
Cooling Towers
Cooling towers are essential facilities used in industry and power generation to dissipate waste heat. They serve to cool the cooling water circulating in a circuit by releasing heat into the surrounding air. This waste heat is generated, for example, in power plants where it cannot be fully converted into electrical energy. Cooling towers are particularly important for increasing the efficiency of power plants and minimising the environmental impact of excessive warming of rivers.

Types of Cooling Towers
The development of cooling tower technology over the years has produced various designs, in particular wet and dry cooling towers. Wet cooling towers use evaporative cooling, in which water comes into direct contact with air to remove heat. Dry cooling towers, on the other hand, isolate the cooling water from the air and use heat exchangers to enable heat transfer. These technologies have evolved over time to meet increasing demands for cooling capacity and environmental sustainability. Today, cooling towers are able to dissipate large amounts of heat efficiently and with minimal energy consumption, making them one of the most efficient cooling technologies.
Wet Cooling Towers
Also known as evaporative cooling towers, wet cooling towers use the evaporation effect, in which water comes into direct contact with air. Some of the water evaporates, extracting heat from the remaining water, thereby cooling it. This type of cooling tower is particularly efficient, as evaporation can dissipate a large amount of heat. Wet cooling towers are usually less expensive to build and operate, but they require a continuous supply of water to replace what evaporates.


Dry Cooling Towers
Dry cooling towers work without direct contact between water and air. They use heat exchangers to transfer heat to the ambient air, which means that no water evaporates and thus no water losses occur. These towers are particularly beneficial in regions with water scarcity or in urban areas. However, the cooling capacity is lower compared to wet cooling towers because the cooling is only done by convection and the achievable cooling limit temperature is higher.
Hybrid Cooling Towers
Hybrid cooling towers combine the technologies of wet and dry cooling towers to provide the advantages of both systems. These towers are particularly useful for minimising vapour formation and reducing water consumption. However, they are usually more expensive to purchase and require more space.

Each of these cooling tower types has specific advantages and disadvantages, which must be weighed according to the requirements of the respective application. The choice of the appropriate cooling tower depends on factors such as the available water volume, climatic conditions and specific cooling requirements
E&S Planbau designs and assembles each cooling tower individually and can thus cover a wide range and also very special conditions, for example with regard to noise emissions and weight. Please feel free to contact us for your tailored offer
Construction and Components of Cooling Towers
Cooling towers are complex structures, made up of various materials and components to provide efficient cooling. The design and choice of materials are crucial to the performance and longevity of the towers.
Materials for Cooling Towers
Cooling towers consist of a supporting structure and a casing, which can be made of different materials depending on the requirements. Commonly used materials are:
- Reinforced concrete: Often used for large, on-site cooling towers, especially for natural draft cooling towers. Reinforced concrete provides the necessary stability and resistance to weather conditions.
- Glassfibre Reinforced Plastic (GRP): This material is corrosion resistant, lightweight yet strong, making it ideal for use in aggressive environments. Fibreglass is a cost-effective alternative to steel and concrete and is widely used in modular cooling towers.
- Stainless steel/coated steel: This is the preferred choice for environments with very aggressive or acidic water, as it is corrosion-resistant and durable.
- Wood: In the past, cooling towers were also built with a wooden supporting structure. Today, this is no longer done due to the less effective wood preservatives.
E&S Planbau has numerous references for new construction, particularly for concrete and glassfibre reinforced plastic (GRP). However, the renovation of wooden cooling towers is also part of our daily business. While concrete and steel are often comparatively cost-intensive, a cooling tower with a glass-fibre reinforced plastic structure is currently the absolute price-performance winner. A service life of at least 30 years can be assumed for such a tower.

Main Components of Cooling Towers
Filling Material
Filling materials are the heart of the cooling tower, where the heat transfer exchange between water and air takes place. In open cooling towers, filling materials are in direct contact with the air, while heat exchanger tubes are used in closed towers.
E&S Planbau has its own tools and types of cooling fills, enabling it to offer large quantities of cooling fills at a reasonable price. We offer cooling fills in small cell coolers, with a few cubic metres, up to natural draft cooling towers with over 15,000 m³.


Water Distribution System
The water distribution system consists of PP or PVC pipes, open channels, and nozzles that distribute the water over the heat exchange surface. Even distribution is crucial for efficient heat transfer.
Through our subsidiary Niroplast, we offer complete water distribution systems for use in cooling towers. This means that the water distribution system can be individually adapted to the cooling tower.
More about Water Distribution Systems →Drift Eliminator
These are located above the water distribution system and prevent micro-water droplets from being carried away by the air flow. Drift eliminators reduce water losses.
More about Drift Eliminators →

Fans
Axial or centrifugal fans are used to generate the airflow necessary to assist evaporative cooling. The choice of fan type depends on the specific design requirements. Fans can be used for suction or blowing.
More about Fans →The careful selection of materials and the integration of these main components ensure the efficiency and reliability of cooling towers. This enables effective cooling in various industrial applications.
E&S Planbau has a wide network of suppliers and we can offer and assemble all common types and almost all spare parts in and on the cooling tower. Due to our large sales volume, our prices are often more attractive than if you were to contact the manufacturer directly. Please feel free to contact us for a non-binding offer.
Functionality and Efficiency of Cooling Towers
The functionality and efficiency of cooling towers are crucial to their performance and environmental impact.
How Cooling Towers work
Cooling towers work as giant heat exchangers, transferring heat from the warm cooling water to the cooler ambient air. The process begins with the introduction of hot water into the tower. Inside the tower, the water is either brought into direct contact with the air (wet cooling towers) or through heat exchangers (dry cooling towers). In wet cooling towers, the water is sprayed so that it partially evaporates and thereby removes heat. This evaporation process makes it possible to lower the cooling water temperature even below the ambient temperature down to the wet-bulb temperature, which is achieved by using the latent heat of evaporation.

