What is a Forced Draft Cooling Tower?

The forced draft cooling towers represent a flexible and powerful but economical cooling technology suitable for the most of industrial plants.

Components of Forced Draft Cooling Tower

• The outer shell (material: FRP, steel, stainless steel, concrete)
• supporting structure
• fan stack
• cooling fill
• drift eliminators
• fan with drive
• water distribution system including spraying nozzles
• water basin

Benefits of Forced Draft Cooling Tower

• Ease of maintenance.
• Lower noise levels.
• Dry air stream drive.
• Low-absorbed capacity.

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Cooling Towers: Operating Principles and Systems

The huge, perfectly shaped cylindrical towers stand tall amidst a landscape, with vapor billowing from their spherical, open tops into the blue sky. Such an image usually provokes a thought related to nuclear power or a mysterious energy inaccessible to the millions of people who drive by power plants every day. In reality, cooling towers – whether the hyperboloid structures most often associated with the aforementioned nuclear power plants or their less elegantly shaped cousins – are essential, process oriented tools that serve as the final step in removing heat from a process or facility. The cooling towers at power plants serve as both an adjuster of a control variable essential to the process and also as a fascinating component of the process behind power creation.

The importance and applicability of cooling towers is extensive, making them fundamentally useful for industrial operations in power generation, oil refining, petrochemical plants, commercial/industrial HVAC, and process cooling.

The following are some of the applications of Cooling Tower:

• Air compressors with a water cooling system
• Blow Molding and Compression Molding Machine
• Machinery for die casting
• Plant for deep freeze and anodizing
• Plant for generating electricity
• VAM machinery and liquid air conditioning systems
• Machines that process natural gas
• Stations that generate electricity
• Oil and gas facilities
• Plants that are semi-conductor
• Hydrocarbon facilities
• Boiler Application
• Chiller Application
• Die Casting Application
• Furnace Application
• Fot Dip Galvanizing
• Hydraulic Press

Operating Principles of Cooling Tower

In principle, an evaporative cooling tower involves the movement of a fluid, usually water with some added chemicals, through a series of parts or sections to eventually result in the reduction of its heat content and temperature. Liquid heated by the process operation is pumped through pipes to reach the tower, and then gets sprayed through nozzles or other distribution means onto the ‘fill’ of the tower, reducing the velocity of the liquid to increase the fluid dwell time in the fill area. The fill area is designed to maximize the liquid surface area, increasing contact between water and air. Electric motor driven fans force air into the tower and across the fill area. As air passes across the liquid surface, a portion of the water evaporates, transferring heat from the water to the air and reducing in the water temperature. The cooled water is then collected and pumped back to the process-related equipment allowing for the cycle to repeat. The process and associated dispersion of heat allows for the cooling tower to be classified as a heat rejection device, transferring waste heat from the process or operation to the atmosphere.

Evaporative cooling towers rely on outdoor air conditions being such that evaporation will occur at a rate sufficient to transfer the excess heat contained in the water solution. Analysis of the range of outdoor air conditions at the installation site is necessary to assure proper operation of the cooling tower throughout the year. Evaporative cooling towers are of an open loop design, with the fluid exposed to air.

A closed loop cooling tower, sometimes referred to as a fluid cooler, does not directly expose the heat transfer fluid to the air. The heat exchanger can take many forms, but a finned coil is common. A closed loop system will generally be less efficient that an open loop design because only sensible heat is recovered from the fluid in the closed loop system. A closed loop fluid cooler can be advantageous for smaller heat loads, or in facilities without sufficient technical staff to monitor or maintain operation of an evaporative cooling tower.

Thanks to their range of applications, cooling towers vary in size from the monolithic structures utilized by power plants to small rooftop units. Removing the heat from the water used in cooling systems allows for the recycling of the heat transfer fluid back to the process or equipment that is generating heat. This cycle of heat transfer enables heat generating processes to remain stable and secure. The cooling provided by an evaporative tower allows for the amount of supply water to be vastly lower than the amount which would be otherwise needed. No matter whether the cooling tower is small or large, the components of the tower must function as an integrated system to ensure both adequate performance and longevity. Understanding elements which drive performance – variable flow capability, potential HVAC ‘free cooling’, the splash type fill versus film type fill, drift eliminators, nozzles, fans, and driveshaft characteristics – is essential to the success of the cooling tower and its use in both industrial and commercial settings.

