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Cooling tower maintenance guide

Should I Repair Or Replace A Cooling Tower

Should I Repair Or Replace A Cooling Tower Cooling Tower Maintenance 

 

If you’re the owner of a commercial or industrial facility, then you know how important it is to have a reliable cooling tower. When your cooling tower isn’t working properly, it can start to seriously disrupt your business. That’s why it’s important to know when to repair and when to replace your cooling tower. In this blog post, we will discuss the pros and cons of repairing and replacing cooling towers, and also give you some top tips on how to make the best decision for your business. (more…)

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What is a Cooling Tower?

A cooling tower is a heat exchanger which, through evaporation, removes heat from the water and that rejected heat is transferred to the atmosphere. The cooling process occurs when the hot water contacts the air drawn through the cooling tower, this reduces the temperature of the hot water.  To improve upon the efficiency of the cooling process, the effective surface area of the water running through the cooling tower is often increased by spraying, splashing or filming of the water to expose more of the water surface area to the air. Evaporative cooling is commonly seen when one steps out of the shower, the water drops still on your body evaporate quickly, leaving one with a cooling sensation.  When a person sweats on a hot summer day, it is to help the body cool down. Sweat glands release sweat onto the skin, which then evaporates and helps reduce the body’s internal temperature.

How Do Cooling Towers Work?

Cooling towers hot water intakes spray hot water, usually pumped through FRP or PVC pipe headers, over PVC fill media. The fill acts as a heat transfer enhancer by providing the maximum amount of water surface area to transfer heat. The water and the air passing through come together, creating evaporative cooling. There is a small amount of water loss through evaporation, which is the result of cooling down the water. The remaining water falls into a water basin to be reused or pumped back into the cooling system. The cooling towers ICS builds are custom heat exchangers to meet industrial customer needs.

Where Are Cooling Towers Used?

Cooling towers are often used in commercial and industrial applications, but in this section, we will focus on industrial applications.

Power plants like biomass, gas – fired, nuclear, and geothermal power all use industrial cooling towers to cool-down processes. Additionally, petrochemicals, oil refineries, pulp and paper plants also use cooling towers to cool process water.

What Are The Different Types of Cooling Towers?

Natural Drafts or Atmospheric Cooling Towers: This type of cooling tower does not require mechanical components to operate, instead, the hot water is sprayed and the airflow through the tower is produced by the density difference between the less dense air inside the cooling tower stack and the more dense air outside the tower.
The natural draft cooling tower can be designed and erected as counterflow or crossflow as well.

Mechanical Draft: Mechanical draft cooling towers are categorized into an induced or forced draft type. These types of towers are usually driven by motors coupled to gear reducers connected to axial fans. It is common to see the cooling towers with a single fan but there are cases where the need of two fans per cell is required to meet the airflow volume.

Induced Draft: These types of cooling towers have axial fans on top of the cell. The fans move the air by suction instead of forcing (pushing) the airflow through the cooling tower. These types of cooling towers have air discharge velocity higher than the entrance velocity. Because of the high discharge velocity, the induced draft cooling towers are less probable to experience recirculation.

Forced Draft: These types are characterized by high airspeed at the air inlet (entrance) and low exit velocities. This makes them susceptible to recirculation and therefore are considered less efficient. Additionally, due to the location of the fans, these types are subject to developing severe icing during the winter months.

Induced and forced draft cooling towers can be built in counterflow or crossflow configurations.

Counterflow Cooling Towers: Air moves vertically upward, entering the cooling tower through the air inlets, then passing through the fill and counter to the down spray of the hot water. Due to the enclosed nature of these types of cooling towers, water is not exposed to the environment; thereby retarding the growth of algae.

Crossflow Cooling Towers: On this type of cooling towers, air moves through the fill positioned horizontally across the downward fall of water. The hot water is poured into hot water basins located at the top of the fill and it is distributed by gravity through nozzles on the floor of the hot water basins.

