Manufacturer, Supplier and Exporter of Cooling Towers

Cooling towers come in various shapes and sizes, but they typically consist of a tall cylindrical or rectangular tower structure. The tower is usually made of concrete, steel, or fiberglass, and it contains several components, including

Fill Material : It provides a large surface area for water to spread out and maximize evaporation.

Fan or Air Blower : It draws air through the tower, facilitating the evaporation process by removing the moist air and bringing in fresh air.

Water Distribution System : It distributes the hot water evenly over the fill material, promoting efficient cooling and evaporation.

Drift Eliminators : These devices help to capture water droplets and prevent them from escaping the cooling tower with the exhaust air.

Water Basin : It collects the cooled water at the bottom of the tower and supplies it back to the process or equipment.

Cooling towers are designed to operate efficiently and economically, balancing the need for effective heat removal while conserving water and energy. They are an essential component of many industrial processes, as they help prevent overheating and maintain optimal operating conditions for equipment and machinery.

Cooling Tower applications

• Cooling the circulating water used in oil refineries
• Petrochemical and other chemical plants
• Thermal Power stations
• Nuclear Power stations
• HVAC systems for cooling buildings

Heating, ventilation, and air conditioning (HVAC)

Cooling towers are also used in HVAC systems that have multiple water source heat pumps that share a common piping water loop. In this type of system, the water circulating inside the water loop removes heat from the condenser of the heat pumps whenever the heat pumps are working in the cooling mode, then the externally mounted cooling tower is used to remove heat from the water loop and reject it to the atmosphere. By contrast, when the heat pumps are working in heating mode, the condensers draw heat out of the loop water and reject it into the space to be heated. When the water loop is being used primarily to supply heat to the building, the cooling tower is normally shut down (and may be drained or winterized to prevent freeze damage), and heat is supplied by other means, usually from separate boilers.

Hyperboloid cooling towers are often associated with nuclear power plants, although they are also used in some coal-fired plants and to some extent in some large chemical and other industrial plants. Although these large towers are very prominent, the vast majority of cooling towers are much smaller, including many units installed on or near buildings to discharge heat from air conditioning. Cooling towers are also often thought to emit smoke or harmful fumes by the general public, when in reality the emissions from those towers mostly do not contribute to carbon footprint, and consist solely of water vapor.

In coal-fired power plants, however, the smoke pipes are often introduced directly into the cooling towers so that these indeed serve also as a chimney.

Nuclear Power stations

Cooling towers are an essential component of many nuclear power stations. Their primary function is to dissipate waste heat generated during the operation of the power plant, particularly from the condenser system.

Nuclear power plants use steam turbines to generate electricity. The steam is produced by heating water in the reactor core, and after passing through the turbine, it needs to be condensed back into water for reuse. This condensation process releases a significant amount of heat, which needs to be removed to maintain the efficiency and safe operation of the power plant.

Thermal Power stations

Cooling towers are an essential component of thermal power stations. They are large, cylindrical structures that help dissipate excess heat generated during the electricity generation process. The primary purpose of a cooling tower is to remove heat from the cooling water that circulates through various parts of the power plant.

Thermal power stations, such as coal-fired or nuclear power plants, generate electricity by converting heat energy into electrical energy. During this process, a significant amount of heat is produced, which needs to be continuously removed to prevent damage to equipment and ensure optimal operation.

Working of Cooling tower in a thermal power station

• Hot water from the power plant's condenser or other heat sources is pumped into the cooling tower.
• The cooling tower sprays the hot water onto a distribution deck, creating a fine water spray or droplets.
• Simultaneously, a fan or fans located at the top of the tower draw air from the bottom and force it upward.
• As the water droplets fall through the tower, they come into contact with the upward-moving air, which causes evaporation.
• The evaporation process absorbs heat from the water, effectively lowering its temperature.
• The cooled water collects at the bottom of the tower and is recirculated back to the power plant for reuse in the condenser or other cooling processes.
• Some cooling towers use a natural draft, where the hot air rises naturally due to the temperature difference, while others rely on mechanical draft systems with fans to create airflow.

Petrochemical and Chemical plants

Cooling towers play a crucial role in the operations of petrochemical and chemical plants by providing a reliable and efficient method for removing heat from industrial processes. These towers are used to dissipate the excess heat generated during various stages of production, ensuring optimal operating conditions for equipment and preventing overheating.

Functioning of Cooling tower in a Petrochemical or Chemical plant

Heat Exchange : The cooling tower receives hot water or process fluids from the plant's equipment, such as heat exchangers, condensers, or reactors. This hot water is usually a byproduct of chemical reactions or thermal processes.

Distribution : The hot water is distributed at the top of the cooling tower through a system of pipes or distribution nozzles. The water flows downward in a controlled manner, either as a spray or in a series of cascading trays.

Contact with Air : As the hot water descends through the tower, it comes into contact with a flow of ambient air. The air, typically drawn in by fans located at the base or top of the tower, interacts with the falling water, absorbing its heat through evaporation and convection.

Heat Dissipation : The heat transfer process causes a portion of the water to evaporate, effectively removing heat from the remaining water. This evaporation results in the release of latent heat, which is carried away by the air passing through the tower.

Cooling and Collection : At the bottom of the cooling tower, cooled water collects in a basin or sump. This cooled water is then pumped back into the plant's equipment for reuse in the industrial processes. Any excess water may undergo further treatment or discharged according to environmental regulations.

Air Discharge : The heated air, now saturated with moisture, exits the cooling tower through louvers or drift eliminators located near the top. These components prevent water droplets from leaving the tower with the air stream, reducing water loss and ensuring compliance with environmental standards.

Regular maintenance and water treatment are essential to prevent issues like scaling, corrosion, and microbial growth, which can negatively impact the tower's performance.