in a Tower or No-Fill Tower) is a simplified, robust type of evaporative cooling tower that operates without traditional fill media. Instead, it relies entirely on spray nozzles to create the water-air interface for heat transfer through evaporation. Core...

Maintenance Requirements

Hybrid/Dry-Wet Operation Many closed-circuit towers can operate in three modes for maximum efficiency: Key Design Considerations In summary: A closed-circuit cooling tower sacrifices some thermal efficiency and adds cost to achieve complete protection of the process cooling fluid. It’s the preferred choice when water quality, system...

Comparison with Open (Direct-Contact) Towers Parameter Closed-Circuit (Indirect) Tower Open (Direct-Contact) Tower Process Fluid Isolated in sealed coils Exposed directly to air Heat Transfer Fluid → Coil → Water Film → Air (Indirect) Water → Air (Direct Contact) Water Treatment Only for small spray loop Required for entire system...

Indirect-Contact or Closed-Circuit Evaporative Cooling Tower An Indirect-Contact or Closed-Circuit Cooling Tower is a hybrid system that combines the efficiency of evaporative cooling with the cleanliness of a closed-loop process. It physically separates the process fluid from the atmospheric air and spray water, while still using...

DRIFT LOSS This is an undesirable loss that represents inefficiency.

OPERATIONAL & CONTROL STRATEGIES 11. Waterside Free Cooling (Water-Side Economizer) •          Opportunity: When ambient wet-bulb is low enough, use the cooling tower directly to produce chilled water, bypassing the chiller. •          Savings: Chiller...

Evaporation Loss vs. Drift Loss: Fundamental Differences Both are forms of water loss in a cooling tower, but they differ fundamentally in mechanism, purpose, controllability, and impact. Evaporation Loss vs. Drift Loss: Fundamental Differences Both are forms of water loss in a cooling tower, but they differ fundamentally in mechanism,...

Energy Conservation Opportunities (ECOs) in Cooling Tower Systems Cooling tower systems offer significant energy savings through fan/pump optimization, water management, and intelligent control. Here are the key opportunities, categorized for clarity: I. FAN SYSTEM OPTIMIZATION (Largest Savings Potential) 1. Variable Frequency Drives...

The Fundamental Heat Rejection Process To understand these terms, visualize the process: a) Approach b) Cooling Duty (or Cooling Capacity) c) Range d) Cooling Tower Effectiveness (or Thermal Efficiency) Visual Summary & Relationship Imagine a cooling tower with these conditions: Calculations: Practical Analogy: Think of cooling a hot cup of...

Purpose of a Cooling Tower: To reject waste heat from a process (like HVAC or industrial cooling) to the atmosphere by evaporating a small portion of the circulating water, thereby cooling the remaining water. Major Components & Their Functions 1. Structure & Casing 2. Fill (or Packing) – The “Heart” of Heat Transfer 3....

Common Types of Nozzles in Field-Erected Towers Type How It Works Best For Spray Nozzle (Hollow Cone) Creates a circular, ring-shaped spray pattern. Water is directed through tangential slots or a swirl chamber, creating a centrifugal “hollow cone” effect. Cross Flow towers (common) and older Counter Flow systems. Good coverage...

The Two Fundamental Types of Fill Fills are categorized by how they create water surface area: Type How It Works Best For Material Splash Fill Breaks water into droplets. As water falls, it hits staggered splash bars (grids, beams, or laths), continuously breaking into smaller droplets. • Water with high suspended solids/silt• Applications...

Critical Ancillary Components The motor is part of a larger drive system: Common Maintenance & Failure Points Best Practices & Trends

Typical Applications of Field-Erected Cooling Towers Advantages vs. Factory-Assembled Towers Advantages of FEP Disadvantages of FEP Customization: Tailored to exact site/process needs. Longer Installation Time: Significant on-site labor and construction schedule. High Capacity & Scalability: Virtually no upper size limit. Higher...