 

Whether you need to repair, upgrade or rebuild your tower, we customize solutions to restore your tower to its optimal condition and operational performance. Our innovative designs will increase tower efficiency, boost profitability, and ensure safety and longevity. Contact us today to request a quote!

 

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The Environmental Advantage of Cooling Towers vs Once-Through Cooling Systems

Did you know that before industrial cooling towers existed, there was a more archaic system called once-through cooling (OTC)? The old system, while functional, wreaked much more havoc on the environment, paving the way for innovative solutions to take their place.
Unfortunately, even though new factories and plants aren’t built with OTC systems, there is still a large percentage of older installations (particularly along the east coast) that haven’t been upgraded. To understand how important industrial cooling towers are, it’s necessary to understand why they were so needed in the first place. In this post, we’ll explore some of the reasons why cooling towers are a far better solution than OTC systems.

How it Works

Industrial cooling towers and OTC mechanisms both serve the same purpose — they’re both water cooling systems that are utilized in factories and plants. The functionality of a water cooling system is relatively simple; machines get hot, and water is used to cool them down.
In a once-through system, the factory withdraws a large amount of water from a local water source, runs it through their system, and then dumps it all out back into where it came from. Meanwhile, a system that uses cooling towers recycles the water, cooling it down so it can be reused for its original purposes. Once-through is a “one and done” system, while recirculating systems operate in a way that’s more economical and efficient.

Why OTC Is Harmful to the Environment

Tainted Water Kills the Wildlife

In an OTC system, a large amount of water is sucked into the factory or plant, and circulated through its entire system, cooling the various machines and technology that run too hot. Once the water has done its job, it’s dumped back into the source.
The water that returns isn’t the same water that went in — technically it is, but the returning water is usually scathing hot, and tainted with residue from the metals that make up the factory. The temperature change and chemicals kill a fair share of local wildlife.
The Cooling Tower Advantage: With cooling towers, water isn’t returned to the source at all. Instead, it’s withdrawn into the factory and recirculated. Evaporating techniques remove the heat out of it, so it can go multiple rounds. Tainted water can’t kill fish when it never gets back into the source to begin with.

Excessive Water Consumption

One major problem with OTC systems is that they withdraw massive amounts of water for every single cooling cycle. Even though the water is eventually returned, it’s tainted, and some of it is lost every time. In an area with a limited water supply, an OTC plant can suck the area dry over time.
This also spells disaster for local water life; depleting habitats predictably wreak havoc on animal populations, and even land animals can start to suffer when their supply gets too low.

The Cooling Tower Advantage: Industrial Cooling Towers solve this problem because they’re much more generous in the way they withdraw water. Essentially, once it’s pulled in enough water to cool its systems, the water is recirculated and cooled by the towers. The heat is evaporated out of the supply, so a small amount of water is lost, but most of it remains, ready for the next cycle.
The next time the system withdraws water, it will only pull in the amount that was lost, which is negligible compared to an OTC plant.
It might seem like this would lead to long-term water loss; the factory never returns water and keeps drawing more, so it would deplete in the long-term, right? While the logic is sound, in reality, most water sources are able to replenish at an equal rate through natural means, such as rivers or rainfall. OTC systems pull out quantities that are too big too often, preventing the source from being able to keep the pace when it replenishes itself.

Industrial Cooling Towers – An Elegant Solution

Now more than ever, it’s important for us to be good stewards over the environment that we’re a part of, and this couldn’t be more true than with factory and plant owners, who have the potential to inflict enormous damage on surrounding ecosystems if they’re not careful.
Fortunately, industrial cooling towers have solved many of the problems that OTC plants cause. We’re moving in a positive direction, and at Industrial Cooling Solutions, we’re happy to supply companies with high quality industrial cooling towers that are not only more efficient than the old system, but more environmentally conscious as well. Do you have a need for cooling solutions? Contact us today for a free quote!

