Cooling Function

Cooling tower systems may face capacity limitations during summer peaks, high ambient temperatures, or increased process loads. Hot water returning from heat exchangers at 40-50°C requires cooling to 30-35°C for effective process heat removal. The circulating water cooler provides supplemental cooling reducing return temperature when towers cannot achieve targets, ensuring adequate cooling water supply for facility operations.

Design Configuration

Air-cooled heat exchangers with finned tube bundles and axial or induced draft fans. Hot circulating water flows through tubes while ambient air removes heat. ERGIL engineers coolers based on water flow rate, inlet temperature, target temperature reduction, and ambient design conditions with typical duties 5-50 MMBTU/hr. Multiple cells enable capacity modulation matching actual cooling requirements.

Applications

Refineries supplementing cooling tower capacity during peak periods, chemical plants requiring additional heat rejection, power generation facilities cooling auxiliary systems, and manufacturing operations managing seasonal cooling demands. Serves facilities with cooling water circulation rates 500-10,000 GPM requiring temperature control.

Control Features

Variable speed fan control modulates cooling capacity based on outlet water temperature. Multiple fans enable staged operation optimizing energy consumption. Automatic control responds to process demands adjusting cooling duty. Integration with cooling tower systems provides overall temperature management. Prevents overcooling during mild conditions reducing fan power consumption.

Material Selection

Carbon steel tubes with galvanized or aluminum fins resist corrosion from cooling tower water. Stainless steel construction for aggressive water chemistry or coastal environments. Tube-side design enables cleaning addressing scale and fouling. Construction accommodates thermal expansion and weather exposure with appropriate structural supports.

Performance Benefits

Increases overall cooling system capacity without tower expansion. Provides operational flexibility during peak demand periods. Reduces process temperature constraints during hot weather. Modular design enables staged installation matching facility growth. Lower operating costs than mechanical refrigeration for moderate cooling requirements.

Operational Considerations

Fan power consumption versus cooling benefit optimized through controls. Periodic cleaning maintains heat transfer efficiency addressing water-side fouling. Freeze protection during winter operation in cold climates. Proper siting ensures adequate ambient air flow and noise management.

Construction Standards

Design per applicable standards with materials suitable for cooling water service. Structural supports for fan loads and wind conditions. Electrical systems for motor drives. Complete documentation including thermal performance curves and maintenance procedures.

ERGIL circulating water coolers deliver reliable supplemental cooling ensuring adequate heat rejection capacity across varying ambient conditions and process demands.