Regular Post
Written by Brian B

Cooling Tower Cost 2021

Cooling towers generally cost around $125,000 to fully replace. A replacement will typically cost between $50,000 and $200,000 in the U.S. in 2021. A commercial cooling tower can last up 20 years.

If you are searching online for “cooling tower cost 2021“, this post will help!

Cooling Tower Costs

This article will go over the typical prices for the following products:

  • Feeder Water System
  • Blowdown System
  • Circulation Water System
  • Cooling Tower Refurbishing
  • Cooling Tower Installation

Feeder Water System

Costs can vary wildly when it comes to the feeder water system. Commercial customers can expect to pay anywhere from $50,000 to $250,000.

Blowdown System

A blowdown system needs nearly 75 percent of the water to be reused in a 100-gallon-per-minute stream. Typically, this system will cost around $300,000 total.

Circulation Water System

This side stream filtration unit can cost $50,000 for 100 GPM and a maximum of $300,000 for 1,000 GPM.

Cooling Tower Refurbishing

Cooling tower repair costs will certainly decrease when regular maintenance is performed. Regular maintenance will also increase the lifetime of the towers, hopefully heading towards a 20-year existence. Compared to a full repair, commercial companies generally pay 60 percent less for a refurbishing.

Cooling Tower Installation Cost

Whenever a cooling tower ages beyond 20 years, a rebuild is almost essential. The cost per ton of the replacement depends on the actual size of the cooling tower. Other features, such as epoxy treatment and equipment needed will affect cost, as well. Larger cooling towers will cost more and require increased maintenance attention.

Again, a complete cooling tower replacement will cost anywhere from $50,000 to $200,000.

Take a look at our cooling tower installation process here:

Cooling Tower Installation, Replacement, & Refurbishment in Arizona & Nevada

Our team offers complete cooling tower refurbishment that will save your company tens of thousands of dollars over buying and installing new cooling towers.  Cooling tower refurbishment and rebuilding adds about another 15 years of life to your equipment and helps you get your money’s worth out of your original investment in your cooling tower or property. We offer cooling tower installation, replacement, and refurbishment in Arizona and Nevada. We also sell other cooling tower parts and products.

Cooling Towers
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Regular Post
Written by Brian B

Cooling Tower Vs Chiller: What Are The Differences?

Both cooling towers and chillers are used for multiple cooling purposes, so what are the differences between the two systems? If you are searching for “cooling tower vs chiller” or “chiller vs cooling tower“, this article will compare and contrast these systems.

Cooling Tower And Chiller Differences

Within chillers, heat is removed directly from the coolant. The heat is then transferred to the surrounding air. This is an essential part of any cooling process. Cooling towers, meanwhile, remove heat from water that is discharged from a condenser. Any plant or factory that happens to choose a system that is not appropriate for the area will have trouble properly cooling their surroundings.

While chillers and cooling towers do produce similar results, the slight differences between the two systems are why they are used in different settings. Cooling towers are generally used in oil and gas refining plants, thermal power stations and power plants neighboring bodies of water. Chillers are found in plastic-industry applications, microbreweries and wineries.

Types Of Chiller

There are two main types of chillers used today.

  • Water-Cooled Chillers
  • Air-Cooled Chillers

Water-Cooled Chillers

Typically, this type of chiller is combined with a cooling tower for large-capacity applications. These applications include water-jet cutting and food processing plants. The combination of water-cooled chillers and cooling towers allows for maximum efficiency. Water-cooled chillers have been shown to produce an excess of heat at times, which is one of the only downfalls of this system.

Air-Cooled Chillers

These chillers absorb heat from water, then transfer this heat outside of the system. The heat flows back into the air surrounding the unit. As soon as the air is transferred outside, the temperature lowers drastically. Factories that do not produce a lot of heat will opt for these models frequently.

Cooling Tower Types

There are many more versions of cooling towers than chillers. Here is a list of the common models on the market:

  • Crossflow Cooling Towers
  • Forced Draft Cooling Towers
  • Induced Draft Cooling Towers
  • Factory Assembled Cooling Towers
  • Counterflow Cooling Towers

Crossflow Cooling Towers

A crossflow tower is designed to make the hot process water flow down the media fill due to gravity. This will occur while air blows horizontally, which cools the water down. The tower gets its name because of the airflow direction. Hot water basins are placed just above the fill, which allows the water to be evenly distributed.

