Intelligent addition to Cooling Towers resulting in huge power savings- PVC fills

PVC fill in cooling tower is perforated material has small corrugations which results in some tensions on the surface and this aids in containing the static air. This static air is responsible for keeping the water flowing from top to bottom of cooling tower for a longer period, which implies that water is cooled more. Since the cooling is more, this results in a more efficient tower.Another quality of PVC fill is that it is self- extinguishing which reduces the risk of spread in case of fire. This is a major risk for towers in an industrial set up with multiple machineries, especially in hot temperatures like in Delhi. 

As cooling tower manufacturers and design teams try to increase effectiveness of towers by playing with structure and material, the concept of fills come in. Fills are nothing but medium added in the tower which increases the contact surface and time between air and water which makes the evaporative process more effective. Let us understand why this happens- basic mechanism in a cooling tower is the heat exchange between falling water and air passing through it and this exchange is affected by 3 main factors- surface area, amount of time this interaction remains and turbulence or perforation in running water which defines how well they get mixed. 

Different materials can be used for fill by the manufacturer depending on requirement of the client as different materials offer different propositions and selection should be made considering factors like amount of heat, quality of water, horse power etc. Different clients have different needs depending on the purpose like some need to address high corrosion, high UV exposure, water clogging due to dirty water, risk of fire spread, high airborne contamination, bacteria, expensive installation due to high labor costs etc. Thus there are different materials used for fill like stainless steel, PVC etc. PVC fills are most popular given their advantages like lightweight, easy to install, good heat transfer properties etc

PVC Fills in towers need replacement and maintenance too as over the time due to usage; it leads to clogging with dirty water, risk of structure coming down due to weather- high humidity or heat etc. It is advisable to replace the fill at appropriate time as thermal performance of the tower is highly affected also making it efficient reducing the cost of operation. This reduced operating cost can be measured by reduction in fan power consumption in definite terms.

Thus PVC fills are an amazing accessory to add to the effectiveness of cooling towers without going overboard with expenses and the savings are quite attractive as a result of improved efficiency of the towers. This is shown by much lower power requirement for pumping.