The cooling tower fills are the medium that is used to increase the surface area for maximum heat exchange and high thermal performance. Fills are materials made with plastic or PVC, utilized to fill the space inside the cooling towers.
The fill packs are an integral component of the cooling towers to maximize the interaction of water and air and to ensure the high efficiency of the cooling tower.
The main function of the fills is to create the maximum surface area for water to spread. As the hot industrial water is falls on the fill material in the form of tiny droplets, it ensures the optimal interaction between warm water and the air. The larger the surface are available for the heat transfer, the greater the evaporation rates take place.
Cooling tower performance and working efficiency depend on multiple factors, and the fill media is one of the most critical factors. Cooling tower fill material, type, quality, and size determine the cooling tower’s efficiency and capability. Choosing the right type is vital for making sure of its ideal thermal performance. There are two main types of cooling tower fill media: splash fill and film fill media.
Splash fill media has horizontal slats and bar layers. Hot water hit these horizontal bars and spread into small droplets. The more tiny drops form, the more air and water contact increases, enhancing heat transfer rates. Initially, the splash fill was made of wood, but now, modern designs have been created with PVC.
It is best for handling poor quality and dirty water. Due to its open design, cleaning and maintaining it is easier than film media. They can tolerate debris and are less prone to clogging due to their unique design. They are less efficient than the film fill because of the smaller evaporation area.
Splash fills require large physical space to accommodate the splash slats and requires more power and structural support than film fill. These splash fills can be the best choice for the mining industry.
The film fill media of the cooling water comprises closely packed lean sheets of PVC with a folded, flat, and textured surface. Industrial hot water forms a narrow or thin film on the PVC sheets and makes a larger surface area for maximum heat transfer.
These fills allow the heat to evaporate faster, boosting the water cooling process. It is best for clean and pure water as any kind of impurity, debris, or rust particles build up in the film media and decrease its overall performance.
They are more efficient at heat transfer, exceed standards set than splash fills and require more maintenance and cleaning as debris easily clogs into the PVC sheets.
Both film fill and splash fill are the best for the evaporative cooling process of the cooling towers, but somehow, film fill is more efficient than splash fill in terms of heat transfer rate and performance rate. However, fil media require more maintenance as there is a high risk of wear and tear due to high temperature.
Here are some key factors you should focus on while choosing the fills for your cooling tower system.
At ICS we offer cooling tower fill media for counterflow and crossflow towers shipping from the USA, Asia, and Europe. The tower fill we offer can be used in Brentwood towers, CE Shepard towers, and others as well as fill replacement.
Have questions on the right type of Fill media for your cooling tower?
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