Hybrid Cooling Towers Assembled On Site

MAIN FEATURES

• Hybrid technology – Combines dry cooling and evaporative cooling to optimize performance under all climatic conditions.

• Water efficiency – Water consumption reduced by up to 50% compared to traditional evaporative cooling towers.

• Low energy consumption – Use of variable speed fans and advanced control systems to reduce energy usage.

• Minimal maintenance – Reduced formation of scale and biofilm, resulting in a lower need for chemical treatments.

• Robust and modular structure – Made of galvanized steel, FRP, or reinforced concrete, designed to withstand wind loads, seismic stress, and extreme environmental conditions.

COMPONENTS AND STRUCTURE

Dry Section

The dry section is located at the top of the tower and consists of finned coils made of galvanized steel or stainless steel, with fins in light alloy. Adjustable dampers optimize airflow, improving cooling efficiency according to operating conditions and reducing energy consumption.

Ventilation Section

Hybrid cooling towers assembled on site are equipped with high-performance axial fans, driven by electric motors installed outside the humid airflow. The transmission system consists of a right-angle gearbox and a dynamically balanced drive shaft, ensuring high efficiency and reliability.

WATER DISTRIBUTION SYSTEM

The water distribution system consists of concrete channels or FRP and PVC piping, equipped with anti-clogging polypropylene nozzles that ensure uniform distribution over the heat exchange surface.

HEAT EXCHANGE SECTION

Available in three configurations:

• FILM Fill – PVC or PP fill packs with an exclusive design that maximizes the heat exchange surface area.

• SPLASH Fill – Ideal for water with a high content of suspended solids and dissolved solids.

• HYBRID Fill (TR.U.S.T. System) – Modular structure made of high thickness polypropylene, ideal for water containing suspended solids. The modular design facilitates handling, cleaning, and maintenance, ensuring extended service life.

DRIFT ELIMINATORS

Modular PVC or PP elements that limit water losses due to drift to less than 0.005% of the flow rate.

LOUVERS AND ADDITIONAL OPTIONS

• Concrete or FRP louvers, designed to direct airflow and prevent water spray carryover.

• Low noise fans and sound insulated motors, suitable for installations in urban or noise sensitive environments.

• Heating elements for louvers, motors, and gear reducers, enabling operation in harsh climatic conditions.

• Variable frequency drive (VFD), to modulate tower operation according to cooling demand.

• Water treatment and filtration systems, to ensure reliable operation and extended service life.

OPERATION OF THE HYBRID COOLING TOWER

Hybrid cooling towers operate with a dual mode system, adjustable according to environmental and operating conditions:

HYBRID MODE

• The system switches from fully evaporative operation to a mixed mode by diverting part of the water flow to the dry coils.

• This allows the water to be cooled by conduction, reducing both water and energy consumption.

• The transition between the two modes is automatically controlled based on ambient temperature and operating requirements, ensuring optimal cooling performance and reducing visible plume formation.

ADVANTAGES OF HYBRID COOLING TOWERS ASSEMBLED ON SITE

1. Water and Environmental Savings

• Reduced water consumption thanks to the combined use of dry and evaporative modes.
• Lower use of chemical products for water treatment.
• No visible plume, ideal for installations in urban areas or locations subject to environmental restrictions.

2. Energy Efficiency and Low Operating Costs

• Variable speed fans – Automatically adjust energy consumption according to plant requirements.
• Reduced maintenance – Lower evaporation limits scale formation and bacterial growth.
• Cost optimization – The combined operating modes reduce both water and energy consumption.

3. Maximum Reliability and Long Service Life

• Corrosion resistant materials, designed for environments with high humidity or exposure to aggressive chemicals.
• Suitable for variable climates, with optimal performance in both summer and winter.
• Modular and scalable structure, allowing future expansion according to operational needs.

4. Integration with Advanced Control Systems

• Remote monitoring and automation, for real time control of operating parameters.
• Predictive diagnostics, with advanced sensors that detect anomalies and optimize preventive maintenance.

APPLICATIONS OF HYBRID COOLING TOWERS ASSEMBLED ON SITE

These towers are the ideal solution for industrial sectors with high thermal loads, including:

• Power generation industry – Cooling of turbines, condensers, and cogeneration plants.

• Petrochemical and refining industry – Thermal management of high temperature industrial processes.

• HVAC for large buildings – Industrial and commercial air conditioning.

• Data centers – Efficient cooling for critical IT infrastructure.

• Food and pharmaceutical industries – Temperature control in production processes.

• Steel and metallurgical industries – Cooling of fluids in metal processing cycles.

OPTIONAL COMPONENTS

• ANTI SPLASH MESH IN THE BASIN
• LOW NOISE FANS
• SOUND INSULATED MOTOR
• CLOSABLE (SHUT OFF) LOUVERS
• HEATING ELEMENTS ON LOUVERS
• HEATING ELEMENTS ON MOTORS AND GEAR REDUCERS
• VARIABLE FREQUENCY DRIVE (VFD)
• WATER TREATMENT / FILTRATION
• POWER AND CONTROL PANEL

CONCLUSION

Hybrid cooling towers assembled on site represent an advanced solution to improve cooling performance, reduce water and energy consumption, and ensure efficient and sustainable operation.

Thanks to the innovative technology developed by ILMED IMPIANTI, companies can obtain a customized, reliable, and environmentally friendly system, reducing operating costs and enhancing the sustainability of industrial processes.