Torraval has replaced an industrial client’s two cooling towers and added a third, all from the PME series, to dissipate a heat load of 8,306 kW with a total flow rate of 800 m³/h. The new installation occupies the same footprint as the previous one, incorporates the TCS control system and solves the maintenance and thermal stability problems of equipment that had been in service for more than three decades. The plant had been cooling its process with two cooling towers for more than 30 years.
The need
The client was looking for a new configuration of its cooling towers that would improve process efficiency and provide headroom for future projects. The existing equipment required increasing levels of maintenance and had lost efficiency over time. In addition, the water temperature fluctuated depending on the time of year, and in the hottest months this fluctuation had a direct impact on production.
The challenge
The installation had to gain capacity without gaining floor area. It meant going from two towers to three using the space occupied by the previous ones, and doing so in a way that made inspection and maintenance tasks simpler and safer than before.
The cooling solution
Torraval proposed three towers from the PME series, model 7204 E NET 150 CVCS, mounted on a new structure custom-designed for the available space.
Installation design data
| Parameter | Value |
|---|---|
| Heat load to be dissipated | 8,306 kW |
| Total water flow rate | 800 m³/h |
| Water flow rate per tower | 267 m³/h |
| Inlet temperature (hot water) | 35.0 °C |
| Outlet temperature (cold water) | 26.0 °C |
| Wet bulb temperature | 22.0 °C |
| Altitude above sea level | 698 m |
Under these conditions, the towers operate with a thermal range of 9 °C and an approach of 4 °C to the wet bulb temperature.
Robust, quiet construction
The structure is made of 3 to 5 mm thick hot-dip galvanised steel, and the casing consists of 22 mm fibreglass panels. This construction provides high mechanical strength and effectively absorbs the noise of falling water.
Ventilation and fill designed for efficiency
The multi-blade axial fans deliver high performance with low power consumption, correcting the lack of efficiency of the previous equipment. The NET fill is designed to minimise the risk of clogging when the water contains solids.
Three cooling towers in the space of two
The new structure houses the three towers in the area occupied by the two that were replaced. Each tower has a removable wall, which simplifies access to the interior and maintenance tasks. An upper platform connects the three units and improves accessibility and safety during inspections.
Continuous control with the TCS system
The TCS control system constantly monitors thermal efficiency and optimises the operation of the towers to avoid unnecessary consumption.
Benefits for the client
The installation gains capacity with a third tower without taking up more floor space. Maintenance is simpler and safer thanks to the removable walls and the upper platform. The NET fill reduces the risk of clogging. The TCS system saves electricity, reduces wear on electromechanical components, lowers water consumption and water treatment costs, and attenuates noise.
Do you have a cooling process that needs better stability or performance?
If you are considering a new installation or the replacement of an existing tower, we can help. At Torraval, with more than 55 years of experience as manufacturers and the backing of the MITA group, we study the conditions of each installation to define the most suitable cooling solution. Contact our technical team.