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Why FRP is Superior to Wood, Aluminum, Steel, and Concrete

While the type of materials that make up industrial cooling towers probably isn’t something that you find yourself pondering in your spare time, it’s nonetheless something that you’ll have to be aware of when it comes to getting a new cooling tower. Whether you’re installing a new system entirely or replacing some of your older industrial cooling towers, investing in the right material will go a long way.
At Industrial Cooling Solutions, it’s no secret that we believe FRP (fiberglass reinforced polymer) is the best choice for your cooling towers. Wood, steel, concrete, and aluminum are all materials that cooling towers can be made with, but we believe that FRP is far and away the best choice, for several reasons.

Corrosion Resistance

Corrosion, in the context of cooling towers, is the gradual decay or deterioration of its material due to the surrounding environment. Since industrial cooling towers spend 100 percent of their time exposed to the elements, it’s important to consider a material that will hold up well.

Wood: Wood can warp, rot, or decay from exposure to water and other elements. It is also susceptible to insect damage (such as termites). Due to these weaknesses, it’s customary to apply preservative coatings over the tower, which, unfortunately, aren’t very environmentally friendly.

Steel and Aluminum: Both of these are metals, making them susceptible to oxidation and corrosion via rust. These require painting, galvanizing, or anodizing.

Concrete: Concrete doesn’t naturally decay very easily, but it is porous, making it an easy target for dirt and bioforms to accumulate, which requires copious amounts of cleaning and maintenance in the future.

FRP: FRP is completely resistant to water and moisture, and has strong resistance to a wide variety of chemicals. Being a synthetic material, it holds its own against the elements much more efficiently than the other materials do.



Strength and Flexibility

Strength and flexibility are important when it comes to cooling towers, especially when it regards their longevity. They need to be able to take an appropriate amount of stress, and weather attacks from mother nature, such as hurricanes or earthquakes.

Wood: Wood is weaker than FRP in just about every measurable aspect. FRP is stronger, and has higher flexural strength. Overall, wood doesn’t have a strong argument here.

Steel: Steel is, unsurprisingly, extremely heavy, weighing 75 percent more than FRP. It carries so much weight that heavy listing equipment is often needed just to be able to move it around. Furthermore, steel is flexible under heavy pressure, and it doesn’t like to bend back to its original shape once it has been transformed.

Aluminum: Aluminum is appealing due to its famously light weight. But guess what? FRP is still lighter, clocking in at about 75 percent of aluminum’s weight. While aluminum is technically stronger than FRP in sheer numbers, FRP is overall stronger when you consider it on a pound-for-pound basis.

Concrete: The yield strength of concrete is absurdly high, but concrete also suffers from having no flexibility, making it rather brittle in the face of damage. Earthquakes are a dangerous threat for concrete towers; even the smallest one can cause a concrete tower to break into pieces.

FRP: FRP is highly elastic but engineered in such a way to where it doesn’t permanently deform. It’s also extremely lightweight, making it the easiest material to handle and install. When it comes to weight to strength ratio, it’s the strongest of them all.

Electrical Conductivity

Although most cooling towers are engineered to withstand the effects of errant electricity, it’s nonetheless important to keep them protected from it to the best of your ability. Cooling towers are closely tied with your water flow, and given the conductivity of water, it’s generally good advice to just protect your towers from lightning as much as possible.

Wood, Steel, and Aluminum: All three of these materials are conductive, particularly the latter two, though those have potential for grounding. Wood is most conductive when it’s wet, but in the case of a lightning strike, this is highly likely due to the presence of rain.

Concrete: Concrete isn’t conductive, putting it on equal ground with FRP in this category, but it is still more susceptible to environmental damages as a whole.

FRP: FRP is completely non-conductive, and has high dielectric capability. There’s not much more to say here — it doesn’t conduct electricity at all, so that’s a problem you’ll never have to worry yourself about.



Cost

An important factor for any business owner is cost — of course superior options always exist, but are they worth the extra price? Fortunately, an FRP industrial cooling tower is quite affordable.

