New Towers

Series EC Cooling Tower

Series EC Cooling Tower

EvapTech Series EC cooling towers are induced draft, counterflow towers custom designed to meet your requirements for cost, footprint, power consumption and pumphead.  Browse the sections to the right for more information on the important details of a Series EC cooling tower. For even more personal service, especially about how we can meet your specific cooling tower requirements, contact EvapTech at newtowers@evaptech.com.

 

 

Counterflow Tower Cross Section

Counterflow Tower Arrangement

A variety of counterflow tower layouts are available to meet the unique plot requirements of each individual project.  An in-line tower is the standard layout for efficiency reasons, but parallel in-line, back-to-back, and round configurations are also options when the plot plan requires a different approach.  Click on the layouts below for more information, and contact EvapTech at newtowers@evaptech.com for guidance on meeting the challenges of your project layout.  

Back-to-Back Arrangement

When  dictated by site constraints, a back-to-back tower configuration can fit within site limitations not possible with an in-line arrangement. However, reduced thermal efficiency and added cost result from a cooling tower arranged in a back-to-back configuration with both increased fan energy and substantially increased pumping head.

Parallel In-line Arrangement

When  dictated by site constraints that would not allow a long single tower in-line arrangement, why not consider splitting the tower into two or more units arranged in a parallel in-line configuration. Although the overall tower footprint is wider than that made possible by utilizing a back-to-back configuration, consider the advantages:

  • Substantially reduced tower pumping head by splitting the air inlet area between two tower faces
  • Substantially reduced tower cost made possible by a reduced tower height and gained efficiency
  • Reduced fan energy by regaining lost efficiency with two air inlets
  • Reduced installed length by utilizing the area between towers for pump pits, MCC, piping, and access provisions
  • More reliable thermal capacity by cutting the air draw through the falling water in half
  • Easier maintenance and staged operation by providing the facility with easily isolated towers

     

Round Configuration
 

When site restrictions dictate truly thinking outside the counterflow "box", a round configuration may provide the right solution for your challenging project site.

In-Line Arrangement

The most efficient and cost effective approach to tower design. Constructing the tower in a linear fashion provides the arrangement with the least parasitic power consumption, including reduced fan energy consumption and lowest pumping head.  By providing efficient entering air access, the tower height  and cost is minimized. 

Counterflow Tower Structure

The vast majority of new counterflow towers are constructed of fire retardant fiberglass because of its high strength and fire/corrosion resistive properties.  EvapTech's Newton, IL facility manufactures these pultruded parts, allowing  superior quality and lead time control.  Learn more about EvapTech manufacturing here.  Treated wood and concrete structures are also available materials.  Click on the materials below for more information and contact EvapTech for guidance on the best material for your particular application at newtowers@evaptech.com.

Series EC: Pultruded Fiberglass

The standard of the industry and the material demanded by most new cooling tower purchasers. But not all FRP frames are created equal, in design or material quality.

Pultruded FRP 's strength is unidirectional and our superior designs utilize line-of-action force distribution of wind and seismic loads.

EvapTech is the only cooling tower company to manufacture our own pultrusions in our state of the art factory in Newton, Illinois. This enables EvapTech to design component strength properties to match the requirements of our frame layout, all of which is verified by rigorous component physical testing activities.

Customers should demand quality fiberglass components that are made in the U.S.A.

 

 

Series ECW:  Douglas Fir & Redwood

Although rare, timber framed cooling towers remain available for use where the absolute lowest cost outweighs the longevity of fiberglass framed cooling towers. Wood framed towers are available in treated Douglas Fir and various grades of redwood.

EvapTech maximizes the potential of timber framed towers by utilizing FRP for critical framing components including structural connectors and distribution header supports.

Optional upgrades create hybrid towers to enhance safety and longevity with fiberglass upgrades of critical fan deck and stairway components.

Series ECC: Concrete Counterflow

Constructed for permanent installations from large utility power generation to  data centers interested in resistance to wind and seismic events, the ECC series counterflow cooling towers constructed of precast concrete offer limitless possibilities.

EvapTech was selected as a preferred cooling tower vendor for the largest mechanical draft cooling towers constructed in modern history.  We can provide a custom design to meet your needs, no matter how large or how small.

EvapTech has the skills to evaluate and modify your existing concrete tower into a model of modern efficiency and structural integrity.

Counterflow Tower Fill

EvapTech provides a variety of counterflow fills to meet all customer's individual needs.  Selecting the correct fill is a balancing act of thermal efficiency and fouling resistance, learn more here.  Click on the fills listed below for more information and contact EvapTech for guidance on selecting the correct fill for your application at newtowers@evaptech.com .


TechClean, TechClean 214 & TechClean 312

The TechClean Family of vertically offset flute fill products were optimized for highly efficient thermal performance with a substantially reduced propensity to foul. TechClean's higher allowable TSS and microbial limits allow operation with higher concentration multiples and a corresponding blowdown reduction to substantially reduce water consumption. In stark contrast to competitive high fouling cross corrugated designs, Evaptech's standard TechClean fill product offers exceptional thermal performance along with trouble free operation.