Here is a look at how a crossflow tower operates:

Forced Draft Cooling Towers

Industrial plants will commonly choose these towers for their cooling needs. Forced draft towers are extremely powerful, yet cost-effective at the same time. In these towers, low-potential heat is removed during the production process. A counterflow of water and air results in a heat transfer. Chemical and paper industries frequently choose forced draft models.

Induced Draft Cooling Towers

A fan at the top of the tower pulls the air upward in induced draft models. This fan induces the hot and moist air out of the discharge. A powerful exiting air velocity is the end result here. Induced drafts will prevent any discharged air from flowing back into the intake point.

Factory Assembled Cooling Towers

HVAC and industrial applications that do not need a high cooling efficiency commonly use these units. Factory assembled towers can be custom made to fit your every need. Easy installation and transportation are two more benefits.

Counterflow Cooling Towers

In counterflow units, the hot process water flows downward all the way to drain onto the cold water basin. The air enters a lower section, though, which differs from crossflow versions. Air flows upward, passing through the water in the fill, with an end result of a cooling down phase. Airflow is free and not restricted in counterflow units.

Here is a look at how a counterflow tower operates:

Cooling Tower Costs

  • Cooling towers generally cost around $125,000 to fully replace. A replacement will typically cost between $50,000 and $200,000.
  • Commercial customers can expect to pay anywhere from $50,000 to $250,000 for a feeder water system. 
  • Typically, a blowdown system will cost around $300,000 total.
  • A side stream filtration unit can cost $50,000 for 100 GPM and a maximum of $300,000 for 1,000 GPM.

Cooling Tower Installation, Replacement, & Refurbishment in Arizona & Nevada

Our team offers complete cooling tower refurbishment that will save your company tens of thousands of dollars over buying and installing new cooling towers.  Cooling tower refurbishment and rebuilding adds about another 15 years of life to your equipment and helps you get your money’s worth out of your original investment in your cooling tower or property. We offer cooling tower installation, replacement, and refurbishment in Arizona and Nevada. We also sell other cooling tower parts and products.

Cooling Towers
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Cooling Tower Fill
Regular Post
Written by Brian B

Cooling Tower Fill

To accomplish a cooling tower’s goal of cooling water quickly and efficiently, the water needs to flow over as much surface area as possible. Cooling tower fill is a medium used to increase surface area that’s available for the water. If you are searching for “cooling tower fill,” this article is for you!

Here is a breakdown of two different types of fill commonly used in cooling towers:

Film Fill

Film fill comes in sheets of material, shaped into a corrugated pattern. This pattern enables the water to travel across it smoothly and quickly. To create various thickness and heights, this fill can be stacked. In other words, film fill can be customized to fit the needs of any particular cooling tower.

This type of fill is the most popular type of film used in cooling towers today. Nearly half of all cooling towers utilize film fill, according to wearelel. The only concern with film fill is its reputation for clogging. Narrow passages at the top often don’t allow the water to redistribute itself, which can lead to clogs.

Film Fill Pros & Cons

Pros:

  • Exposes greater water surface
  • Customizable

Cons:

  • Won’t let water redistribute
  • Narrow passages

Splash Fill

This type of fill works by causing the water to cascade through a large series of parallel bars. Water will redistribute at each level of these bars, unlike film fill. Splash fill will offer very little opposition to horizontal airflow, which is why it is commonly used in crossflow cooling tower models.

One advantage to this fill is that it is forgiving of insufficient water distribution, initially. General maintenance on this fill can be easier than on film fill. The wide open nature of this fill makes a visual inspection very simple. Water flow pattern and overall fill condition can be identified by professionals with ease.

Splash Fill Pros & Cons

Pros:

  • Water redistributes at multiple levels
  • Easy maintenance

Cons:

  • Interrupted flow pattern of water
  • Less available than film fill

Cooling Tower Fill Installation:

Cooling Tower Fill Removal:

Cross Flow Fill

Here are the fill materials for cross flow cooling towers available from Cooling Tower Products in Phoenix, Arizona:

  • BXF Fill Kits
  • Cross Flow Fill Packs
  • BAC Series
  • Marley Series
  • Fill Support Deck

Check out our full inventory of fill right here.