A Field-Erected Cooling Tower (FEP) is a large-scale, custom-engineered cooling tower that is assembled entirely on-site from individual components delivered to the project location. Due to their size and capacity, they cannot be factory-built as a single unit and are designed for heavy-duty industrial applications requiring long service...

When to Choose Factory assembled cooling Towers vs. Field-Erected Choose FAP when:✓ Capacity < 2,000 tons✓ Quick installation required✓ Budget is constrained✓ Space allows modular placement✓ Standard performance is acceptable Choose Field-Erected when:✓ Capacity > 2,000 tons✓ Extreme durability needed (30+ year life)✓ Highly...

. Quick Installation 2. Lower Initial Cost 3. Quality Control 4. Space Efficient 5. Scalability Easy future expansion by adding modules

Forced Draft Advantages: Induced Draft Advantages:

Forced Draft vs. Induced Draft Parameter Forced Draft Induced Draft Fan Position Bottom or air inlet side Top (discharge) Air Movement Fan pushes air in Fan pulls air through Internal Pressure Positive pressure below fan Negative pressure (suction) Common Fan Type Centrifugal (pressure blowers) Axial (propeller) fans...

Why Choose Counter flow Over Cross flow? Choose counter flow when:

Cross flow vs. Counter flow Design Feature Cross flow Cooling Tower Counter flow Cooling Tower Air/Water Direction Air horizontal, water vertical (90° cross). Air upward, water downward (opposite directions). Water Distribution Gravity basins (low pressure). Pressurized spray nozzles (higher pressure). Air Pressure...

Cross Flow Cooling Tower Components & Their Roles Component Function Hot Water Distribution Basins Hold water at top; gravity distribution via metering orifices. Louvers Side openings that guide air into the fill, prevent water splash-out. Fill/Packing Creates large surface area for air-water contact (usually PVC splash bars or film fill). Cold...

Cooling Tower Common System Types Type Typical Size Range Typical Applications Natural Draft (Hyperbolic) 500 – 10,000+ MW (heat rejection) Large power plants Induced Draft, Cross flow (FRP) 100 – 1,000 tons Commercial HVAC, light industry Induced Draft, Counter flow (FRP) 50 – 500 tons Data centers, hospitals, precision cooling...

Cooling Tower Selection Guide: Which Type to Choose? Parameter Favors Wet Tower Favors Dry Tower Favors Hybrid Water Availability Ample Scarce / Expensive Limited Water Discharge Regulations Lenient Strict Moderate Approach Temperature Needed Close (< 7°C) Wide (> 10°C) Variable Ambient Climate Any Prefer cooler/dry Variable Plume...

Application-Based Selection of Tower Type Application Typical Cooling Tower Type Key Reason for Choice Large Power Plant Natural Draft (Hyperbolic) Massive capacity, no fan power, very reliable. Commercial HVAC Factory-Assembled Induced Draft Cross flow or Counter flow Compact, cost-effective, easy to maintain, good part-load performance....

Cooling Tower Applications by Industry & Sector 1. Power Generation (The Largest Application) 2. Heating, Ventilation, and Air Conditioning (HVAC) 3. Oil Refining & Petrochemical 4. Chemical & Pharmaceutical Manufacturing 5. Heavy Industry & Manufacturing 6. Data Centers & Telecommunications 7. Miscellaneous & Specialized...

Core Functions & Benefits Function Benefit Heat Rejection Removes large heat loads (often 10-1000+ MW) efficiently. Water Conservation Recycles 95-98% of cooling water (vs. once-through systems). Energy Efficiency Lower power consumption than air-cooled systems for same duty. Space Efficiency Smaller footprint than air-cooled heat exchangers...

Cooling Range in a Cooling Tower Simple Definition The Cooling Range (also called Temperature Range or simply Range) is the temperature difference between the hot water entering the cooling tower and the cold water leaving it. It is expressed as:...

A cooling tower is a specialized heat exchanger that removes waste heat from a system (like an industrial process or an HVAC system) by transferring it to the atmosphere through the cooling of water. It uses evaporation to cool down water, which is then reused in the process. How It Works (Basic Principle)