Wood: Wood has a lower initial cost than FRP, but almost always requires long-term maintenance and a shorter product life. Wood gradually corrodes and is susceptible to insect damage. While the upfront cost is cheaper, you save more in the long-run with FRP by avoiding the repeat costs that wood incurs.

Concrete: Concrete is much costlier in the long-term, especially since they’re particularly vulnerable to cracking. Installation costs more with concrete industrial towers, due to the process of engineering, casting, and drying that’s tailor made for your business. Concrete takes a long time to set, which also lengthens the installation process significantly.

Steel: Steel has a lower cost for the initial materials, but the installation is significantly more expensive, and like the other materials, is subject to much more long-term maintenance costs than FRP.

Aluminum: Aluminum is the one material that slightly edges out FRP in the cost department. FRP tooling costs and price per lineal foot are marginally higher.

FRP: FRP edges out all of the other materials save for aluminum in cost. And, despite aluminum’s cheaper price tag, it could be argued that FRP is still a better deal due to the various other advantages that it has.

Conclusion

Overall, when you look at the big picture, FRP edges out all of the other materials when it comes to high-quality industrial cooling towers. It lasts longer, it’s stronger and yet more elastic, it’s cheaper, safer, and it’s easier to maintain and install. It’s hard to argue that FRP isn’t the best solution by far, and that’s why, at Industrial Cooling Solutions, we offer FRP in spades. Whether you’re repairing an FRP tower and need parts, installing a new tower entirely, or replacing an older obsolete one, you can’t really go wrong with FRP industrial cooling towers. Having a functioning cooling system in your plant and factory is supremely important, and we want to make sure everybody has a functional and reliable solution. We will happily provide you with industrial cooling tower solutions, or provide you with the parts you need to make repairs on our own. Whatever your need is, we can cover it, so if you’re in the need for Industrial Cooling Solutions, contact us today for a free quote!

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How To Inspect A Cooling Tower – Part 2

Hello, and welcome back to our blog here at Industrial Cooling Solutions. ICS is located in Lakewood, Colorado with offices around the world. Our highest priority is to provide our clients with innovative cooling solutions that are both environmentally sustainable and feasible for any business.

If you recall from last time, we talked about how to inspect a cooling tower. If you haven’t yet read our first blog on this subject, you can read it here. This time, we’re going to cover the rest of the procedure. If you’ve never done a cooling tower inspection before, you should know that there is no set-in-stone way of going about it. However, there are some general ideas that you should keep in mind as you do it. Once you’ve done your first inspection, you can develop a procedure that will work best for your company and the type of cooling tower you have.

Louvers

A louver is a component that allows air to pass through it while preventing water, dirt, and other debris from entering. If your Louver is removable, you should check for effectiveness and structural integrity.

Cold and Hot Water Basins

One of the most challenging aspects of maintaining a cooling tower is keeping the cold water basin clean and free of other debris like biological growth. Airborne debris may pass through the louvers and sit in the basin, exposed to sunlight. Once this happens, water treatment chemicals may be your only option to combat the biological growth. Take note of this as you perform your inspections. Hot water basins in crossflow towers may corrode and result in inadequate spray distribution over the fill material. You should check the basin for holes and a sagging fill caused by excessive water force on a specific area. The nozzles on the basin can also become clogged due to rusting sheet metal or piping. You may be able to replace your hot water basin with galvanized or stainless steel.

Mechanical Equipment

Like with all components, you’ll want to check for structural integrity, unusual noises, and vibration. If you’re able to, check the RPMs, airflow, and amperage. Any leaks should be noted and documented.

Water Treatment

Your water treatment methods and results should be well documented. It is best practice to manage these processes regularly and perform tests to ensure efficiency and safety.

Other inspections

If you can think of any other inspections that need to be done on your cooling tower, don’t hesitate to add them to your list. Depending on your system, you may need to check hardware, circulating water percentage, fire protection systems and more. Every company will have different needs so you should continue to refine your inspections as you see fit.

