July 2000

Heat Transfer

Cooling tower fill: the neglected moneymaker

New designs improve performance and reduce costs

Burger, R., The Burger Cooling Tower Company Inc.

In the 1960s, process cooling tower design abruptly changed direction.1 At that time, large industrial cooling towers were of the cross-flow configuration (Fig. 1). The most dramatic change has been the introduction of specialty engineered film fills that provide significantly higher thermal performance through increased water-to-air contact area and reduced pressure drop.   Fig. 1. Typical modern counter-flow tower utilizing highly efficient cellular film. For the cooling tower owner, this equates to reduced capital expenditures, lower operating costs and a smaller tower footprint. This high efficiency fill

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