Counter Flow Fill

Here are the fill materials available for counter flow cooling towers from Cooling Tower Products:

  • BXF Fill Kits
  • Cross Flow Fill Packs
  • BAC Series
  • Marley Series
  • Fill Support Deck

Check out our full inventory of fill right here.

Whether you are looking for cooling tower fill, fill installation or removal, Cooling Tower Products can serve every need. Contact the team at Cooling Tower Products today!

Cooling Tower Installation, Replacement, & Refurbishment in Arizona & Nevada

Our team offers complete cooling tower refurbishment that will save your company tens of thousands of dollars over buying and installing new cooling towers.  Cooling tower refurbishment and rebuilding adds about another 15 years of life to your equipment and helps you get your money’s worth out of your original investment in your cooling tower or property. We offer cooling tower installation, replacement, and refurbishment in Arizona and Nevada. We also sell other cooling tower parts and products.

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Cooling Tower Types
Regular Post
Written by Brian B

Cooling Tower Types

If you are searching online for “cooling tower types,” then this post is for you! We will go over the five of the most commonly used tower types, including crossflow, counterflow, forced draft, induced draft and factory assembled devices.

Crossflow Cooling Towers

Because of its design, crossflow cooling towers force the hot process water to flow down the fill media. This is caused simply by the force of gravity. This process takes place at the same time as the air is being blown horizontally across the falling water, which cools it down significantly. The air flow and pattern of the water is where the crossflow model gets its name. Water will require only gravity for downward flow because there is no other present force going against it. Water will then be evenly distributed by the hot water basins located above the fills in the tower.

Counterflow Cooling Towers

Hot process water flows downward on the fill media, continuing its flow all the way onto the cold water basin. The air, though, enters in a lower section of the tower, compared to crossflow versions. From there, air will flow up, passing through the water flowing the fill. The end result here will be a cooling down phase. Pressurized pipes and nozzles are placed further apart than in crossflow towers. This is done to ensure nothing will obstruct airflow to the tower.

Forced Draft Cooling Towers

There are many benefits of using a forced draft cooling tower. And that is exactly why so many industrial plants opt for this model over the other options. Forced draft cooling towers are very powerful, yet economical at the same time. These models will remove low-potential heat that is generated in the production process. A counterflow of air combined with hot water results in a transfer of heat in the cooling fill. Paper and chemical industry plants often prefer to used forced draft cooling towers.

Factory Assembled Cooling Towers

Simple and easy transportation, installation and operation are some of the biggest reasons why plants love factory assembled towers. These versions continue to be extremely popular because they are some of the few towers that can be customized to your specific needs. Generally, these towers are used for HVAC and industrial applications where cooling efficiency is not a priority and space is limited.

Induced Draft Cooling Towers

This version features a fan at the top of tower, pulling the air upward. Fans in induced draft cooling towers then induce the hot, moist air out of the discharge. A powerful exit air velocity reduces any possible recirculation within the tower as the end result. That is the main goal for these models: to eliminate the possibility of any discharged air flowing back into the air intake area.

Cooling Tower Uses

These cooling towers are used to cool several products and machinery. Despite the various uses and machinery associated with this product, all cooling towers operate in the same way. Evaporative cooling is utilized in all circumstances.

Cooling towers are used for the following, plus many more applications:

  • Food and beverage service
  • Machine tools
  • Chemicals
  • Semi-conductors

Cooling Tower Installation, Replacement, & Refurbishment in Arizona & Nevada

Our team offers complete cooling tower refurbishment that will save your company tens of thousands of dollars over buying and installing new cooling towers.  Cooling tower refurbishment and rebuilding adds about another 15 years of life to your equipment and helps you get your money’s worth out of your original investment in your cooling tower or property. We offer cooling tower installation, replacement, and refurbishment in Arizona and Nevada. We also sell other cooling tower parts and products.

Cooling Towers
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Regular Post
Written by Brian B

What Are Cooling Tower Drift Eliminators?

In each and every cooling tower, there is an amount of evaporative water loss to the environment. Drift eliminators are designed to minimize how much water is actually carried out of the tower with the exhaust air. Simply put, keeping water droplets from exiting the tower is a drift eliminators’ main responsibility. If you are searching online for “what are cooling tower drift eliminators,” this post will explain the different functions and features of this essential part.

