Design considerations

Cooling tower types and sizes: Different types (such as cross-flow and counter-flow) and sizes of cooling towers have different requirements for packing. For instance, cross-flow cooling towers typically require the packing to have a large horizontal ventilation area to facilitate the lateral flow of air and water. Counter-flow cooling towers require that the packing can ensure that water and air fully contact in the vertical direction.

Cooling water volume and water quality: The cooling water volume determines the load-bearing capacity of the packing and the water passage area. The water quality affects the selection of packing material. If the water contains corrosive substances or impurities, packing materials with strong corrosion resistance and low clogging rate should be chosen.

Air flow and resistance requirements: According to the designed ventilation volume of the cooling tower, select the appropriate shape and structure of the packing to ensure that while providing sufficient contact area between air and water, the air flow resistance is minimized and the energy consumption of the fan is reduced.

Temperature and humidity conditions: If the ambient temperature of the cooling tower is high or the humidity is large, the heat dissipation performance and anti-scaling performance of the packing need to be considered to ensure that good cooling effects can still be maintained under extreme conditions.

Selection of packing material

PVC (polyvinyl chloride) : It has excellent corrosion resistance, water resistance and relatively low cost. Its molding process is simple and it can be made into fillers of various shapes. However, its heat resistance is limited and problems such as deformation may occur in high-temperature environments.

PP (polypropylene) : It has better heat resistance than PVC, higher mechanical strength, good chemical stability and is not prone to aging. It is suitable for cooling towers with high temperature requirements, but the price is relatively high.

FRP: It features high strength, corrosion resistance, aging resistance and excellent insulation performance. It can be designed into various complex shapes and adapt to harsh working environments. However, its production cost is relatively high and its weight is relatively large.

Packing shape and structure

Droplet packing: Composed of a series of droplet elements, water forms water droplets on the surface of the packing, and air flows between the water droplets. The heat exchange between air and water is achieved through the dispersion and collision of the water droplets. This kind of packing material is suitable for occasions with poor water quality and prone to scaling because it is not easy to clog and is convenient to clean.

Thin-film packing: It is usually composed of thin plates or thin sheets. Water forms a thin water film on the surface of the packing, and air and water film fully contact for heat exchange. The gas-water contact area of the thin-film packing is large and the cooling efficiency is high, but it has high requirements for water quality and is prone to clogging.

Composite packing: By combining the advantages of droplet and film packing, different structural forms are adopted at different parts of the packing, which can not only improve the cooling efficiency but also enhance the anti-clogging capacity.

Customized process

Demand communication: Have detailed communication with the cooling tower user or design unit to understand their specific requirements for the cooling tower packing, including performance parameters, usage environment, installation conditions, etc.

Design scheme: Based on the user's requirements, design a packing scheme that meets the requirements, including material selection, shape and structure design, size and specification determination, etc., and optimize the design scheme through computer simulation or experimental verification and other methods.

Sample production: Produce samples based on the design plan for users to conduct tests and inspections. The samples should simulate the actual usage conditions as much as possible to ensure that their performance meets the requirements.

Production and manufacturing: After the samples pass the acceptance inspection, large-scale production is carried out in accordance with the design plan and quality standards. During the production process, the quality of raw materials, processing techniques and product quality must be strictly controlled to ensure that each batch of fillers can meet the customized requirements.

Installation and commissioning: Provide professional installation guidance or on-site installation services to ensure that the packing is correctly installed in the cooling tower. After installation is completed, conduct commissioning and operation to check whether the performance of the packing meets the design requirements. If any problems are found, make timely adjustments and improvements.