Modular cooling tower SGSL

hybridcounter-currentfor the food and beverage industry

Overview
The SGSL series hybrid cooling tower is an industrial circulating water cooling solution combining an air (dry) radiator and an evaporative (wet) cooling coil in an L‑type layout. It is designed to reduce water consumption, abate visible plume, and maintain stable outlet water temperature for heavy industries (food & beverage, pharmaceutical, steel, chemical, electronics, silicon, coal chemical, nonferrous metals).

Cooling challenges addressed

• High makeup water consumption (approx. 1.5%–1.8% of circulating water) and associated wastewater treatment costs.
• Persistent winter plume (white fog) causing environmental and safety issues.
• Need for retrofit solutions to reduce water use while ensuring process cooling requirements.

1. Hybrid cooling tower — Structure and operation
The unit integrates a finned‑tube air radiator (dry section) mounted vertically outside the tower and a smooth‑tube evaporative coil (wet section) arranged horizontally inside. Water flows in series through the dry then wet sections; airflow is arranged in parallel. Seasonal operation is automated via PLC/DCS to modulate louvers and fan speeds.

Function

• Water saving: Automatic seasonal modes (Summer/Winter and transitional) adjust louver openness to maximize evaporative cooling in summer and maximize dry cooling in winter, minimizing evaporation.
• Plume abatement: Mixing dry, heated air from the dry section with saturated wet air lowers discharged moisture content and prevents the exhaust from crossing the saturation line, reducing visible plume year‑round.
• Control: PLC/DCS control of louvers, fan frequency and spray pumps; optional cloud connectivity for remote monitoring and predictive maintenance.

Main features

• Combined air and evaporative cooling to stabilize outlet temperature while minimizing water use and plume.
• Patented L‑type layout (dry vertical outside, wet horizontal inside) for efficient water‑side series flow.
• Low thermal resistance: slotted fins and close fin‑to‑tube fit for sustained heat transfer performance.
• Optimized flow path with double‑flow counter cross flow to enhance heat transfer coefficient.
• Reduced fan power: lower wind resistance yields ~30% less fan power vs. comparable demisting water‑saving towers.
• High water‑saving capability: expandable dry tube bundles and additional fans can enable up to ~85% water savings in optimal configurations.
• Year‑round fog elimination through controlled mixing of dry and saturated air streams.
• Modular design and removable tube boxes for simplified maintenance.

2. V Type dry cooling tower
V Type dry cooler can operate independently or be integrated with existing wet towers for retrofit projects. It comprises a finned‑tube bundle, circulating water piping and fan groups; arranged for staged operation across seasons (dry‑only in winter, combined in spring/autumn, wet‑dominant in summer).

Main features of V Type

• Modular, self‑supporting structure for simplified installation.
• Horizontal tube bundle and removable cover plate tube box for easy internal cleaning and maintenance.
• High annual water savings (typical ~60%).
• Antifreeze design enabling safe winter operation without blinds.
• Flexible layout options (including overhead installation for space constraints).
• Suitable for retrofit water‑saving conversions.

3. Mist spray dry cooling tower
System composed of stainless‑steel tube radiator, louvers, circulation system, expansion tank, spray cooling system and fan group. Dry radiator sits vertically outside the tower; intermittent spray on the radiator surface is applied only during short high‑temperature periods to assist cooling.

Main features of Mist Spray Dry Cooling Tower

• Very low water consumption: spray used intermittently in high ambient temperatures; annual water saving >95% in typical operation.
• Simplified maintenance—no continuous spray water quality management required.
• Closed, low‑lift circulation design reduces operating cost of the circulating water system.
• Double reverse cross‑flow process increases total heat transfer coefficient and reduces required heat transfer area by ~20%.
• Compact back‑to‑back arrangement reduces hot‑air recirculation and footprint.
• Suitable for high inlet circulating water temperatures (e.g., >38°C).

Applications and typical cases

• Food & beverage, pharmaceutical, steel, chemical, electronics, monocrystalline silicon, coal chemical and nonferrous metal plants.
• Examples include monocrystalline silicon production sites, coal chemical projects with V Type separation systems, and installations achieving >95% annual water‑saving with mechanical ventilation dry coolers.

Technical specifications

• Product series: SGSL series hybrid cooling tower.
• Operating modes: Summer (wet‑dominant), Winter (dry‑dominant), Spring/Autumn (intermediate with automated louver control).
• Layout: L‑type — dry section vertical outside, wet section horizontal inside; water flows dry→wet.
• Water saving: up to ~85% (hybrid), V Type ~60% annual, Mist Spray Dry >95% annual in typical conditions.
• Fan power: approx. 30% lower vs. comparable water‑saving demisting towers.
• Heat transfer enhancements: slotted fins, close fin‑to‑tube fit, double‑flow counter cross flow.
• Control: PLC/DCS automation; optional cloud platform for remote monitoring and predictive maintenance.
• Maintenance: modular design and removable tube boxes; antifreeze options for V Type.