Film Fills
Film Fills
Film fills allow the water to form thin flowing sheets to expose as much water surface area as possible to the interacting flow. They are the most efficient filling media available for cooling towers. The usage of film fills in both counter flow and cross flow cooling towers allows relatively smaller sized towers to cool an equivalent amount of water compared to cooling towers using splash fills. These fill media are manufactured meeting CTI standards.
Film fills are selected for direct replacement, performance enhancement & water condition compatibility. Each fill has performance characteristics that allow selections to be made for various heat loads, flow rates, water quality & horse power combinations.
Thermal Care Engineers Offers Following Type Of Fill Media.
Thermal Care - TC-12 is designed for application in the HVAC Industry as well as other industries were the quality of makeup water is one with TSS.
Cooling towers using TC-12 fills must have little to no contamination from oil, grease or process dust.TC-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 Thermal Car 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 Thermal Care TC-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
| Characteristics | TC-12 |
|---|---|
| Primary Cooling Towers Application | Counterflow |
| Flute height | 12 mm |
| MOC | Rigid PVC (Virgin and reprocessed) |
| Longitudinal pitch | 37.5 mm |
| UV Stabilization | White - Titanium Dioxide Black - Carbon Black |
| Spiral angle | 28o |
| Std. Sheet size L x W |
600mm x 300mm |
| Recommended Max Fill Sheet size L x W | 1200 mm x 600 mm |
| Surface area per unit volume | 258 m2/m3 |
| Standard Weight | 26.5 Kgs/m3 |
| Maximum continuous Operating temp. | 55 oC |
| Minimum Fill Sheet Finished Thickness | 0.175 mm |
| Standard Followed for Material properties | CTI STD-136 |
Thermal Care TC-19 is the workhorse high efficiency film fill that is designed for cooling towers used in power plants and process industries.
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.
TC-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 Thermal Care 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 Thermal Care TC-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
| Characteristics | TC-19 |
|---|---|
| Primary Cooling Towers Application | Counterflow |
| Flute height | 19 mm |
| MOC | Virgin rigid PVC |
| Longitudinal pitch | 50 mm |
| UV Stabilization | White - Titanium Dioxide Black - Carbon Black |
| Spiral angle | 28o |
| Std. Sheet size L x W |
1200mm x 600mm |
| Recommended Max Fill Sheet size L x W | 1800 mm x 600 mm |
| Surface area per unit volume | 158 m2/m3 |
| Standard Weight | 27 Kgs/m3 |
| Maximum continuous Operating temp. | 55 0C |
| Standard Fill Sheet Finished Thickness (Available in 0.23mm thickness Other thickness on request) |
0.25 mm |
| Standard Followed for Material properties | CTI STD-136 |
While Thermal Care cross-corrugated PVC fill media have been proven to be the most efficient fill media as far as thermal design and strength factors are concerned.
Thermal Care offers a number of alternatives when water is expected to be of poorer quality.For water with TSS < 200, Thermal Care offers vertical fluted fills that offer the associated superior thermal performance but are not as prone to clogging as the cross corrugated film fill.
Features and Advantages
- The lack of intersection points of alternate sheets ensures that there is no particular point on the fill where suspended solids could accumulate or bio growth prosper.
- The vertical structure of the flutes implies large opening between sheets allowing higher water velocities which help clogging material pass through the fill structure.
- Weight gain on the vertical fluted fill (as a result of depositions) is lower than those observed in the cross-corrugated film fill over an extended period of time.
- The vertical fluted fill can be used in conjunction with a small layer of cross corrugated fill at the top giving a mixed fill configuration. Fill choking usually occurs bottom to top. The mixed fill configuration offers effective water distribution from the top cross corrugated layer while keeping the bottom portion of the fill assembly almost clog free.
- Allows higher cycles of concentration for the tower water supply.
Technical Specifications
| Characteristics | TC-LC19 |
|---|---|
| Primary Cooling Towers Application | Counterflow |
| Flute height | 19 mm |
| MOC | Virgin rigid PVC |
| Longitudinal pitch | 50 mm |
| UV Stabilization | White - Titanium Dioxide Black - Carbon Black |
| Spiral angle | 00 |
| Std. Sheet size L x W |
1200 mm x 600mm |
| Recommended (for ease of module making) Max Fill Sheet size L x W |
1800 mm x 600 mm |
| Surface area per unit volume | 146 m2/m3 |
| Standard Weight | 35 Kgs/m3 |
| Maximum continuous Operating temp. | 55 0C |
| Minimum Fill Sheet Finished Thickness | 0.3 mm |
| Standard Followed for Material properties | CTI STD-136 |
Advantages
- More efficient heat transfer as it generates a bigger surface area.
- Minimum resistance to air flow.
- Reduced fill height & greater cooling capacity which results in low power consumption.
- Long lasting in the good quality of water.
- Self-supporting, high strength & self-extinguishing characteristics.
- Ability to fold the edges of the sheets providing strong edges.
- Allows the structural designer to reduce number of support beam thus inturn reduces the pressure drop and cost of construction.