Drift Eliminator Functions

  • Create a sudden change of direction in air stream.
  • Separate droplets from the air.
  • Deposit these drops on the eliminator surface.
  • Droplets drain back into the tower.

The original drift eliminators were created to trap water droplets from the air stream, preventing this moisture from leaving the cooling altogether. Effective and efficient drift eliminators will remove these water droplets from the air and minimize the loss of processed water within the tower. This cooling tower part can swiftly change the direction of the water droplets in the air. If working effectively, the water will then be separated from the air. This eventually leads to the droplets being pulled back into the tower. The amount of circulating water is then limited from the cooling tower’s exhaust. There is no doubt that these drift eliminators serve a crucial purpose within the cooling tower.

Drift Eliminator Features

When shopping around for the appropriate parts, it is very important that the drift eliminators possess these following qualities:

  • Cost-efficient.
  • Seamless process.
  • Perform at high level.
  • Certified with safety regulations.
  • Easy to use and inspect for maintenance issues.

Read all about Cooling Tower Products’ inventory of drift eliminators here.

Types Of Drift Eliminators

There are several drift eliminator types available on the market today. With that being said, generally, drift eliminators are only classified under two categories: crossflow and counterflow.

Crossflow drift eliminators: These feature horizontal air flow while water flows in the same direction, downward. The advantages of a crossflow model are that it produces minimal noise, consistently performs at a high level and requires little to no general maintenance.

Counterflow drift eliminators: This sends air flow vertically instead of horizontally. Water actually flows from the top all the way to bottom with this design, though. This flow allows the water to exhaust quicker. As is the case with crossflow, there are many benefits of the counterflow drift eliminators. A low amount of energy is consumed within these models. Maintenance is again minimal, and this features a lower pumphead.

Standard drift eliminators: These eliminators are tasked with the duty of preventing harmful water droplets from escaping into the environment. (pictured furthest to the left)

Cellular drift eliminators: Designed for maximum drift removal efficiency. The cellular design allows for a lot more flexibility for installations. (pictured furthest to the right)

Blade drift eliminators: This is a cost-effective option known for its long lifespan and durability.

Cooling Towers That Use Drift Eliminators

Drift eliminators are utilized by all of the following cooling tower types:

Drift Eliminators For Sale

The following drift eliminators are available for sale now at Cooling Tower Products:

Cooling Tower Installation, Replacement, & Refurbishment in Arizona & Nevada

Our team offers complete cooling tower refurbishment that will save your company tens of thousands of dollars over buying and installing new cooling towers.  Cooling tower refurbishment and rebuilding adds about another 15 years of life to your equipment and helps you get your money’s worth out of your original investment in your cooling tower or property. We offer cooling tower installation, replacement, and refurbishment in Arizona and Nevada. We also sell other cooling tower parts and products.

Cooling Towers, Drift Eliminators
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Cooling Tower Drift Eliminator
Regular Post
Written by Brian B

Cooling Tower Drift Eliminator

Drift eliminators are a crucial piece within cooling towers. These parts are needed to recycle and ultimately save water. If you are searching for “cooling tower drift eliminator,” then this post will explore the details of this key cooling tower feature.

What Are Drift Eliminators?

A drift eliminator is exclusively created to trap water droplets from the air stream, keeping this moisture from escaping the cooling tower altogether. Effective drift eliminators will remove water droplets from the air and minimize the loss of processed water. This cooling tower part can rapidly change the direction the water droplets are headed in. Water will then become separated from the air, and pulled back into the cooling tower. Amount of circulating water is then limited from the cooling tower’s exhaust. Put simply, drift eliminators remove water droplets from the air and serve a crucial purpose within the tower.

Drift Eliminator Types

There are several drift eliminator types available on the market today. With that being said, generally, drift eliminators are only classified under two categories: crossflow and counterflow. Crossflow drift eliminators feature horizontal air flow while water flows in the same direction, downward. The advantages of a crossflow model are that it produces minimal noise, consistently performs at a high level and requires little to no general maintenance.

