Closed-circuit cooling tower, also called dry cooling tower, involves no contact between the flowing air and the water being cooled. This kind of closed cooling tower has two separate fluid circuits, one in which the water is recirculated on the outside of the second circuit, which is the tube bundle through which the hot water is flowing. The air drawn through the water provides evaporative cooling similar to the open type cooling tower, except that the cooled water never contact with the air directly. Closed-circuit cooling towers require much more power to achieve the same cooling effiency as an open circuit cooling tower.
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Counter-flow Closed Cooling Towers
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Different Types of Closed Circuit Cooling Towers
Evaporative closed-circuit coolers
This type of closed-circuit coolers eliminates the need for a heat exchanger between the process loop and the heat rejection equipment. Unlike a cooling tower, where process water is used as the energy transfer medium and is open to the atmosphere, the coil inside a closed-circuit cooler isolates the process fluid.
Eco/Hybrid Closed Circuit coolers
Hybrid coolers combine dry and evaporative cooling to maximize energy efficiency while simultaneously reducing water consumption. These units provide heat rejection in dry mode until the load exceeds dry rejection capacity. At this switch-over point, the unit enters evaporative mode to increase cooling capacity. Operating in wet mode only when needed can dramatically reduce annual water consumption, sewer expense, and eliminate plume while in dry mode.
Adiabatic coolers
Coolers function similarly to dry cooling systems, but with the addition of pre-cooling pads. Water runs over porous media while air is drawn through the pads, lowering the dry bulb temperature of the incoming air. The influence of reduced dry bulb temperatures at the coil provides greater heat rejection. As a result, adiabatic systems are most effective in hot, dry environments, and use up to 80% less water than traditional evaporative units.
Dry coolers
Dry coolers are best specified where water conservation and reduced maintenance are the key considerations. Since dry coolers do not utilize any water or evaporative cooling whatsoever, dry coolers eliminate water treatment, all plume and Legionella concerns.
No contamination of the primary circuit. Many civil and industrial processes require to maintain the process fluid uncontaminated by the external environment: for instance, this is true for most of food production processes. Closed-circuit cooling towers, grant this need: in effect, coils separate process fluid from ambient air drawn in by the fans, keeping it clean and uncontaminated in a closed loop.
Reduction of freezing risk. Since the process water circulates in heat exchange coils and never gets in contact with air, glycole can be added to it to lower the fluid freezing point. This can be a big advantage especially in cold countries (in e.g. Scandinavian countries, Russia, Canada, …) where temperature frequently goes below zero.
Longevity. Less wear and tear on equipment due to cleaner water circulation.
Contamination prevention
The sealed system prevents contaminants from entering the cooling water.
Efficiency
Reduced risk of scaling and fouling, maintaining efficient heat transfer.
A simpler system
A closed-circuit cooling tower can be an alternative to a system composed by an open circuit cooling tower and a heat exchanger.
Application Occasions Of Closed Cooling Tower
1. Induction heating and metal smelting equipment, such as high and medium frequency quenching equipment, medium frequency power supply and electric furnace, induction heat burning, insulation furnace, etc.;
2. Cooling of circulating water of various reactors and condensers in the chemical industry;
3. Cooling of industrial solutions. Such as quenching liquid, electroplating liquid, etc.;
4. Cooling of large molds such as metal die-casting molds and injection molds. The most widely used are air conditioning cooling, refrigeration, plastic chemical industry;
5. Cooling of large motors, diesel engines, rectifier equipment, welding equipment, hydraulic stations and continuous casting equipment;
Sometimes, an open cooling tower is paired with a heat exchanger to capture some of the benefits of closed loop cooling. Choosing closed circuit cooling towers over this open tower/heat exchanger combination may still be a better choice for the following reasons:
Total cost: Addition of a heat exchanger (pump, piping, etc.) to the open tower loop brings the initial cost much closer to that of the closed circuit tower system
Single piece of equipment: Compact design of the closed circuit tower conserves space in a self-contained package, compared to multiple locations for the tower/heat exchanger arrangement
Maintenance: Narrow spacing in the heat exchanger (e.g. plate and frame) may trap solids introduced by the open tower, requiring frequent, time consuming cleaning to assure optimum performance
Dry operation: Open tower/heat exchanger system cannot be run dry in the winter
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