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Cooling Towers

Cooling Towers – Aqua Cooling can design, supply and install a range of Industrial Cooling Towers – from one off units to multi-cell solutions. The size of Cooling Tower and levels of thermal performance are unlimited, with completely bespoke options available. Our product range includes both open and closed design towers, fully factory assembled or field erected – crossflow, counterflow, forced draft and induced draft.

Help With Product Selection

With so many different types and configurations possible, we’re only too aware that cooling towers can often appear quite daunting. The type of cooling that’s needed depends on the design criteria and operating conditions required and sizes and models of tower do vary considerably. Our engineers are fully conversant with the different variants available and are on hand to help you with product selection and system design – selecting the very best option for your application and/or process.

Technical excellence and robust engineering play a huge part in the design of our cooling tower units. We offer a product that is highly reliable, yet cost effective, with maintenance kept as low as possible, whilst giving you a unit and/or system that’s built to last.

Design Options

Design options include galvanised steel, stainless steel 304 or 316, GRP and low silhouette. GRP – Glass Reinforced Plastic (GRP) – is non-corrosive and unaffected by water treatment chemicals.

We can also offer closed circuit towers with cooling coils which give water quality advantages. If the application is particularly noise sensitive then we have low noise options – for example a range of silencers or centrifugal fans.

Types Of Cooling Tower

Here’s a very brief overview of the main types of cooling towers and their differences:

> Crossflow – with a crossflow cooling tower the air and the water components effectively cross each other because the air flows horizontally and the water drops vertically through the flow media.

> Counterflow – with a counterflow design, air flows vertically upwards, counter to the water flow in the fill media (which is flowing vertically down). This means it’s not possible to use the basin’s gravity flow so pressurised spray systems are used to spray the water onto the fill media. Here it’s important not to restrict airflow so the pipes and nozzles are further apart.

> Forced draft – air is pushed or forced by blowers located at the base of the air inlet face.

> Induced draft – fans are used to pull air up and through the fill media. The fans are commonly sited on top of the unit.

> Field erected – constructed on site, normally prefabricated and then assembled in situ.

> Factory assembled – normally shipped in sections (unless very small) and just final assembly happens on site.

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How Do Cooling Towers Work?

Fundamentally, cooling towers are an organic heat exchanger. Warm or hot water from a process is cooled by passing it through the tower and then back out into the process. A cooling tower enables the water to come into contact with the air so that some of the water evaporates, lowering the overall water temperature.

Water is pumped, usually from the basin of the tower or a sump tank below the cooling tower, through pipework to the process. This is then returned to the cooling tower, where it is either sprayed by nozzles or returns to a tank at the top of the tower – to gravity drain onto fill media to maximise air to water contact. The water flows over the fill media or packing and meets air, which is then either pulled or pushed through by fans. This, in essence, is evaporative cooling.

Open vs Closed Cooling Towers

Closed circuit cooling towers and open circuit cooling towers both cool the water but just go about it in different ways.

With an open circuit cooling tower, the process water comes into direct contact with the external air stream, with the hot/warm water being distributed over a specialised fill or packing. This gives a platform for the evaporative cooling to take place as the air and water interface. The water is cooled as it passed through the packing and then collected in a basin below. The air, now heated and moisture laden, leaves the fill and is discharged into the atmosphere. The issue here is that any contaminate within the air is passed into the cooling water. Also, as the water is treated for biocides and softened, these can build up in the system over time.

A closed circuit tower has an internal or external heat exchanger and the process water is separated from the ambient air, therefore maintaining its quality and cleanliness at all times. The disadvantage is that the heat exchanger adds to the size of the cooling tower and therefore price is significantly higher.

Call Aqua's experienced engineers today to talk about your Cooling Tower requirements and how Aqua can help! Trust the UK Experts in Cooling!

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