Cooling towers are common in many areas of the United States. You’ve likely seen one on a road trip or facility tour, or if you’re in the manufacturing or power production industries, you’ve probably worked in a building that used a cooling tower system.
But do you really know what cooling towers are, how they work, and why they’re used? If the answer is no, this guide will help you learn more about cooling tower systems and answer some of the most commonly asked questions.
A. What Cooling Tower Systems Do
A cooling tower system uses water evaporation or airflow to remove excess heat from industrial equipment and HVAC systems. Most commonly, cooling towers are used at facilities that need water circulation to reject heat from the building or equipment and machinery.
These facilities can include:
- Large corporate buildings
- Schools and universities
- Hospitals
- Manufacturing facilities
- Power production plants
- Petrochemical and chemical plants
- Thermal power stations
- Oil refineries
- Food processing plants
- Metal processing plants
- Rubber and glass manufacturing plants
Cooling tower systems remove this heat by spraying water down through the tower, transferring the heat to the inside of the building as air comes in from the sides and passes through the falling water. This leads to efficient heat exchange and water evaporation, which escapes via the top of the tower in a cloud-like mist.
The cooled water that falls to the bottom of the tower is pumped back into the plant or facility to be reused for various industrial purposes, including ventilation and air conditioning. Generally, cooling tower systems are considered to be one of the most cost-effective and energy-efficient cooling solutions in North America.
As a result, cooling tower systems are critical to thousands of commercial, industrial, healthcare, hospitality, and residential facilities. As of 2020, there are more than 2 million cooling towers operating in the United States. That means there are actually more cooling towers than there are elevators!
B. How Cooling Tower Systems Are Installed
Cooling tower systems are large, ranging from 130 to 660 feet tall and 260 to 330 feet long. Their sizes tend to depend on their location, use, and purpose for the facility.
Modern cooling towers tend to be smaller and more efficient than some of the older models, but it’s best to speak with a cooling tower system professional to understand which size and design best fits a specific commercial or industrial space.
When it comes time to install the cooling tower, the elements are installed in this order:
- Main components (tower itself)
- Water distribution device
- Ventilation equipment
- Drift eliminator
Of course, additional components can be added or customized depending on the facility’s specific needs. Another crucial element to consider is the piping system. Water will need to be properly delivered to the cooling tower, and the efficiency of the piping system can dramatically impact the system’s functionality and safety.
If you have questions about removing old cooling towers or installing new ones, our team is happy to help.
C. The Different Types of Cooling Towers
Although most cooling towers can look similar to the untrained eye, there are different types for different industrial operations. These various towers use different techniques to eliminate excess warmth in water and disperse it to the surrounding biosphere.
At Pinnacle CTS, we primarily work with and see facilities choose four different types of cooling tower systems.
(1) Natural Draft Cooling Tower
In this kind of cooling tower, the air is naturally (or “passively”) circulated through the system. The tower combines the upward motion of the warm air with a steep chimney to organically pull air through the tower, usually through a counter or crossflow transport design.
(2) Crossflow Cooling Tower
Crossflow towers force air to flow horizontally rather than vertically using a splash fill. This allows in-flowing air to move over the stream of water from the upper reservoirs. As a result, these towers are somewhat easier to maintain than others, but they are also more vulnerable to frost and therefore less common in Northern areas of the United States.
(3) Mechanical Draft Cooling Tower
Mechanical draft cooling towers are similar to natural draft towers, but instead of organically moving they air, they use fans and other mechanical components. This makes them highly efficient and popular in large buildings with big cooling needs. Usually, they are located outside of the building.
(4) Counterflow Cooling Tower
Lastly, there are counterflow towers, which push air upward. The in-flowing air travels vertically over the splash fill as the water streams into the tower. These towers are typically small, compact, and extremely efficient – especially for smaller building systems. However, they do require more energy to push the air upward against downwards flowing water, which can increase energy consumption and costs.
As we mentioned before, the size and kind of cooling tower system needed for each facility depends on a range of factors. If you’re considering implementing a new cooling tower, it’s best to speak with a CTS expert to understand which type suits your needs.
D. The Future of Cooling Tower Systems
Cooling towers are a popular topic of conversation in many industries, especially power plant facilities and manufacturing plants. There’s a growing need for more energy-efficient cooling methods, and this has encouraged many companies to re-evaluate their current cooling setups.
According to Fortune Business Insights, the cooling tower market is projected to grow from $3.82 billion in 2020 to $5.03 billion by 2028. Not only are cooling tower systems becoming increasingly energy-efficient, but facilities are also finding new ways to improve their efficiency and mitigate deterioration and risks.
Furthermore, government initiatives in the United States and in other countries are pushing big industries to find more sustainable, environmentally friendly ways to cool water. If you’re looking for large HVAC or industrial cooling solutions, now might be a good time to do some more digging on cooling tower installation services and upgrades.
E. Looking for More Information on Water Cooling Towers?
This brief guide has hopefully given you a basic understanding of cooling tower systems, but we understand there’s probably a great deal more to learn about efficient cooling solutions. Fortunately, Pinnacle Cooling Tower Service is here to help.
Our mechanical contracting company is based in the Greater Tri-State area and specializes in cleaning, maintaining, repairing, and installing all makes and models of cooling towers. It doesn’t matter if you’ve been working with cooling tower systems for years or if you’re just learning about them – we’re happy to answer questions and service your system.
Contact us
Pinnacle CTS’s factory-trained mechanics and technicians are on standby. Give us a call to learn about our complimentary inspections, walk-throughs, and consultations. You can reach us online or give us a call at 732-570-9392.