TechClean Flyer

TechClean 214 & 312 Flyer

VertiClean

VertiClean fill was developed to specifically address those applications where high circulating water contaminant levels would lead to unacceptable fouling potential in either cross corrugated or vertically offset flute fills. VertiClean has vertically oriented flutes throughout its air travel to assure the most effective fouling resistance while its textured sheets retain reasonable thermal efficiency and low pump head when compared to splash fill alternatives.

VertiClean Flyer
EvaPak

On the rare occasion that plot plan is critical and very clean water conditions exist, EvaPak fill may be the appropriate fill choice. Cross corrugated in design and tight spaced to maximize surface area EvaPak is the highest efficiency fill product available per unit volume; but heat transfer comes at the expense of high pressure drop and parasitic power consumption.

EvaPak Flyer
SplashPack

SplashPack open mesh fill is an alternative to traditional splash fill products when TSS and other contaminants eliminate the potential for using film fills. With a compact pack arrangement, SplashPack also reduces or eliminates the pump head penalty of traditional splash fills and its polypropylene construction represents a competitive alternative for high temperature process applications.

SplashPack Flyer
Opti-Grid

When fibrous or large solids are anticipated in the circulating water, wide spaced splash fill products may be the only acceptable arrangement. Opti-Bar grids have large square openings and are typically arranged on 8" vertical centers to withstand even the most difficult water conditions. In addition, polypropylene construction can withstand harsh chemicals and high temperature applications.

Counterflow Tower Drift Eliminators

EvapTech's DriAir80 drift eliminators represent the BACT (Best Available Control Technology) in cooling tower drift eliminators, limiting drift rates to as low as 0.0005%.  Click on the eliminator models below for more information on EvapTech's drift eliminators, or contact newtowers@evaptech.com.


DriAir80

Drift rates as low as 0.0005% can be achieved with this state of the art drift eliminator. DriAir 80 eliminators have tight spaced surfaces to achieve exceptional drift performance and highly efficient air paths to minimize pressure losses.

DriAir 150

Drift rates as low as 0.002% can be achieved with this wide spaced cellular drift eliminator for those applications with less restrictive drift requirements or when there is the potential for fouling of tighter spaced eliminators.

Counterflow Tower Water Distribution

Evenly distributed water is key to a cooling tower's thermal performance.  EvapTech engineers the distribution system to meet the requirements of each application for maximum thermal performance with minimized operating pump head.  Click on the links below and contact EvapTech at newtowers@evaptech.com for more information on the water distribution systems and custom options.

EvapJet II Spray Nozzle

The EvapTech water distribution system's foundations are based upon the patented EvapJet II spray nozzle providing a unique approach to counterflow water distribution with its filled cone spray pattern. Unlike typical hollow cone distribution systems that rely upon splash plates to create crossover between nozzles, the EvapJet II system's dynamic flow pattern based upon advanced fluidic motion creates complete coverage beneath each nozzle.  Combined with its high quality ABS construction and low pressure drop, the EvapJet II nozzle represents the most advanced nozzle technology in the industry.

 
Distribution System

EvapTech utilizes a central header location, dual laterals per bay, and side mounted nozzles to assure even coverage is provided and maintained to all nozzles throughout its operating life. Course threaded nozzle couplings assure water deposits will not interfere with the removal of nozzles months or even years down the road and each header and lateral is fitted with a standard cleanout connection. Support of laterals is provided by the tower structure and bolted to these members adjacent to the header to assure they remain engaged, not cantilevered on top of stamped metal brackets or supported from flimsy  plumbers tape.

Optional Scope Upgrades

EvapTech would be pleased to provide an extended scope of work for those customers seeking our involvement outside the boundaries of the cooling tower. The extended scope often includes FRP risers, riser sway bracing, expansion joints, isolation valves, bypass connections, and bypass supports. Please see the Upgrades section for additional information.

Cooling Tower Mechanical Equipment

The ability of a mechanical draft cooling tower to efficiently and reliably transfer waste heat is entirely dependent upon the reliability of the mechanical equipment package. Therefore EvapTech provides fans, gearboxes, driveshafts and motors from a select group of equipment suppliers specializing in the supply of top quality mechanical components to assure exceptional reliability of their thermal performance.  Read about EvapTech's mechanical equipment support system below and contact EvapTech at newtowers@evaptech.com for more information on mechanical equipment.

 


Mechanical Equipment Support

Equally as important as the mechanical component selection,  equipment support design utilizing a properly sized round torque tube to effectively restrain rotational dynamic loads is essential to assuring the longevity of these costly and critical tower components. The devil is in the details and the design details of support bracing and its attachment to the tower structure will determine if the support effectively restrains rotational and vibration loads. 

