R V Cooling Tower

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PVC Film Fill

Film Fills are the most efficient filling media available for cooling towers. The usage of film fills – in both counterflow and crossflow cooling towers allows relatively smaller sized towers to cool an equivalent amount of water compared to cooling towers using splash fills. This results in the saving of not only capital costs for a new tower but also reduces operational costs on account of lower height and hence lower pumping costs.

Film Fills work on the principle of offering heat exchange by spreading the falling water droplets into a thin molecular film where the air can effectively contact the entire surface of the water film to carry away heat and mass.

Advantages

    • Minimum resistance to air flow

    • Good distribution of water leads to turbulent mixing of air and water to maximize heat transfer.

    • Reduced fill height and greater cooling capacity results in lower power consumption.

    • Erosion and rotting resistant and long lasting (10-12 years of service time in good quality water)

    • Self-supporting, high strength and self-extinguishing characteristics

    • Resistance to weather exposure (fungii/oxidation) ; Nearly impervious to chemical degradation by Alkali, acid, grease, fats, oils and biological attack

    • Easy to glue at site, reduces transportation cost.

Our Product Range

Cooling towers using CD-12 fills must have little to no contamination from oil, grease or process dust.CD-12 is a cross fluted film fill that works on the principle of water droplets developing a fine film on the surface of the media. The surface tension of the polymer holds the film long enough for efficient heat transfer with the ambient air.
The flute height of 12-mm along with COOLDECK’s effective and efficient microstructure gives an effective surface area of 250 m2/m3 resulting in the highest thermal (KaV/L) performance.

Features and Advantages

  • In-house calendering units, which ensure proper fusion of PVC and other additives. The process thus imparts superior mechanical and physical properties to the fill sheet as well as also ensures uniform thickness on the sheet. Most fill manufacturers outsource the film from outside reprocessing units.
  • Enhanced flat surface glue point locator along the flutes resulting in stronger modules and a better visible honeycomb
  • Both sides have folded edges << edge folding sheet image>> that impart maximum strength at critical load bearing points. A double edge folded COOLFill CD-12 with a thickness of 0.175 mm (0.35 mm at the edges) will have the equivalent application strength of a comparable flute fill at 0.25 mm thick.
  • Choice between Translucent White / White (UV+IR stabilized), Blue (resistant to direct sunlight), Black (UV stabilized) and fill media.
  • Can be supplied in either module form from factory or assembled at location.
  • Manufactured in PP and ABS for high temperature applications

Technical Specifications

CharacteristicsCD-12
Primary Cooling Towers ApplicationCounterflow
Flute height12 mm
MOCRigid PVC (Virgin and reprocessed)
Longitudinal pitch37.5 mm
UV StabilizationWhite – Titanium Dioxide
Black – Carbon Black
Spiral angle28°
Std. Sheet size
L x W
600mm x 300mm
Recommended Max Fill Sheet size L x W1200 mm x 600 mm
Surface area per unit volume258 m²/m³
Standard Weight26.5 Kgs/m3
Maximum continuous Operating temp.55 °C
Minimum Fill Sheet Finished Thickness0.175 mm
Standard Followed for Material propertiesCTI STD-136
There are sectors where the makeup water may have TSS upto 100 on account of the source of the water. There may also be relatively poorer microbiological control. However it is assumed that the plant will be following some water treatment procedures including those for removal of oil and grease and heavy salts.
CD-19 is a cross fluted film fill that works on the principle of water droplets developing a fine film on the surface of the media. The surface tension of the polymer holds the film long enough for efficient heat transfer with the ambient air.
The flute height of 19-mm along with COOLDECK’s efficient microstructure gives an effective surface area of 158 m2/m3 resulting in high thermal (KaV/L) performance.

Features and Advantages

  • Virgin PVC resin is processed on in-house T-die/calendering units, which ensure proper fusion of PVC and other additives. The process thus imparts superior mechanical and physical properties to the fill sheet as well as also ensures uniform thickness on the sheet. Most fill manufacturers outsource the film from outside reprocessing units.
  • Double folded edges that impart maximum strength at critical load bearing points. A double edge folded COOLFill CD-19 with a thickness of 0.25mm (0.5 mm at the edges) will have the equivalent application strength of a comparable flute fill at 0.38 mm thick.
  • Minimum weight per unit volume assures easier handling and inexpensive support structures
  • Both the top and bottom of the formed fill sheet have defined gluing points – an enhanced flat surface along the flutes. This results in reduced glue consumption per cubic meter of fill volume. For a fill which is mostly site assembled, this can give up to 30% saving in the glue consumption compared to similar products as well as a better visible honeycomb
  • Choice between Black (UV stabilized) and Translucent White / White (UV+IR stabilized) fill media.
  • Can be supplied in either module form from factory or assembled at location.

Technical Specifications

CharacteristicsCD-19
Primary Cooling Towers ApplicationCounterflow
Flute height19 mm
MOCVirgin rigid PVC
Longitudinal pitch50 mm
UV StabilizationWhite – Titanium Dioxide
Black – Carbon Black
Spiral angle28°
Std. Sheet size
L x W
1200mm x 600mm
Recommended Max Fill Sheet size L x W1800 mm x 600 mm
Surface area per unit volume158 m²/m³
Standard Weight27 Kgs/m3
Maximum continuous Operating temp.55 °C
Standard Fill Sheet Finished Thickness
(Available in 0.23mm thickness Other thickness on request)
0.25 mm
Standard Followed for Material propertiesCTI STD-136

Film Fill Products

CharacteristicsUnitsCD – AWCD-12
Cooling Tower Application Air WasherCounterflow
Flute heightMm812
Longitudinal pitchMm2538
Spiral angle°(degree)11/7928
Spiral angle°(degree)11/7928
Std. Sheet size L x Wmm x mm600×300600×300
Max Recommended Fill Sheet
size L x W
mm x mm600×6002400×600
Surface area per unit volumeM²/m³
ft²/ft³
375
115
250
76
Standard Sheet Thicknessmm
in
0.18
0.007″
0.2
0.008″