Key Questions to Ask When Ordering Crossflow Fill

I have a number of cooling towers on the coast / beach like the image below. Most are more traditional with the fan on the top of the towers, but the fans are working and not my concern.

My first question is what is the proper term for the circled area? Air flows into this side of the cooling tower.
The baffles/fill are supposed to be black/grey. They are currently white due to a build up of sand, I know it is sand because you can pick it off with your fingers. The baffles/fill is approximately 12 inches thick as best I can tell.

Here is a close up of the same tower.


Here you can see that the sand is trying to build up and reduce the air flow over the baffles/fill. Also the jagged edge where the vertical panels of the baffles/fill is being damaged. Although not present on this one, a few towers have a slick calcium scaling under the sand.

Second question is can these baffles/fill be cleaned/replaced or does the entire tower need to be replaced. Fans, pumps and other ancillary equipment is working fine. Our maintenance contractor is pushing to replace the towers. It's not easy to tell from those photos alone, but it looks like an inlet screen to me to stop leaves / twigs etc blowing in and / or water blowing out.

Any sectional drawings or pictures of what is inside the box or can you sketch it?

Make and model number?

So the water falls vertically down and air is drawn through and up the louvers?

Can you not simply remove the screens and clean or replace? Have you tried washing / jet washing it off as it looks like salt crystals mainly with perhaps a bit of sand thrown in.

Remember - More details = better answers
Also: If you get a response it's polite to respond to it. Units are old, no sections or internal details. No make or model number at this time.
Yes you are correct, air goes in through the screen, water down, air out through louvers.
Here are some pictures of another cooling tower at another building. This one is even closer to the beach.
Photo 1

This one has a big hole on the side. In the picture above, there is a large streak of rust running vertically down the side. The hole below is in a similar position on the other side.

Photo 2


Photo 3 - Is this the fill where water trickles down?


Photo 4


A look inside this tower
Photo 5


If the external feature where air enters is just a screen, this changes my outlook and recommendations on what to do with these cooling towers.
Just trying to better understand what I am looking at. That'll teach me!

Looks very much like this is a Marley ( the clue is the painted name on the side of the unit) cross flow with what looks like an MBX or similar fill which is a drop in pre formed plate pack.

If I was you I would find a local Marley distributor and take their advice.




how it works


Remember - More details = better answers
Also: If you get a response it's polite to respond to it.

A cooling tower is an essential component to run a power plant, manufacturing units, and factories. The primary job of the cooling tower is to simply remove the excess heat and humidity from the building caused by machines. Cooling towers are also used for ventilation and air conditioning (HVAC) and other industrial purposes. They are energy-efficient and cost-effective in operation.

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If you're planning to buy a cooling tower for your factory, you may come up with several questions about the product? In this blog, we will discuss some of the frequently asked questions related to cooling towers.

Q1. What is a cooling tower?
A cooling tower is a specialized heat exchanger in which the water and air are brought in direct contact to remove the heat and humidity from the building. After water comes in contact with air, it starts to reduce temperature; as a result, a small amount of water is evaporated, thereby reducing temperature.

Q2. Why should I use a cooling tower?
The machines at factories and manufacturing units generate a tremendous amount of heat which needs to be cooled down for operating efficiently. The most cost-effective way of maintaining machines is by installing a cooling tower.

Q3. How many types of cooling towers are there?
We offer 3 types of cooling tower

CROSS FLOW COOLING TOWER

Tower Tech's crossflow cooling tower is one of the widely used cooling towers in the industries. In the crossflow cooling- air flows via the fills in the horizontal direction, and water flows down in vertical direction. The cooling tower has splash type fillings that hold the higher suspended particles.

Application of crossflow cooling tower

• Chemical Plant
• HVAC
• Light to medium scale industries
• Furnace
• Pharmaceutical Plant
• Plastic Processing Plant
• Refrigeration
• Process Cooling

Rectangular/Square Cooling Tower

Tower Tech's square/rectangular cooling tower comes in different capacities and shapes. This type of cooling tower operates according to the COUNTERFLOW COOLING TOWER principle, where air flows vertically through the fitted fillings at the top while the water flows downward. In a rectangular cooling tower, an induced draught fan is attached to the motor which pulls in air to draft it upwards leading to faster cooling of the air. Less pressure and circulation required for cooling.

Benefits of Square Cooling Tower

• Energy Efficient
• Low Fouling Film or Splash fills
• Low height Pump head
• High Performance
• Less Maintenance
• Optimized cooling
• FRP Wood or Concrete Structures

Round/Bottle Cooling Tower

The round cooling tower has a unique design and outstanding technology. Because of the round shape, the airflow inside the cooling tower is uniformly distributed. The hot water inlet fitted at the bottom flows water to the mechanical rotary sprinkler. The inlet water pressure rotates the sprinkler, featuring arm pipes with orifices to evenly disperse water to the fill. The evaporated water removes the excess heat from the rest of the water.

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The Bottle or Round cooling tower stands apart from the rest because of compact design and varying flute sizes to offer maximum heat transfer.

Benefits of Round Cooling Tower

• High Strength
• Chemical Resistance
• Part Consolidation
• Durability
• Incombustible
• Inexpensive

Fan less, Fill less Cooling Tower

Tower Tech offers the best INDUSTRIAL COOLING TOWERS that are fanless and fill less. This type of cooling system don't have fans and fills. To restrict the water spillage, wooden louvers are used on the sidewalls of the cooling towers. The cooling of water takes place from the outside wind that enters into cooling towers and acts as a cooling medium. The hot water is sprayed on the top of the cooling tower with spray nozzles.

Benefits of Fanless, Fill less Cooling Tower

• Inexpensive because no fans and fills are fitted
• Less noise
• Energy Efficient
• Durable
• Low Maintenance

Q4. How much does a cooling tower cost?

The price of cooling towers starts from INR 20,000 and ranges up to 2 lakh depending on the structure, features, and application. The cost varies as per industrial cooling towers manufacturers.

Q5. Why do cooling towers require maintenance?

A well-maintained cooling tower will work with original optimum efficiency, keeping energy costs low.
Lubricating fan shaft bearings every three months is required to maintain the proper functioning of the cooling system.

Annual maintenance of cooling towers by professionals will help in the following ways.

• The operating efficiency of your cooling tower remains optimal
• Your cooling tower continues to operate as a new system
• Your cooling tower holds its cooling capacity
• The risk of Legionella's disease is reduced
• Regular cooling tower services extends the working life of cooling tower is extended (so you do not have to replace your cooling tower so soon)
• Premature wear and tear, spillage of your cooling tower is avoided

In Summary

Cooling Tower is a heat exchanger system that is essential in factories, and manufacturing units to remove excess heat and from the building and facilitate machines to run smoothly.

The company is the world’s best Counterflow Fill supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.