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Cooling Tower Filling

Cooling Tower Filling

Cooling Tower Fills

Cooling tower fills are an important component of cooling towers, which are widely used in various industrial processes to remove excess heat from systems such as power plants, HVAC systems, and manufacturing facilities. The cooling tower fill plays a crucial role in the cooling process by increasing the contact surface area between the air and water, facilitating the transfer of heat through evaporation and convection.


Cooling tower fills are designed to increase the surface area available for the exchange of heat between the warm water inside the tower and the cool air that is drawn through the tower. This process helps to reduce the temperature of the water, allowing it to be recirculated for further cooling. Cooling tower fills also assist in maximizing the efficiency of the cooling tower by promoting the evaporation of water, which is a key mechanism for heat removal.

Types of Fills

There are two main types of cooling tower fills: splash fills and film fills.

Splash Fills: These fills consist of a series of horizontal surfaces that water falls or "splashes" on as it flows through the fill. The splashing action helps to break up the water into smaller droplets, increasing its surface area and promoting efficient heat transfer. Splash fills are simpler in design and are commonly used in industrial cooling towers.

Film Fills: Film fills are designed to create a thin film of water that spreads over the surface of the fill material. This film forms a larger surface area for interaction with the air, enhancing heat transfer through evaporation and convection. Film fills are generally more efficient than splash fills and are often used in larger and more modern cooling towers.


Cooling tower fills are typically made from various materials, such as PVC (polyvinyl chloride), polypropylene, and other plastics that are resistant to corrosion, chemicals, and degradation due to exposure to water and air. These materials are chosen for their durability and ability to withstand the harsh conditions present in cooling towers.

Design Considerations:

The design of cooling tower fills takes into account factors like the specific heat load requirements, water flow rates, temperature differentials, and the type of cooling tower being used. Proper selection and design of cooling tower fills are essential to achieving optimal heat transfer efficiency and overall cooling tower performance.

As a cooling tower manufacturer, we supply different materials for the cooling tower fills with good prices such as PP and PVC. The honeycomb design principle is adopted, which is an important part of cooling tower. The function of fill in cooling tower is to increase heat dissipation, prolong the residence time of cooling water, increase heat exchange area, and distribute water evenly.

Types Of Fills In Cooling Tower

Characteristics Of Cooling Tower Filling

Feature 1: The cooling tower fill media adopts inclined suspension installation and the bottom of the filling is suspended. This way the cooling tower will not deposit debris and the water will flow smoothly, preventing algae and bacteria from growing.

Feature 2: No glue bonding, no deformation, no embrittlement, effectively solve the problem of filling scaling. The old installation method used glue bonding, and the filling was stacked in the cooling tower. When it was used, the bonding point of the filling was easy to scale, which accumulated over time and collapsed after serious bending deformation, thus affecting the cooling performance.

Feature 3: Increase the effective air intake area. More steel frame is needed to support the bottom of the bonded filling, which reduces the effective air inlet area of the filling, while the suspended installation of the fill media in the cooling tower does not need to support the steel frame.

Feature 4: Filling installation, transportation, and maintenance are simple and convenient.

Advantages Of Cooling Tower Filling

a.There is no geometric deformation at 65 ℃ - 35 ℃.

b.It is not broken or brittle under the design temperature.

c.Under normal operation and service conditions, its service life shall not be less than 20A.

d.High thermal performance, far more than 90% of the national standard requirements;

e.The floating water rate is lower than 0.001% of the circulating water volume, and the three in one design of self-contained water collector and air inlet louver is adopted; the filling is made of flame retardant PVC vacuum molding,

f.It has good flame retardancy.

Attention Requirements For Cooling Tower Filling

a. Removal of the old cooling tower filling, turn off the power supply of the motor; removal of the cooling tower filling reinforcement; removal of the old filling; tower garbage cleaning; cleaning up the site;

b. Due to a large amount of bonding, in order to ensure that there is enough space for the filling binder to be placed during curing, the contact point should be on the same horizontal plane during bonding, so as to ensure that the force on the contact point of the filling is uniform and tight during crimping;

c. Clean up the floating dust and garbage on the internal parts of the cooling tower to ensure cleanliness. Place the filling blocks in the cooling tower in turn. It is strictly forbidden to squeeze the filling during the process. Ensure that each layer of the filling block is neat and tight, and the filling is tight and seamless with the corner and column;

d. Pay attention to the up and down direction of the assembly block during installation. The top surface of each layer should be laid flat, and the interlayer should be cleaned, and there should be no debris blocking.

e. When installation, maintenance, and other work need to work on the filling, it must be paved with a flat plate, and it is strictly forbidden to step on it directly.

f. In the process of construction, assembly, and installation, it is strictly forbidden to weld above the filling of the cooling tower, and fire prevention measures shall be taken when necessary. After installation, all construction tools and facilities are waiting for acceptance, and the whole filling replacement procedure of the cooling tower is completed.

Advantage of Cooling Tower Filling

a. The raw materials of cooling tower fill are PVC and PP, with good toughness, no white line and aging resistance.

b. By vacuum molding, the volume heat dissipation quality is high.

c. The service life of cooling tower fill is generally more than 10 years.

d. Vacuum pressure forming. The unique fill curve ensures the high efficiency of heat transfer.

e. The bearing capacity of cooling tower fill is large, and the bearing capacity per square meter is more than 3.5kn.

f. Good chemical stability, acid, alkali and organic solvent corrosion resistance.

g. The product has strong hydrophilic property, good film-forming property and easy to conduct the heat of filler.

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Zhejiang Aoshuai Refrigeration Co., Ltd.
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