Contact Industrial Cooling Solutions

Industrial Cooling Solutions combines American-based engineering with localized engineering and field service to provide each client with world-class industrial cooling services at a competitive price. We provide solutions for Power Generation, Geothermal Power, Refining, Petrochemical, Chemical industries, and more. When you contact Industrial Cooling Solutions, we’ll work closely with you to determine what issue you’re having. We’ll help you decide whether you need cooling tower replacement components, upgrades, a complete system install, or a simple repair. No matter which services you trust us with, you’ll be guaranteed to see increased tower efficiency, improved profitability, safety, and longevity. Our dedicated staff has an immense amount of experience with applications in all industries. The quality of our products and services are unmatched by our competitors, so give us a call today or browse our site to learn more.

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How To Inspect A Cooling Tower

Depending on what type of cooling tower you have, the way you inspect it can vary. Large, multi-cell industrial cooling towers tend to be much more difficult to inspect than small packaged units, and small units tend to be much quicker. Although there is no set-in-stone way of inspecting a cooling tower, there is still a basic set of things that should be taken into consideration. Once you’ve established a foundation for your inspection, you can start to adapt it to your business’ needs.

Inspect the Site

You should start every cooling tower inspection with a general inspection of the site. Is the area free of debris and other obstructions that may affect the way the way your cooling tower performs? Is there recirculation like discharge flume returning to the inlet? These are all questions you should ask yourself as you inspect the area. Make sure to take notes as you go so you know what you’ll need to work on. Another thing you should look for is environmental factors. Are there trees in the area releasing pollen or are there leaves all over on the ground? Is your cooling unit exposed to chemicals, dirt, sand, or anything else that may be destructive? Make note of it.

Inspect the Units

It never hurts to check the manufacturer, model number, and serial number of your unit if you don’t already have this information on record. If there is no branding on your unit or your company doesn’t have any record of it, you should take measurements that will help you better understand your cooling tower. Additionally, you should be taking pictures so that you can reference individual components without having to go back to the site. These measurements will be important when you need to make repairs or replacements.

Frame

As you go into a deeper inspection of your unit, you should take a look at the overall structure of it. Does it appear to be sturdy and not have any missing or loose components? If it’s exposed to extreme weather conditions, this will be an important step.

Pipes

Both pipes that are outside of the perimeter of the cooling tower and pipes that belong to the cooling tower should be inspected. You should check for structural soundness as well as proper installation.

Fill

The fill is an integral component in your cooling tower. It’s the medium used to increase the surface area of the tower, allowing for maximized air-water contact, thus resulting in greater evaporation rates and more cooling. When you inspect your fill, check its general physical condition, look for algae growth, fouling, and other deposits, or uneven water distribution.

Drift Eliminators

Drift eliminators are important for preventing water droplets and mist from leaving the cooling tower by causing water droplets to change direction. Check for areas of excessive drift as you inspect this component.

Industrial Cooling Solutions

Whether you’re looking for cooling tower repairs, replacement, upgrades, or a brand new installation, Industrial Cooling Solutions is your dependable outlet for all your needs. Our company was founded with the mission to create value for our customers by developing and implementing innovative cooling solutions that are financially and technically feasible, all the while, being environmentally sustainable.

Headquartered in Lakewood, Colorado, we have placements in Japan, Thailand, as well as representatives located globally. Our professional staff come from various backgrounds in cooling tower, power generation, and other relevant fields. Each one of our employees is dedicated, hardworking, and committed to the success of our clients. Stay tuned to our blog to learn more about the cooling tower inspection process and contact us today.

Learn more here in part 2 of how to inspect a cooling tower.

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Counterflow Vs. Crossflow

Cooling towers are manufactured in many different configurations and sizes to match a wide range of applications across many different industries. Understanding that different configurations may have different advantages and disadvantages is important for you to be able to decide which one will be most efficient and cost-effective for your company. In this blog, we’re going to discuss the difference between a crossflow and a counterflow cooling tower.