Design or selection of an evaporative cooling tower is an involved process, requiring examination and analysis of many facets. Share your heat transfer requirements and challenges with cooling tower specialists, combining your own facilities and process knowledge and experience with their application expertise to develop an effective solution.

What is Cooling Tower Valves?

Cooling towers are a critical need for any industrial and manufacturing operation. Their role in extracting heat and delivering it to the atmosphere through evaporative cooling leverages the principle of heat rejection. The essential element of a cooling tower is water that is delivered through a piping system. These steady flow devices cool the water by evaporation with direct contact of the air. Evaporatively cooled equipment like cooling towers typically utilize a multi-cell configuration. While these systems offer improved efficiency, operational flexibility, and advanced controls, they can only perform as well as their hardware is designed and built. One of the most important components of a cooling tower is its valves. This is why Zeco offers cooling tower valves to optimize the performance of your cooling towers, reduce downtime, and eliminate maintenance.

How do Valves improve the performance of Cooling Tower?

A direct replacement valve that is optimized for all existing crossflow cooling tower distribution valves and can mitigate the need of constant maintenance and replacement while improving efficiency and performance. A valve that is manufactured entirely from 304L or 316L stainless steel and UHMW-PE plastic eliminates corrosion concerns. Also, valves that feature a 30% larger discharge area and 40% reduction in weight compared to conventional distribution valves are the new industry standard.

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CORROSION PROOF

Plastic cooling towers are made of a corrosion proof engineered plastic. The cooling tower shell will never rust, flake, chip, peel, or ever need painting or protective coatings applied.

Some industry experts are predicting that plastic towers may just be the future of the industry. Metal towers do not have the long-term corrosion protection advantages for outdoor usage.  The Galvanizing or other metal treatments only delay the corrosion of the underlying, often thin gauge sheet metal.

SEAMLESS CONSTRUCTION

Some manufacturers offer a totally seamless cooling tower.  The tower shell is rotationally molded of polyethylene plastic. One manufacturer, Delta Cooling Tower, offers the only large packaged cooling tower in the industry that has a “one Piece” shell, thereby eliminating the seams, panels, rivets, or hundreds of fasteners that potentially fail and compromise the performance or integrity of the product.

LIGHTER IN WEIGHT

Due to our materials of construction, plastic cooling towers can be 30% to 50% lighter in weight than steel towers of the same capacity. This is beneficial  on roof installations, light weight raised platforms, or at ground level installations by reducing the rigging / placement cost.

LONGER WARRANTIES

Plastic cooling towers typically offer longer warranties than their metallic cousins. A 20 year warranty isn’t unusual for the structural shell of a plastic cooling tower.

LOWER MAINTENANCE

Plastic cooling towers are, by their very nature, lower maintenance than metallic.

What is a cooling tower valve?

Cooling tower valves are devices designed to control, regulate, distribute, and allow, or disallow the passage of water through certain parts of the cooling tower’s system. The different valves throughout a cooling tower system play an important role in their performance and the overall operation of your facility. The types of valves needed will depend on the flow capacity and the size of piping in the cooling tower. Temperature and pressure are also critical considerations when it comes to valve selection.

What are cooling tower flow control valve?

Control valves in cooling towers are manually operated devices that regulate the flow of water in the system. These valves should be simply designed to ensure reliability. They are available in a range of sizes that are appropriate for all types of cooling towers. These valves should also have a protective coating that can withstand corrosive atmospheres.

What are cooling tower isolation valve?

An isolation valve in a cooling tower stops the flow of water in a certain location.  This valve is designed to enhance maintenance and safety efforts. Isolation valves are intended to be operated on an infrequent basis. They are only employed when the flow of water needs to be restricted for testing or servicing purposes.

What are cooling tower distribution valve?

A distribution valve regulates the flow of hot water to evenly distribute it to the cells. The body of the valve in a distribution valve is made to withstand the corrosive nature of its environments. It is important for the flow of hot water to be maintained for optimal performance.

What are cooling tower float valve?

Float valves, or float switches, are essential for maintaining proper water levels inside of a cooling tower. These valves are designed for cooling applications that rely on water being cooled by contact with the air. This process requires constant water flow and water level management to create evaporative cooling. These valves control the water level fluctuation inside of the cooling tower and require very little maintenance.

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