Counterflow drift eliminators send air flow vertically instead of horizontally. Water actually flows from the top all the way to bottom with this design, though. This flow allows the water to exhaust quicker. As is the case with crossflow, there are many benefits of the counterflow drift eliminators. A low amount of energy is consumed within these models. Maintenance is again minimal, and this features a lower pumphead.

Drift Eliminator Features

Choosing the right drift eliminator for your cooling towers can be a difficult task. When shopping around it is very important that the drift eliminators possess the following qualities:

  • Cost-efficient
  • Seamless process
  • Performs at high level
  • Certified with safety regulations
  • Easy to use and inspect for maintenance issues

Read more about Cooling Tower Products’ line of drift eliminators here.

Cooling Tower Installation, Replacement, & Refurbishment in Arizona & Nevada

Our team offers complete cooling tower refurbishment that will save your company tens of thousands of dollars over buying and installing new cooling towers.  Cooling tower refurbishment and rebuilding adds about another 15 years of life to your equipment and helps you get your money’s worth out of your original investment in your cooling tower or property. We offer cooling tower installation, replacement, and refurbishment in Arizona and Nevada. We also sell other cooling tower parts and products.

Cooling Towers
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Cooling Tower Cost 2020
Regular Post
Written by Brian B

Cooling Tower Cost 2020

If you are searching online for “cooling tower cost 2020” or even “how much do cooling towers cost,” this post will help! Cooling towers generally cost around $125,000 to fully replace. A replacement will typically cost between $50,000 and $200,000. A commercial cooling tower can last up 20 years.

Cooling Tower Replacement Cost

Whenever a cooling tower ages beyond 20 years, a rebuild is almost essential. The cost per ton of the replacement depends on the actual size of the cooling tower. Other features, such as epoxy treatment and equipment needed will affect cost, as well. Larger cooling towers will cost more and require increased maintenance attention.

Feeder Water System Cost

Costs can vary wildly when it comes to the feeder water system. Commercial customers can expect to pay anywhere from $50,000 to $250,000.

Blowdown System Cost

A blowdown system needs nearly 75 percent of the water to be reused in a 100-gallon-per-minute stream. Typically, this system will cost around $300,000 total.

Circulation Water System Cost

This side stream filtration unit can cost $50,000 for 100 GPM and a maximum of $300,000 for 1,000 GPM.

Cooling Tower Refurbishing Cost

Cooling tower repair costs will certainly decrease when regular maintenance is performed. Regular maintenance will also increase the lifetime of the towers, hopefully heading towards a 20-year existence. Compared to a full repair, commercial companies generally pay 60 percent less for a refurbishing.

Looking for updated 2021 cooling tower costs? Click right here.

Cooling Tower Installation, Replacement, & Refurbishment in Arizona & Nevada

Our team offers complete cooling tower refurbishment that will save your company tens of thousands of dollars over buying and installing new cooling towers.  Cooling tower refurbishment and rebuilding adds about another 15 years of life to your equipment and helps you get your money’s worth out of your original investment in your cooling tower or property. We offer cooling tower installation, replacement, and refurbishment in Arizona and Nevada. We also sell other cooling tower parts and products.

Cooling Towers
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How Do Cooling Towers Work?
Regular Post
Written by Brian B

How Do Cooling Towers Work?

Industrial cooling towers provide a proven way to remove heat from one place to another by using water as a transportation agent. Typically, cooling towers are utilized in areas that need a reliable source of cool when temperatures range from 70-100 degrees, year round. So, how exactly do these cooling towers work?

How Cooling Towers Work

Cooling towers are generally found in large power plants and manufacturer buildings. The towers can vary in size, though. Cooling towers can also be spotted on mall, university and hospital rooftops. They are commonly found inside an HVAC system, used to cool the inside of a building. The cooling load is determined by the amount of space in the building and/or location which needs the heat extracted. Humidity of the air is also accounted for, as cooling towers in Florida will differ from a tower located in the dry heat of Arizona.

Evaportaive cooling is a cycle that turns cooling evaporating water into air. This is a natural process, and one that can be seen utilized often in athletics. Next time you watch any sort of game, scan the sidelines for misters used to cool the players down after competing. Another example would be what happens the moment one steps out of the shower. The water on the skin quickly evaporates and pulls the heat from the body. We then feel the cooling sensation taking over.