What is a Cooling Tower?

A cooling tower’s main purpose is to remove heat from whatever it is that needs to be cooled. This is done through the process of evaporation which occurs when air and water are brought together inside of a cooling tower. A cooling tower is needed in many cases because it maximizes the surface area of the water, resulting in more evaporation. There are two configuration designs of cooling towers: counterflow and crossflow towers.

Crossflow Cooling Towers

With a crossflow tower, hot water flows downward from a distribution basin while air flows horizontally. They are filled with splash, hybrid or film type fill and can be applied when water has higher suspended particles, when plan area is tight or just per owner preference. At Industrial Cooling Solutions (ICS), we offer crossflow towers in concrete, FRP, and wood structure as well as splash fill, film fill and low fouling fill materials. ICS cooling towers are built to withstand the most demanding of situations and provide the most cost-effective solution for you.
Benefits:

  • High Performance
  • Low Maintenance
  • High tolerance for particulates, oils and contamination in the water. Well suited for Fertilizer, Steel, Food Processing or other industries which have high particulate loads or other water contaminators.
  • Low Noise
  • Optimized Power Consumption
  • Easy maintenance access inside the tower

Disadvantages:

  • Higher potential for re-circulation due to the air inlets being open to the hot water deck.
  • Water noise harder to control due to the large open inlet areas.
  • Low water loading per M2

Counterflow Cooling Towers

A counterflow mechanism is a newer and quite popular design in which water flows vertically through the fill or packing from the top while air enters the bottom of the tower and flows upwards. In a counterflow cooling tower, there is an induced draught fan that is attached to the motor. This fan pulls in air to draft it upward resulting in air that is exhausted faster than it is pulled in. In turn, you’ll see lower pressure and re-circulation.

Benefits:

  • Low Power Consumption
  • Low Fouling Film, Hybrid or Splash fills
  • Plume Abated Systems
  • Low Pumphead
  • High Performance with Minimal Maintenance
  • Optimized Footprint
  • FRP Wood or Concrete Structures

Which one should you choose?  

The type of cooling tower you choose will depend entirely on the industry and the application. What works for one company may not be effective for another. Another factor that is taken into consideration is the typical climate on your site. ICS’s cooling tower experts can assist you in selecting the correct tower configuration for your industry, site and project needs.

Contact us to learn more about which type of cooling tower is right for your company, 

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Cooling Towers In Cold Weather

Depending on where you are in the world, there’s most likely a cold season that could present a potential change in the way you operate your cooling tower. If the temperature is cold and there’s snow, there are several things you should do to keep your rooftop unit chiller operating as efficiently as possible.
When it’s cold out you may notice that your cooling tower may fail to restart after turning off or operate inefficiently. Follow these tips to ensure that your cooling tower operates efficiently even during the coldest days and nights:

Remove Biological Contaminants

Preventing bacteria growth is important for making sure your cooling tower runs as efficiently as possible. Bacteria growth, scale and lime can all contribute to making a tower run poorly, so you should use the necessary chemicals to kill them. Bacteria can also increase corrosion rate which can negatively impact the rate of heat transfer. If it’s a closed system that has no water added, you should only need to do this when the system is installed.

Remove Ice and Snow

You should regularly inspect your unit and remove ice and snow from your condenser unit, coils and fan blades. This debris acts as a barrier when it comes to heat transfer.

Apply Antifreeze

Antifreeze in a cool tower will work similar to antifreeze in a car: it will reduce the temperature at which the water freezes. Even during the coldest nights your water will flow smoothly and without a hitch.

Keep The Heat

If your water pump is running continuously, the water that enters the tower will be warmer than the water that’s currently in the tower. Since cooling towers are designed to take heat from the building to the tower and pumps produce heat, you’ll be maintaining the heat in the tower.

