Filler

Our company has been engaged in large-scale cooling tower construction and equipment installation for nearly 30 years and has undertaken the installation of more than 2,000 large-scale industrial cooling towers.

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FILLER

Fillers are critical heat exchange components in cooling towers. Their main function is to achieve more efficient heat dissipation by increasing the contact area between air and water and prolonging the contact time. The fillers in cooling towers play a core role in the cooling of hot water, allowing the circulating water in industrial systems to be reused without the need for a large amount of additional water resources. Therefore, fillers are widely used in industrial cooling, air conditioning systems and the power industry.

WORKING PRINCIPLE

In a cooling tower, hot water flows through the surface or internal channels of the filler through pipe spraying or overflow distribution devices. At the same time, air is introduced by the ventilation system of the cooling tower and directly contacts or intersects with the flowing water in countercurrent. In this process, the filler disperses the water flow into smaller water droplets or forms a thin water film through its designed surface structure, greatly increasing the surface area of the water, thereby increasing the contact area between water and air. This large-area contact enhances the heat and mass transfer process between water and air, thereby achieving the purpose of reducing the water temperature.

Specifically, the role of the filler is not only to increase the contact surface area, but also to promote turbulent mixing between air and water through the turbulent design, making the heat exchange process more thorough. This mechanism significantly improves the performance of the cooling tower and reduces the load of water temperature on the heat source system (such as boilers or air conditioning systems).

Design Features

Geometry: The shape and size of the filler directly affect its contact with water. Common filler structures include corrugated, grid, and grid types. By designing specific geometric shapes, the surface area of the filler can be effectively increased while reducing water flow resistance. This design not only helps to optimize water flow distribution, but also enhances the air disturbance effect and improves the heat exchange rate.

Surface characteristics: The surface characteristics of the filler will affect the distribution of water flow on its surface. A rougher surface is conducive to the dispersion of water, thereby forming a more uniform water film or fine water droplets, increasing the contact time and area between air and water. Surface treatment technology can also adjust the flow characteristics of water by changing the hydrophilicity or hydrophobicity of the filler, further improving the cooling efficiency.

Durability and corrosion resistance: The filler will be affected by the chemical corrosion of cooling water and the high temperature and high humidity environment during long-term use. Therefore, the material selection and surface treatment process of the filler need to have good corrosion resistance and mechanical strength to ensure its stability in high temperature and high humidity environments. In addition, the filler must also have anti-aging properties to adapt to long-term changes in the water chemistry environment.

Airflow resistance of packing: The design of packing needs to strike a balance between heat exchange efficiency and airflow resistance. Low airflow resistance can reduce fan energy consumption, while higher air turbulence helps to enhance heat exchange. Therefore, the design of packing needs to comprehensively consider the flow characteristics of air and water to achieve the best balance between airflow resistance and cooling performance.