Simply put, cooling towers are large boxes equipped to maximize the evaporation of water. Plastic sheets inside the tower create a large surface area, ready for evaporation. Just like nuclear power plants, these cooling towers rely on natural airflow throughout the tower. To help the process, some towers utilize a motor to generate quicker and more efficient airflow.

Cooling Tower Uses

These cooling towers are used to cool several products and machinery. Despite the various uses and machinery associated with this product, all cooling towers operate in the same way. Evaporative cooling is utilized in all circumstances.

Cooling towers are used for the following, plus many more applications:

  • Food and beverage service
  • Machine tools
  • Chemicals
  • Semi-conductors

Evaportavie Cooling Process

To further expand on evaportaive cooling, this is a very simple but necessary process used by cooling towers. Essentially, warm water is pumped all the way up to the top of the tower. This is where the water distribution system is located. Water is then spread out and sent to the wet deck, courtesy of the cooling tower nozzles. Air is released from the tower at the same time, thus forcing water to evaporate. Finally, the hot air leaves the tower.

Looking For Cooling Tower Maintenance?

Cooling Tower Products has over 4 decades of experience with cooling tower maintenance and can help you with any cooling tower related project. Contact us today and get the professionals at Cooling Tower products on your side.

Cooling Towers
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Chiller Tips For Hot Weather
Regular Post
Written by webtechs

Chiller Tips For Hot Weather

In the hot summer time, the efficiency of any industrial liquid chiller is reduced. Read on to learn more about keeping your chiller working smoothly when the sun comes out!

Water-Cooled Chillers

  • Make sure the plant water system is operating correctly.
  • Most chillers require three gallons per minute of cooling water for every ton of system capacity delivered at a pressure differential of 20 pounds per square inch.
  • Keep it clean by phsicially cleaning the condenser tubes or utilize a chemical cleaning system. The slightest build up of scale can have a dramatic effect on performance.
  • Make sure the pressure activated water modeling valve is opened fully when required.

Air-Cooled Water Chillers

  • Utilize a non-acid based commercial coil cleaning system to keep the condenser coil clean and the fins properly combed to allow proper airflow.
  • Make sure the space is adequate around the chiller to ensure thecorrect amount of airflow. Most need four to five feet of clearance space on the air inlet side and clear space above as well as four to five feet of clearance space for units that discharge on the side.
  • Ensure the ventilation is adequate so air recirculating is prevented.
  • Make sure fan blades, motors and blowers are working correctly and well maintained.

Looking For Cooling Tower Maintenance?

Cooling Tower Products has over 4 decades of experience with cooling tower maintenance and can help you with any cooling tower related project. Contact us today and get the professionals at Cooling Tower products on your side.

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Regular Post
Written by webtechs

What Is A Cooling Tower

A cooling tower can be thought of as a specialized heat exchanger where water and air meet with the purpose of reducing the temperature of the water. When this happens, a small total of the water evaporates, hence reducing the water temperature that is circulated throughout the tower.

This water is pumped through pipes to the cooling tower. Nozzles are used as the water sprays onto material known as fill that slows the flow of the water as it travels through the cooling tower and maximizes air and water contact. When they meet, a cooling action is created and the cooled water is then pumped back to the processing equipment where it absorbs hear. From there it is pumped back to the cooling tower and obviously, cooled again.

Crossflow Cooling

In these the water flows vertically while air flows in a horizontal manner. Hence, air doesn’t have to pass through the system of distribution, allowing the use of hot water that is gravity flowed with basins for distribution mounted at the top of the cooling unit.

Counterflow Cooling

These are designed so air flows in an upward direction to counter the falling water in the fill. it is not possible in the vertical airflow to utilize open gravity-flow basins in crossflow designs. Instead they use pressurized sprays to spray water onto the top of the fill. As air must pass through the system the pipes and nozzles are further apart so airflow is not restricted.

Induced Draft Versus Forced Draft

Induced system have fans on top of the units and they pull the air throug hthe fill. On the other hand, air is pushed by blowers located near the base of the air inlet on draft towers that have been forced.

Looking For Cooling Tower Maintenance?

Cooling Tower Products has over 4 decades of experience with cooling tower maintenance and can help you with any cooling tower related project. Contact us today and get the professionals at Cooling Tower products on your side.

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