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Cooling towers solutions and overview of the last development achieved over the years. Here in Cooling Towers we will give you the latest advanced info about the Cooling Towers method adapted around the globe.

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Concrete cooling towers

Concrete cooling towers have been ruling the roost since a long time. Many of them are still in operation in different regions of the world due to their intrinsic efficiency and durability. Every country has its own penchant for cooling tower material. A concrete cooling tower is made out of 100 percent material that is corrosion free. This is because the manufacturers agree on the fact that even the best of the stainless steel used in the cooling tower has been known to get oxidized, turns brown, and requires regular cleaning. If the walls of the FRP cooling tower are doubled, its life span may be increased to match that made of concrete. When manufactured by a company of repute and maintained properly, concrete cooling towers emerge as clear winners among all material. They can be expected to last for over 50 years without suffering break-downs.cooling towers

Concrete cooling towers create a lower level of noise than conventional FRP towers. This occurs due to the natural properties of concrete. Towers made of concrete are usually constructed as an ordinary part of the architectural design and, thus, have a pleasing appeal. The towers turn out to be considerably more flexible, where space is concerned. The client can allocate separate area where the concrete tower manufacturer can erect the tower as a substitute for having them installed in separate plant rooms which might be tight on space. The client is only required to work alongside the architect and have the concrete cooling towers constructed in tandem with the other structures of the plant.

Concrete cooling towers are mostly found in industries of petro-chemicals, energy, crude oil processing, and metallurgy. The fundamental parts of the tower comprise of its concrete skeleton, diffuser, axial ventilator, eliminators, spraying jets, and fillers. A thorough understanding of the working of the cooling tower is needed in order to the construct them. The structure, as well as, the foundation has to be designed so that they can withstand vibrations from the fan, motor, gear-box, etc, strong winds, and seismic movements over a long span of time. Continuous contact with water makes these towers susceptible to attacks by fungi, algae, decay, and deposits left by water of inferior quality.

FRP cooling towers

FRP Cooling Towersfrp cooling towers

Fiber Reinforced Plastic or FRP cooling towers are made of composite material fabricated out of polymer matrix that has been reinforced with fibers of carbon, glass, aramid, asbestos, paper, or wood. These cooling towers are known for their superior design and technology and are commonly utilized by:

Paper mills        Air conditioning plants

Induction furnaces           Die casting machines

Compressors           Chilling plants

Oxygen plants           Pharmaceutical industries

Heat exchangers            Diesel generating sets

Anodizing plants            Extruders

Injection molding machines            many HVAC applications

Generally manufactured in cuboid or bottle shape, FPR cooling towers, have an advantage of being compact and elegant to look at. The round shape allows the flow of air to be evenly distributed and without interruption, making them the most thermodynamically efficient design among all others. This directly reduces the cost of running. The vertical design with induced counter flow have uniform water distribution and, therefore, offers optimal transference of heat.

FRP cooling towers may be installed independent of velocity of the wind. The fans of the cooling towers are energy efficient, induced draught axial kind with adjustable speed. The blades of the fans are dynamically balanced by the manufacturers. The FRP induced cooling tower is made out of resistant fiberglass and is structurally strong enough to hold out to vibrations and high wind velocity. Some kind of protective gel is applied on the outer shell to defend against ultra violet rays, and extend its life. The water sump is leak proof and is made of FRP.

FRP cooling towers have rigid fill, usually made out of Poly Vinyl Chloride (PVC) and have a design of a honey comb, with a surface area that is large. The function of the fill is to divide the air and water into many streams to augment the contact time and also the transference of heat between the two. The motors are entirely enclosed, induction weather proof, and have extended shaft that are specifically designed for cooling towers. The eliminator attached to the sprinkler slashes the loss of water and is also made of PVC. The sprinklers are made of stainless steel/brass/aluminum/PVC, are non-clogging, need low pressure to function, and assure uniform flow of water.

Cooling Towers – What They Are, What They Do

Cooling towers are a key feature of many large industrial plants and serve as heat removal, or heat rejection, devices. This means that they transfer the waste heat produced by various industrial processes into the atmosphere. The main purpose of cooling towers is to cool the circulating water used in these plants.
Cooling towers come in various shapes and sizes. They can come as small units designed for roof tops, as well as massive hyperbola-shaped structures. The largest  can be up to 200 meters high and 100 meters in diameter. These are designed to handle hundreds of gallons of water a minute and supplied by water pipes as large as 5 meters in diameter. On the other hand, small cooling towers can handle only a few gallons of water per minute. The water is supplied to them by small pipes, which are similar to the water pipes we have in our houses.

There are several types of cooling towers. Two main classifications refer to their structure and their use. Package type cooling towers are compact, preassembled structures that can be easily transported by trucks. For this reason their capacity is limited and they are used by facilities that require low heat rejection, such as hospitals, schools, textile plants, hotels and so on. However, large plants such as oil refineries, chemical plants and power plants have much larger heat rejection requirements and therefore have a need for field erected cooling towers, which are much larger in size than package type towers.
As to their use, cooling towers can be classified into HVAC towers and industrial cooling towers. HVAC (heating, ventilating and air conditioning) towers reject heat from chillers and both serve conjointly as a part of the conditioning system in structures such as large office buildings, schools and hospitals. Industrial cooling towers are used to remove heat from sources like heated process material or industrial machinery. They are usually found in chemical plants, oil refineries, food processing plants and other large industrial plants.