The EvapTech Edge:

Support Sizing - EvapTech properly sizes the torque tube for the fan diameter and applied horsepower - Flexing of undersized supports is a common cause of reduced gear, motor, and driveshaft operating life.

Support Design - Equipment mounting plates braced against movement in all directions - simple bent plates welded to the tube do not provide the rigidity required by the driveshaft and will ultimately lead to failure of the shaft and gear/motor bearings.

Positive Positioning - Jack bolts are provided for ease of alignment and assure properly secured motor and gear placement - do not rely upon a simple spiral pin to maintain alignment during numerous start/stop cycles.

Structural Attachment - Torque tube loading must be applied directly to the tower's vertical column framing  with steel plates bolted directly from the support to vertical framing members - never allow horizontal framing members, plastic gromments, or hollow leg fan deck panels sandwiched between the support and tower framing to be used to transmit loads.

Vibration Bracing - Diagonal bracing immediately below the supports transmits and spreads loads into the  surrounding structure - Both pultruded fiberglass and timber are unidirectional strength materials, anticipating that vibration loading will be adequately restrained by moment loading of these members will result in a substantially reduced life cycle of mechanical components.

Counterflow Tower Upgrades

In order to meet our clients' custom needs and requirements, EvapTech offers a wide variety of tower upgrades designed to improve safety, matinenance access and aesthetics.  Click on the options below to learn more and contact EvapTech at newtowers@evaptech.com for more information.

SafeLift™ Equipment Handling Packages

Whether you want to lift tools, oil, or mechanical equipment components from grade to the fan deck, EvapTech has an option available to meet the need safely.

SafeRoute™ Cable Tray Supports

Eliminate trip hazards and fan deck clutter with EvapTech supplied and installed externally mounted cable tray supports.

Stairway

Retained landings and individual stair treads to avoid potentially hazardous winter grip conditions are just two of the features the separate EvapTech's stairway design from the rest.

Ladder

Standard FRP ladders in safety yellow enhance safety for the life of the product by assuring long term durability and improved grip over less costly HDG steel. Options are available for intermediate landings and landings at the collection basin level to improve worker safety and save project costs.

Plenum Area Walkways

With this upgrade access to the mechanical equipment is quick, convenient, and without the need to remove the fan cylinder access door. When installed in combination with the EvapPad™ gear access platform this system provides exceptional mechanical access for routine inspection and maintenance.

Removable Aluminum Catwalk

Providing safe, convenient, and portable fan deck access to the mechanical equipment. The removable catwalk safely transports workers to either the OSHA tie-off location at the gear or to the optional EvapPad™ access platform to perform routine inspection and maintenance of mechanical components.

EvapPad™ Access Platform

Access via a removable aluminum catwalk or an FRP walkway, the EvapPad access platform provides unsurpassed access to the heart of the most critical mechanical draft cooling tower component, its gear reduction unit.

Architectural Casing

In standard gray and custom colors, EvapTech’s architectural casing options not only enhance the appearance of your cooling tower. They also upgrade from standard 12oz corrugated fiberglass to 32oz pultruded fiberglass for drastically improved longevity and leak resistance. (Note that an enclosed stairway and casing extended to top of perimeter handrail option are also shown).


WST™ Cellular Inlet Louvers

EvapTech’s Water and Sight Tight cellular inlet louvers offer exceptional water containment while blocking sunlight from reaching the circulating water to help reduced chemical consumption. In addition to being easily removable without tools, WST louvers can be fitted with framed access doors to ease routine inspection. Commonly provided on HVAC projects, WST louvers offer owners a highly desirable clean aesthetic appearance.

Grade Piping, Valves, Inlet Risers, Expansion Joints, Sway Braces, and Supports

EvapTech designers can properly design and supply above grade plant piping to fit your project needs in state of the art fiberglass construction. Consider single point connection of your next cooling tower.

Grade header, risers, riser swaybraces, isolation valves, and expansion joint options shown.

Wide Spaced Louvers

Louvers constructed of wide spaced FRP panels and supported from either timber or FRP members is a common option to control water splashout and reducde basin footprint. Insist upon reinforced leading and trailing edges when gthe potential for exposure to freezing is a concern.

Collection Basin Bypass Piping

Winter operation requires direct bypass into the collection basin? Allow EvapTech to design and install the correct piping to interface with your system and the cooling tower structure.

Special Basin Requirements

Extending onto an existing basin? Steeply sloped pump pit transition? Integral mud trench? EvapTech will design the cooling tower structure to interface with your special needs to reduce project basin costs.

Distribution Basin Covers & Walkways

Maintenance personnel safety is of paramount importance. Why not reduce their exposure to slippery conditions and at the same time reduce chemical consumption used to control algae by installing raised distribution basin covers and full length access walkways.

Enclosed Stairway

Take safety to an elevated level by upgrading to an enclosed stairway. For those in freezing climates this can be a critical maintenance upgrade.