Contact Industrial Cooling Solutions

Industrial Cooling Solutions is an American-based cooling tower company offering its clients cooling tower replacement, repair, upgrade, and installation services. Our experienced staff is experienced with servicing cooling towers for all applications and industries and are committed to the success of each company that reaches out to us. Our refined cooling tower services are designed to improve your tower’s efficiency, boost profitability, and ensure safety and longevity every time. If you would like to learn more about ICS, read through our website or contact us today to get started. We’d be glad to hear from you.

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Steps To A More Energy Efficient Cooling Tower

 

 

We live in a world that is constantly in need of more and more energy in order to meet consumer demands or government regulations. So it’s not surprising that people are looking for a way to make industrial cooling systems more advanced and energy efficient, not only for the sake of the environment but in order to be able to satisfy everyone’s demands. Additionally, more efficiency means more money that your company will be saving.

Many industrial environments need cooling systems to custom fit their size and design, so it’s important to consider your situation in order to determine what will be most important. The electronic and chemical industries are some that may need precision control of heat and humidity in order to avoid bad chemical reactions or bacterial growth. This can damage items and lead to inefficient business practices, so it’s important to have the right cooling solutions to avoid the chance of damage. For many corporations, this can result in cooling systems running at full power all the time, eating away at the company’s budget, and harming the environment.

In this blog, we’re going to talk about how you can make your cooling towers more efficient so that you don’t have to worry about if you’re saving enough money or not. Here are several ways to save money with your industrial cooling tower.

GREEN Energy Management System (GEMS)

Cooling towers are designed to meet cooling demands on the hottest days of the year and therefore rarely need to be running at full power to maintain design cold water output. In fact, most of the time, a properly designed and maintained cooling tower is over performing at off-peak weather conditions & in evening or early morning hours. ICS’s intelligent GEMS System is designed to modulate the cooling tower energy consumption and therefore performance to keep the cold water temperatures within a predetermined temperature range. This results in substantial energy savings and reduced wear on mechanical equipment & lower noise emissions during off-peak operations.

GEMS will help you save money by optimizing the cooling tower operations and reduce fan energy. If you have any questions about how to save money and increase efficiency with your cooling tower, don’t hesitate to contact Industrial Cooling Solutions today. GEMS can help make your plant operations more energy efficient & environmentally friendly. A Win-Win solution for you and the planet.

Having the Right Filtration System

Like a standard in-home HVAC system, industrial cooling towers require a good filtration system in order to be energy efficient. Once water is evaporated in a cooling tower, dissolved solids are left behind. These solids include magnesium, calcium, silica, and more. If these aren’t removed properly or avoided with a good filtration system, they can start to take a toll on your cooling tower efficiency and even damage it. In the long run, this could result in thousands of dollars worth of damages. In addition to taking a look at your water treatment company to see if they’re providing you with an adequate water supply, you should consider an alternate filtration system like a side stream sand filter.

Consider All the Cooling Tower Options Available

You always want to choose a cooling tower that meets ASHRAE 90.1 standards. This standard provides the minimum energy-efficiency requirements for whatever building you’re trying to cool. Not only should you be complying with the regulations, but it can help you run a more efficient cooling tower if that’s ever a concern to you. If you have any questions about this process, you should contact Industrial Cooling Solutions. We offer complete evaporative cooling tower services ranging from cooling tower engineering to tower repair that is custom fit to each customer’s needs. Contact us today to learn more and start saving money for your company.

ICS specializes in providing leading edge engineering, construction, thermal upgrades, and replacement parts for your cooling towers, worldwide. There are a lot of different types of towers that could prove to be more of an asset to certain industries than others. When you choose a cooling tower or need replacement parts, it’s important to know exactly what you need. We have wood, fiberglass and concrete cooling towers in addition to counterflow and crossflow towers, so contact us today for a consultation.

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The Benefits Of FRP Fan Blades

Why are FRP Fan Blades Better?