B2B products are products that are not sold directly to consumers but to businesses (B2B means ‘business-to-business’). Cooling towers are a classic example of B2B products, as they are used in the manufacturing of other products (in this case, providing heat rejection to cool large structures) and do not go directly to consumers.

FRP Cooling Towers are in Great Demand in Large Industries

Nowadays, you’ll see that most of the large industrial plants having FRP cooling towers. They are basically used for cooling the water which gets heated up in the manufacturing processes. The basic principle and functioning of these towers is pretty simple to understand. All the hot water that flows through the heat exchangers will be routed to these towers to cool the water. In this way, the temperature of the water can be lowered effectively. The cool water so obtained is routed back to manufacturing line to carry out the processing of any plant.

Currently, the FRP cooling towers being used by most of the industries are of two different types, namely:

  • Natural Draft Towers
  • Mechanical Draft Towers.

Globally, you will notice that natural draft towers are generally used in large power stations and refineries due to their heavy sizes. On the other hand, the mechanical draft towers are much smaller in size and thus, mostly electric fans are used for forcing the draft of air from the tower.

In general, the water flows down from the FRP cooling towers with the gravitational pull. During the fall, the water and air will remain in contact with each other for a long duration. In the process, maximum heat gets transferred between air and water, which gets dispersed through natural atmosphere. The cool water collected is again recycled and additional water is added for the loss that happened due to evaporation.

There are many companies in various parts of the world who are in the business of manufacturing FRP cooling towers. Many of them produce world class quality evaporative devices, which are ISO certified company. If you want to find out which of these companies could suit your needs, then look up the net and get the desired deal.

In any country, where industrial revolution is taking place, there will be large demand for these FRP cooling towers. Particularly in tropical countries, there is a great demand for these towers, due excess heat. Most of the countries have also started manufacturing these towers to meet the demands of their industries. Many of countries that specialize in this field also export these cooling devices to other parts of the world.
Earlier, these towers were made of wood. However, with advancement in the technology, FRP cooling towers have started appearing in the market. FRP is short form of Fiber Reinforced Plastic. If you are running any large scale industrial plant, then you can contact any of the manufacturer of these towers to find out the specification to fulfill your requirements.

Different Types of FRP Cooling Towers and Their Industrial Applications

FRP cooling towers are used to supply cool water in the systems like air conditioners and electric
power generators. Different types of FRP cooling devices are manufactured in the industry,
depending upon the demands of the industry. Some of the types are package towers, dry towers,
RCC towers, square shape towers, industrial towers, fanless filles towers, timber towers,
induced tower, and many others.
FRP fanless towers - advantages and functioning of the system
Common specifications of fanless filles towers include:
  • Energy of the water is directly converted into kinetic energy of air
  • Jet ejected nozzle is used for inducing air current
  • Air is induced through external means at the top of the tower.
Structure of the tower is designed with heavy tee or channel sections,
which are further hot-dipped galvanized. Fiberglass reinforced plastics are used for the making of louvers.
This material is used to resist corrosion.
Advantages and characteristics of these FRP cooling towers
Water distribution headers are the main characteristic of FRP cooling devices.
They are made from heavy duty pipes. Polypropylene is used to provide good corrosion resistance to nozzles.
Few advantages of these towers include:
  • No breakdown
  • No difference in their performance – these towers provide high quality performance even after few decades of installation.
  • Zero consumption of power, as no electric motor is not fitted in these systems
  • Minimal percentage of loss
  • No future replacement – best quality components are used in manufacturing these cooling towers and hence, the chance of replacing the products decreases.

Application of FRP cooling towers

These towers are primarily used in air compressors, chemical industries,
dairy and food processing industries, A/C plant and chilling plants,
aluminum die casting,  glass manufacturing plants, herbal, aromatics and extraction plants,
gensets and megawatt projects, oil refineries, industries heat process,
steel factory and foundry and PVC pipes manufacturing plant.
Evaporative FRP cooling towers are getting good responses since many years.
The businessmen are able to keep their business or company cool by using these systems.
Try to buy these towers from reputed makers or dealers to avoid any inconvenience in the future.
Steps to be taken care of before buying a tower
You could take assistance from the manufacturing units on maintenance,
installation and selection of the right tower. You could take guidance from other neighboring
companies that have installed such systems.
Before installing the towers, the manufacturing company will send a few experts to examine your place.
Later, they will install the perfect tower, which suits your needs. Once these towers are established,
you will automatically notice the difference in the productivity of your industry.
Maintenance of these towers is important
Routine testing and maintenance of these towers ensures that they work effectively and contribute
towards the productivity of the industry. 
The testing procedure is carried out keeping in mind the following parameters:
  • Cold water temperature
  • Hot water temperature
  • Circulating water flow rate
  • Fan power
  • Make up and blow down temperature
  • Circulating water flow rate
  • Wet bulb rate
Major benefit of these FRP towers is that they are resistant towards corrosion.
These systems require minimum maintenance.

How to choose the best system?

It is essential to select a good system that contributes towards the productivity of any company.
Consider the following points while choosing the perfect solutions.
How easy is the system to install and maintain?
What is the cost of installation of the system?
Is it possible to install the filtration systems without shutting down the cooling tower?
What part of the system requires maximum maintenance?
What kind of debris is most problematic?
Find the answers to these questions before you proceed
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