Hybridization of Existing Cooling Towers

AN INNOVATION FOR EFFICIENCY AND SUSTAINABILITY

The hybridization of existing cooling towers is an innovative solution that allows optimization of thermal performance, reduction of water consumption, and improvement of energy efficiency, without the need to completely replace operating systems.

ILMED IMPIANTI offers the conversion from WET cooling to WET/DRY, combining evaporative cooling with dry cooling. This process allows the system to dynamically adapt to operational and climatic conditions, ensuring more efficient and sustainable operation.

HOW DOES HYBRIDIZATION WORK?

Hybridization is achieved by installing a dry section in the upper part of the cooling tower, utilizing the available space along the longitudinal sides of the plenum. This system makes it possible to modulate the evaporative section, reducing water use and vapor emissions according to environmental conditions.

MAIN CONVERSION INTERVENTIONS

• Installation of dry heat exchangers – Enables cooling without evaporation, reducing water consumption.
• Advanced control systems – Intelligently regulate the switch between dry and evaporative modes to optimize performance.
• Variable speed fans (VFD) – Adjust airflow to reduce energy consumption.
• Optimization of water distribution – Ensures balanced and efficient use between the two cooling modes.

ADVANTAGES OF HYBRIDIZATION

1. Water savings and sustainability

• Water consumption reduction of up to 30% compared to a traditional tower.
• Lower environmental impact thanks to reduced vapor emissions and decreased need for chemical treatments.
• Ideal for urban environments – Reduced visible plume, compliant with stricter environmental regulations.

2. Energy efficiency and cost reduction

• Lower electricity consumption thanks to variable speed fans.
• Reduced costs related to filtration, biocide dosing, and sludge management.

3. Greater reliability and lower maintenance

• Reduced formation of scale and biofilm, with a lower risk of Legionella.
• Less corrosion and scaling due to reduced water usage.
• Adaptability to climate variations – The system automatically adjusts according to seasonal temperatures.

4. Lower investment and fast return

• No need to replace the entire tower – Hybridization upgrades existing systems without invasive structural interventions.
• Fast return on investment – Savings on water, energy, and maintenance allow conversion costs to be recovered quickly.

APPLICATION SECTORS

Hybridization of cooling towers is an ideal solution for several industrial sectors, including:

• Thermal power plants and cogeneration systems
• Petrochemical and refining industry
• HVAC for large commercial and industrial buildings
• Data centers and IT infrastructure
• Food and pharmaceutical industry
• Steel and metallurgical industry