In the world of industrial cooling towers, great pains have been taken to make sure that efficiency is increased as much as possible. While the average person may not think about cooling towers too often, without these amalgamations of metal, plastic, and concrete, most of the industries that we have come to rely on to make the goods that we use would cease to exist. Here at Industrial Cooling Solutions, Inc., we have been in the business of constructing, maintaining, and repairing cooling towers for decades. In this time, we have seen the industry change quite a bit through the introduction of new technology, better processes, and better building materials. Of all these advancements, however, FRP composite materials have been the one thing that we feel has the greatest impact on cooling towers as a whole. In today’s post, so that all of our readers understand just how important FRP has been to this industry, we are going to go over some of the benefits that this amazing material has had on the design and function of the fan blades that are used in a large amount of towers scattered across the world. Continue reading below to learn more.

Fibre-reinforced Plastics

FRP, or fibre-reinforced plastic as it is also referred to, has been a blessing to multiple industries. Developed in the early 1900s and used mostly for military applications in the early stages, this material was quickly adapted to industrial processes that required a material that not only had a great strength to weight ratio, but one that was also resistant to many of the corrosive elements that are present in the production and transportation of chemicals and other corrosive materials. While industrial cooling towers are not exactly known for a huge presence of caustic chemicals, there is still enough of a presence to necessitate a substance that could resist these elements and continue to function in harsh conditions. The component that has benefited the most from FRP materials, without a doubt, has been the fan that is present in many of the cooling towers that are used today. Below, we have listed a few reasons that FRP fan blades have become an industry standard and why more and more cooling tower manufacturers are recommending these fan blades over their aluminum counterparts.

  • Shape: When designing a cooling tower to meet a specific industrial need, two things must be taken into account. First, the designers must make sure that enough water is pumped into the system to effectively mitigate the heat that is produced by the specific industrial process. Second, they must make sure that an appropriate amount of airflow is forced through the tower in order to make sure that the water is properly cooled along the fill material. FRP fan blades are ideal for this application because they allow designers a greater degree of control over the shape of the fan blades and mold them into the best shape possible to achieve the airflow that must be achieved. Traditional aluminum blades could only be shaped to a certain degree before the structure of the blades themselves was compromised. Additionally, metal fan blades must be attached to an axis at multiple points, greatly increasing the chances that a connector will fail or the balance of the fan will be thrown off. Because FRP fan blades are molded into a single piece, there are far fewer points on the entire fan assembly that can fail. Even better, these fan blades can be shaped to the most optimal angle possible, meaning that they are able to circulate air more efficiently than an aluminum fan blade could ever hope to accomplish.
  • Resistance to Corrosion: As we stated previously, most cooling towers are not exactly teeming with caustic chemicals, however, this does not mean that corrosive elements are not present within the system. Given enough time, water is one of the most corrosive elements in the known universe. This seemingly innocent substance has shaped the surface of our planet, digging canyons and valleys out of solid rock. While aluminum is excellent at resisting the corrosive properties of water, it is still only a metal and, as we all know, metal and water don’t exactly get along. Over time, an aluminum fan blade will always succumb to the effects of water, requiring a replacement lest the fan blade break and cause damage to the internal components of the tower. FRP fan blades, on the other hand, do not suffer from this same defect. These fan blades are highly resistant to any and all corrosive elements and are able to stand the test of time in a way that is vastly superior to any other substance used in the construction of fan blades.
  • Weight: Because cooling tower fans tend to run at thousands of RPMs, it is necessary to construct fan blades out of a material that is not only strong enough to stand up to the rotational forces that are placed on it but a material that is also light enough to place unneeded stress on the motor of the fan assembly. Before the introduction of FRP materials, aluminum was the best option for fan blade design because of its excellent strength to weight ratio. FRP fan blades, however, are even better than aluminum at providing a fan blade that is both strong and light.

At Industrial Cooling Solutions, Inc., we are dedicated to providing the best cooling tower services possible and we believe, quite strongly, the FRP fan blades are the best option for nearly every application that our customers may have.

Contact us to learn more about the types of FRP fan blades that we offer.

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