What are the different types of packing in cooling tower?

Cooling Tower Packing - All You Need to Know

Cooling Tower Packing - Maintaining High Performance in Your Cooling Tower

When it comes to heat transfer and, more specifically, cooling water, the most efficient method is through evaporative cooling. This technique dates back thousands of years to the ancient Egyptians and Persians, who used wind shafts on their roofs to catch the wind and pass it over subterranean water. This cooled air was then discharged into buildings, laying the foundation for comfort cooling.

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Today, evaporative cooling uses the same principles but employs technological advancements in materials and design to improve efficiency. This article focuses on open circuit cooling towers and the critical role of cooling tower packing in heat transfer.

What is an Open Circuit Cooling Tower?

An open circuit cooling tower has no separation in the cooling loop through the process flow. The cooled water flows through the process, returns to the cooling tower heated, and is then cooled again through evaporative cooling.

In contrast, a closed circuit cooling tower has a primary and secondary circuit, separating the cooling circuit from the process loop. Water circulates over a coil within the tower, providing evaporative cooling through a fan. This can turn an open circuit tower into a closed circuit by introducing a heat exchanger, separating the process and cooling sides of the system.

What is the Purpose of Cooling Tower Packing?

Cooling tower packing, also known as a heat transfer pack or fill pack, provides a large surface area for evaporative cooling. Located beneath the water distribution layer and above the sump, it allows air to either be pushed (forced draft) or drawn (induced draft) through the packing layer, cooling the water as it passes over.

Are There Different Types of Packing?

Yes, packing comes in varied shapes and sizes, and it’s crucial to know when and where to use each type, particularly when it comes to replacement. Historically, cooling tower packing was made of wood. Today, plastic materials like polyurethane (PP) or Polyvinyl Chloride (PVC) are prevalent, offering efficiency, lightweight handling, and ease of cleaning.

Plastic packing is highly resistant to erosion, has a self-supporting structure, and a long service life due to resistance to UV, chemical, and bacterial damage. They're either modular blocks or stackable PP grids. Modular blocks can be assembled through welding, gluing, or using rods or baskets. Welded sheets are strongest and most environmentally friendly, while rod-assembled packs may lose shape over time.

Cross Fluted Modular Packing

PP and PVC packing, highly resistant to erosion and UV, provide a self-supporting structure and long service life.

Vertical Offset Packing

Vertical fluted packing offers easier flow for more polluted water, reducing clogging.

What Determines Packing Type?

The process and the tower design are critical factors in deciding the type of packing to use. The water quality and temperature also influence the choice. For heavily polluted water, grid or diagonal splash packs are recommended, while larger cross fluted options are available for specific needs.

The flute size within packing ranges from 12mm to 38mm, with smaller sizes offering larger surface areas and higher potential heat rejection. In vertical fills, the flutes are arranged vertically for easier flow of polluted water.

For temperatures exceeding 80°C, specialized high-temperature packs should be used to prevent melting.

Understanding the cooling tower's duty is vital. If replacing the packing, ensure the new pack meets or exceeds the original duty. Contrary to popular belief, using a generic pack instead of OEM doesn't necessarily reduce performance, as long as it matches the required specifications.

Anti-Legionella Packing

Despite robust water treatment, areas in the packing may remain in a wet/dry state, posing a risk for bacteria such as Legionella. Anti-Legionella packing, impregnated with a non-leaching biocide, offers extra protection. This does not replace water treatment but provides additional safety in hard-to-reach areas.

Maintenance, Cleaning, and Changing Out Packing

Maintaining the cooling tower packing is pivotal for the tower’s performance. Regular inspection and cleaning are essential to prevent fouling and harmful bacteria growth. Modular packing, which is easier to remove and clean, enhances maintenance.

Over time, packing will need replacement due to fouling, brittleness from UV exposure, or damage during removal. When replacing, ensure the new packing is suitable and may consider more efficient options if required.

Updating packing also allows installing a permanent safe-clean platform, adding safety and support while extending the pack’s lifespan.

Conclusion

The heat transfer surface, or cooling tower packing, is crucial for an open circuit cooling tower’s performance. Choosing the right packing ensures the tower meets its design duty. Water quality, temperature, and tower design dictate the packing choice. Anti-Legionella packing offers extra protection but doesn’t replace water treatment. Seek specialist advice to ensure replacement packing provides the necessary heat rejection and system performance.

For more information, send me a message at richard.crunden@vistechcooling.co.uk or call our technical sales team on 01403 892622.

What is cooling towers pack? Introducing ...

One of the consumables in cooling towers is packing, which is crucial for system efficiency and performance. Packing increases the contact time and surface area between water and air, enhancing heat transfer. Various models exist, and factors such as replacement time, type, quantity, and capacity must be considered. Here, we introduce different types of cooling tower packing, examples, and their uses and benefits.

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Various Packaging Materials for Cooling Towers

There are two main types of cooling tower packing: splash and film. Splash packings increase the water and air contact area by breaking the water flow into smaller droplets. While they have less sediment, their energy exchange level is lower. Made of welded plastic, splash packings are easier to descale than film packings.

Film packing forms a thin water layer on its surface, enhancing contact time and area between air and water. Film packings, made in blocks with special adhesives, offer a higher heat transfer rate.

The Significance of Using Packing in the Cooling Tower

The packing is the most crucial internal component, responsible for creating a useful heat exchange surface. Its importance becomes evident when the system gets blocked or sedimented. Sediment layers reduce heat exchange efficiency, increasing the temperature of the outgoing cold water.

Typical Packing Methods for Cooling Towers

Cooling tower packing comes in various models, with common examples described below.

Cascade or Film-Based Packing

Cascade packing passes water as a thin layer over its surface, contacting air. Known as honeycombs due to their hexagonal shape, they are used in most circular and cubic cooling towers. Made from PVC or PP, cascade packings are classified by pitch or distance between diagonal sheets. Reducing pitch increases heat transfer but also sedimentation and clogging.

PVC is preferred over PP due to cost-effectiveness. Steps 19 and 14 are commonly used, while step 12 has limited use. Steps 23 to 30 are used in sewage treatment for beneficial bacteria growth. Advantages of PP cascade packing include:

• Higher temperature resistance than PVC
• Acid washability every cycle
• Thermal welding instead of glue
• Longer lifespan with less maintenance

Packing Net Splash

Net Splash packing reduces water droplet size, enhancing the surface area for heat exchange. Made of PP, it’s easy to descale and resists fouling. It can withstand temperatures of 90-95°C. Benefits include:

• Acid-washing capability and ease of descaling
• Lower fouling rates
• High temperature resistance
• Simple installation
• Lightweight and easy to transport

Random Splash Packing

Random splash or glass packing is placed haphazardly inside the tower, allowing water to fall in various directions. Used in crossflow and counterflow towers, it consists of small cylinders, offering a heat exchange level of 110-170 m² per cubic meter. Benefits include:

• Acid-washing capability and ease of descaling
• Less fouling than film models
• Easy replacement and assembly
• High boiling water resistance
• Durability without glue or welding

Other popular packings include comb and splash-grade packing, splash tube, roll, and turbo impact packaging. You can also read the article LOW CONSUMPTION AIR CONDITIONER AND DUCTED SPLIT for more information.

Final Thoughts

You can find all types of cooling tower packing and hundreds of other products from the specialized collection at Damatajhiz, the leading authority in building facilities equipment and air conditioning devices since 2004. The collection guarantees product originality, valid warranties, and fair pricing. For more information on selection and contrast of brands, call +98 21 88822550 to speak with the specialists at DamaTajhiz Engineering and Production Company.

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