Increasing the efficiency of Cooling Towers
The efficiency of cooling towers can be improved by various techniques:
Cooling Fill
A greater cooling capacity can be achieved by adding extra layers or using a more powerful cooling fill. We select your cooling system according to your specific requirements and the water quality in order to achieve the best possible cooling performance. We would be happy to check whether performance optimisation or energy savings are possible at your location.
Optimisation of the Machinery
By using energy-efficient fans or by adjusting the blade angle, more power can also be generated. Likewise, the types of fans and the designs of motors and gear boxes have been further developed so that they can be operated more and more efficiently. E&S Planbau has all the usual suppliers in its programme and we always use the latest components with the best efficiency.
Use of Interpretation Tools
The use of interpretation software can help to optimise the operation of cooling towers by identifying the best operating parameters. This means that the above-mentioned measures can first be simulated on the model before they are implemented. Based on these models, we can identify the parameters with the greatest influence and implement the measure with the best possible benefit. This way, you always get the best price-performance ratio from us.
Acoustic Optimisation
The noise emissions from cooling towers have become increasingly important in recent years. Time and again, existing cooling towers have to be optimised in terms of noise. And even with a new build, the requirements for the noise level have become increasingly strict. E&S Planbau can offer all noise control measures for cooling towers in new and existing plants. The portfolio ranges from impact attenuators, acoustic enclosures at or in air inlets and outlets to low-noise fans and motor enclosures.
By implementing these and other measures, cooling towers can increase their efficiency, which leads to a reduction in operating costs and less environmental pollution. Please feel free to contact us for a non-binding offer.
Environmental Impacts through Cooling Towers
Cooling towers can have various environmental impacts, affecting both air and water quality. Here are some of the main environmental impacts associated with cooling towers:
Air Pollution
Cooling towers can contribute to the spread of microorganisms, in particular legionella. These bacteria can multiply in the cooling tower water circuits and be spread through the air, posing a potential health risk to people in the surrounding area. Our engineers are trained to plan and inspect the cooling towers according to the applicable hygiene rules. Please feel free to contact us if you would like a hazard assessment.


Water Pollution
Thermal Pollution
Cooling towers release large amounts of waste heat into the environment. In once-through cooling systems, this heat can be discharged into nearby watercourses, causing a rise in water temperature. This can reduce the oxygen solubility in the water and alter the composition of the aquatic biocoenosis.
Chemicals from Water Treatment
Chemicals such as biocides are often used to control the growth of microorganisms. These can find their way into the environment and impair water quality. A good partner for water treatment is indispensable. We would be happy to put you in touch with a competent company with which we have had many years of good experience.
High Water Consumption
Cooling towers require large amounts of water to work effectively. This can lead to a considerable water consumption, which can be problematic in water-poor regions. The use of efficient drift eliminators is a matter of fact for us.
These environmental impacts make it clear that the operation of cooling towers must be carefully monitored and regulated in order to minimise negative effects on the environment. Cooling tower operators are obliged to take measures to reduce these impacts, for example by using more efficient technologies and complying with environmental regulations. We will be happy to advise you on any questions you may have.
Future Developments and Challanges
The future of cooling tower technology faces a number of developments and challenges that affect both technological innovation and regulatory requirements. These aspects are crucial to increasing efficiency while minimising environmental impact.
Technological Innovations
The integration of artificial intelligence and electronic controls is revolutionising the monitoring and operation of cooling towers. These technologies enable precise control and optimisation of operating parameters, resulting in improved energy efficiency. Automated operation using a frequency converter is increasingly being used to precisely control the required cold water temperature. E&S Planbau has already implemented many cooling towers with a fully automated operation and has gained very good operating experience with it. You can also benefit from this by implementing your new construction directly in an automated way or by converting your existing system to an automated operation.

Recent developments in materials technology, such as the use of advanced construction materials (e.g. GRP), also help to improve the price-performance ratio. GRP is particularly interesting for special lightweight construction requirements, for example on roofs.
The use of innovative assembly technologies is a significant part of our work. For example, in the case of time-critical projects, the pre-assembly and subsequent lifting of entire cooling tower cells is a common method of minimising downtime. Thanks to its individual planning and experience in this field, E&S Planbau is perfectly equipped to successfully implement such projects.

Regulatory Requirements
Cooling towers are subject to a large number of environmental regulations concerning water use, wastewater treatment and pollution prevention. Complying with these regulations is essential to minimise environmental impact and protect public health, particularly with regard to legionella prevention. European and national authorities are setting standards for wastewater disposal and water treatment that operators must comply with. New regulations, such as hyperhalogenation for legionella control, are also being introduced to minimise the risk of waterborne diseases.
The challenge is to integrate these new technologies and regulatory requirements into existing systems without disproportionately increasing operating costs. At the same time, these developments offer the opportunity to increase the efficiency of cooling towers and improve their environmental performance, which is crucial in an increasingly regulated and resource conscious world.
E&S Planbau has many years of experience in all these areas. Please feel free to contact us without obligation if you would like to discuss any of the topics presented above with us. We look forward to hearing from you!
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