Skid Mounted Cooling Tower
In industries where cooling is a crucial factor, efficiency and ease of installation play a significant role in choosing the right cooling solution. One such innovation that has transformed cooling systems is the skid-mounted cooling tower. These pre-assembled, portable systems offer a hassle-free, plug-and-play solution, making them ideal for various industrial applications. United Cooling Systems is a skid-mounted cooling tower manufacturer in India.
What is a Skid-Mounted Cooling Tower?
A skid-mounted cooling tower is a fully integrated cooling system built onto a steel skid platform. Unlike traditional cooling towers that require on-site assembly and complex installation, these units are pre-engineered and pre-assembled, allowing for quick deployment and immediate operation.What are the three types of cooling towers?
Cooling towers are generally classified into three main types based on their heat transfer method and airflow design:1. Open-Circuit (Wet) Cooling Towers
- Also known as direct-contact cooling towers, these use the process of evaporative cooling to reject heat.
- Hot water from the system is sprayed over a fill media, and as air passes through, some of the water evaporates, removing heat.
- Common Applications: HVAC systems, industrial processes, and power plants.
2. Closed-Circuit (Fluid) Cooling Towers
- Also called dry or hybrid cooling towers, these have a coil system where hot fluid circulates inside a closed loop.
- Air passes over the coil, and in some cases, a secondary water loop assists in cooling.
- Reduces water consumption and prevents contamination of the working fluid.
- Common Applications: Data centres, food processing, and chemical plants.
3. Hybrid Cooling Towers
- A combination of wet and dry cooling methods, designed to reduce water consumption while maintaining efficiency.
- Operates as a dry tower in cooler conditions and switches to evaporative cooling when needed.
- Common Applications: Industrial plants and locations with water restrictions.
- Since these towers come pre-assembled, installation is significantly faster compared to conventional cooling towers. This reduces downtime and ensures operations start smoothly.
- Skid-mounted units are designed for mobility, making them perfect for temporary cooling needs, rental applications, or industries with changing operational demands.
- The compact layout of these systems makes them ideal for facilities with limited space, as they eliminate the need for large, separate cooling components.
- Reduced installation and maintenance costs make skid-mounted cooling towers a budget-friendly choice for industries looking to optimise their cooling operations.
- These cooling towers often include all necessary components such as pumps, piping, heat exchangers, and control systems, providing a turnkey solution for industrial cooling needs.
- Warm water from industrial equipment, HVAC systems, or processes is pumped into the cooling tower through inlet pipes.
- The water flows into distribution nozzles or spray headers located at the top of the tower.
- The hot water is evenly distributed over the fill material inside the tower.
- The fill increases the surface area for better heat dissipation.
- A fan (or natural draught) draws air through the cooling tower.
- The air absorbs heat from the water as it flows over the fill media.
- Some of the water evaporates, carrying heat away and lowering the remaining water’s temperature.
- The now-cooled water drips down into the collection basin at the bottom of the tower.
- This cold water is then recycled back into the system for further use.
- The fan system expels the warm, moist air out of the tower through the top.
- This ensures continuous cooling and optimal system performance.
- A skid-mounted cooling tower often comes with pre-installed pumps, sensors, and control systems.
- These help automate water flow, fan speed, and temperature regulation for efficiency.
- If needed, chemical treatment or filtration systems prevent scale buildup and contamination.
- Typically ranges from 10 TR (Tonnes of Refrigeration) to 1000+ TR
- Designed based on heat load and process requirements
- Forced-draft or induced-draft fan systems
- Fan type: Axial or centrifugal
- Airflow rate: Varies based on design and cooling requirements
- Typically ranges from 50 GPM to 10,000+ GPM (Gallons per Minute)
- Adjustable based on process needs
- PVC or wooden fill media for improved heat dissipation Coil material: Copper, stainless steel, or galvanised steel for closed-loop systems
- Frame: Galvanised steel, stainless steel, or FRP (fibre-reinforced plastic)
- Casing: FRP, stainless steel, or coated steel for corrosion resistance
- Water basin: Stainless steel or FRP for durability
- Pre-installed piping, pumps, and valves for efficient operation
- Motor power: Ranges from 1 HP to 100+ HP based on cooling requirements
- Fan speed: Variable speed drive (VFD) available for energy efficiency
- PLC-based control system with temperature and pressure sensors
- Remote monitoring and automation options available
- Designed to handle inlet temperatures of 80°F to 150°F (27°C to 65°C)
- Cooling temperature drop: 10°F to 30°F (5°C to 15°C)
- Low-noise fan options available for industrial and commercial applications
- Sound levels: Ranges from 60 dB to 90 dB depending on design
- Hot Water Inlet Temperature: 80°F to 150°F (27°C to 65°C)
- Cold Water Outlet Temperature: 60°F to 95°F (15°C to 35°C)
- Cooling Range (ΔT): 10°F to 30°F (5°C to 15°C)
- High-temperature applications: Up to 180°F (82°C) inlet temperature
- Low-temperature applications: As low as 50°F (10°C) outlet temperature
- Customised cooling range based on specific industrial needs
- The performance of a cooling tower is influenced by the wet bulb temperature of the environment.
- Typically designed to operate 5°F to 7°F (2°C to 4°C) above wet bulb temperature.
- 1 TR (Tonne of Refrigeration) = 3.517 kW
- 1 TR = 12,000 BTU/hr (British Thermal Units per hour)
- In cooling towers, TR is used to specify how much heat can be rejected to the atmosphere.
- A cooling tower's capacity in TR is calculated based on the amount of heat it removes from the system.
- It depends on factors like water flow rate, temperature difference (ΔT), and evaporation losses.
- LPM = Litres per minute of circulating water
- ΔT = Temperature difference between hot and cold water (°C)
- 4.187 = Specific heat of water (kJ/kg·°C)
- 3024 = Conversion factor to get TR
- Used in large commercial buildings, hospitals, malls, and data centres to regulate temperatures.
- Helps dissipate excess heat from air conditioning and refrigeration systems.
- Essential for cooling turbines and generators in power generation facilities.
- Helps maintain optimal operating temperatures and prevents overheating.
- Used in steel plants, automotive factories, and chemical production.
- Keeps machinery and industrial processes cool, improving efficiency and longevity.
- Helps regulate temperatures in refineries, drilling operations, and petrochemical plants.
- Used to cool heat exchangers and compressors in offshore and onshore applications.
- Maintains cooling for pasteurisation, brewing, dairy processing, and refrigeration systems.
- Ideal for temporary cooling needs at events, construction sites, and backup cooling for industries.
- Quickly deployed for disaster recovery or system failures.
- Provides efficient cooling for servers and networking equipment to prevent overheating.
- Used in locations with space constraints and high-density cooling needs.
- Helps cool heavy machinery, furnaces, and hydraulic systems in mining operations.
- Reduces wear and tear on equipment by managing excessive heat.
- Used for cooling chemical reactors, distillation processes, and laboratory equipment.
- Ensures temperature-sensitive processes remain stable and efficient.
- Used in ship engine cooling, offshore drilling rigs, and marine HVAC systems.
- Helps regulate temperatures in harsh environmental conditions.
