Not surprisingly, cooling towers are also called “evaporative towers” or “evaporative cooling towers”.

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• Open-circuit cooling tower: water flows downward through a fill material, distributing itself in a thin film. Fans inside the tower draw in cold air from outside, which flows through the fill material, in contact with the “hot” water. A very small part of the water evaporates, absorbing heat from the air, while the remaining part cools and is collected in a basin for reuse. Video of open-circuit evaporative tower operation.
• Closed-circuit cooling tower: the “hot” water from the industrial process does not come into direct contact with the air, but instead circulates in a closed circuit within the tower. A secondary fluid flows in a separate circuit, adjacent to the primary circuit: this is “sprayed” onto the smooth-tube primary circuit and removes the heat of the liquid contained therein. Contact between the air, drawn by the fans, and the sprayed water causes the latter to cool in turn. Video of closed-loop evaporative tower operation.

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• No contamination of the primary circuit.
• Reduced risk of freezing by being able to insert ethylene glycol into the circuit, for example.
• A simpler system, due to type of layout and small footprint.

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Components common to open and closed cooling towers:

• tower body,
• water collection basin,
• one or more fans,
• droplet separator pack (to prevent entrainment of water droplets),
• pumping system,
• electrical control system (optional).

Given the different heat exchange system, the component assigned to this function is naturally peculiar to the two systems: heat exchange pack (in the case of the open circuit cooling tower) and heat exchange coils (for the closed circuit cooling tower, as well as the evaporative condenser).

Both common and peculiar components require periodic maintenance, therefore, designs that allow easy access to the internal parts of the machine are always preferable: deadlines are precise and can be specified by the manufacturer or cooling consultant.

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In general, the costs of an open-loop cooling tower range from a few thousand euros to hundreds of thousands.A good cooling consultant can help you select the best tower for your needs, including the support of advanced calculation and sizing software. This will optimize acquisition costs and ROI.

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• Low installation and maintenance costs.
• Very high cooling efficiency.

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There are three main types of evaporative cooling systems: open circuit cooling towers, closed circuit cooling towers, and evaporative condensers.

In open-circuit towers, the water to be cooled comes into direct contact with the ambient air, evaporating in small amounts and giving off heat. In closed-circuit towers, the water to be cooled does not come into direct contact with the air: it flows in a closed circuit inside a heat exchanger, where it gives up heat to a second circuit of water that partially evaporates. The operating principle of the evaporative condenser is the same as that of a closed-loop cooling tower. As the only structural difference, the process fluid to be cooled is a gas (often ammonia) instead of water.

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During the cold period of the day and/or year, cold outside air is drawn in by fans and comes into contact with a finned coil in which the process fluid (water or gas) is present: in this way, the air itself absorbs heat. In contrast, during the hot period of the day and/or year, a different operation is set up thanks to the electronic control system: in fact, the outside air is pre-cooled by passing through a water-impregnated adiabatic pack. From this point, operations are the same as for a simple dry cooler. However, the water resource used is very small.

Video of operation of an adiabatic cooler or condenser.

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• require the use of water (but in different amounts);
• can be used to cool industrial processes and civil air conditioning systems;
• have a low environmental impact due to a number of technical specifications and are excellent systems for recirculating valuable resources in industrial settings.

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