The heat dissipation performance of cooling tower fillers is affected by many factors. The following is a detailed introduction:

1. Filler material

Thermal conductivity: Different materials have different thermal conductivity. The higher the thermal conductivity, the faster and easier it is to conduct heat inside the filler, which helps to transfer heat from cooling water to the filler surface and then to the air. For example, the thermal conductivity of metal materials (such as stainless steel, aluminum alloy, etc.) is usually much higher than that of plastic materials. In theory, the basic heat dissipation performance of metal fillers will be better, but metal fillers may be limited in practical applications due to cost, corrosion resistance and other considerations. Commonly used PVC (polyvinyl chloride) fillers have relatively low thermal conductivity, but they are also widely used due to other advantages (such as good corrosion resistance and low cost), but they are slightly slower than metal materials in the heat conduction link.

Specific heat capacity: Specific heat capacity determines the amount of heat absorbed by a unit mass of material when the unit temperature rises. Materials with smaller specific heat capacity rise relatively quickly after absorbing the heat of cooling water, and can form a temperature difference with the surrounding air more quickly to promote heat exchange. For example, the specific heat capacity of PP (polypropylene) material is smaller than that of some polymer composite materials. Under the same heat absorption, the temperature change is more obvious, which is conducive to the transfer of heat to the air, thus affecting the heat dissipation performance.

2. Filler shape

Specific surface area: The larger the specific surface area of ​​the filler, the larger the contact area with cooling water and air, and the more opportunities for heat exchange. For example, compared with flat fillers, corrugated fillers greatly increase the specific surface area by folding, curling, etc. Taking the common sinusoidal corrugated filler as an example, water will form a thin liquid film at the grooves and protrusions of the corrugations, and the air can fully contact the water film on these complex surfaces, thereby achieving efficient heat exchange and improving heat dissipation performance.

Porosity: The porosity of the filler affects the flow state and residence time of air and water in the filler. The appropriate porosity can ensure that air and water are evenly distributed and have sufficient contact time for heat exchange. If the porosity is too large, water and air can pass through quickly, the contact is not sufficient, and the heat exchange is not thorough; if the porosity is too small, the resistance will increase, the flow of air and water will be limited, which is also not conducive to heat exchange. For example, honeycomb fillers have a regular hexagonal pore structure. By reasonably designing the pore size and wall thickness, a good porosity can be achieved, allowing air and water to pass smoothly while fully exchanging heat, thereby improving the heat dissipation effect.

3. Filler size

Thickness: The thickness of the filler has a certain effect on the heat dissipation performance. During the heat transfer process, the heat conduction distance of thinner fillers is short, and the heat can be transferred to the surface and exchanged with the air faster, but too thin may lead to insufficient structural strength, unable to maintain a good shape and guide water and air. On the contrary, although the structure of too thick fillers is relatively stable, the heat conduction path becomes longer, and the heat exchange efficiency may be reduced. For example, in some small cooling towers, fillers with moderate thickness (such as 20-50 mm) are selected, which can not only ensure a certain strength, but also take into account good heat dissipation performance.

Unit size: For packing with unit structure such as honeycomb and grid, the size of the unit affects the distribution of air and water. Smaller unit size can make air and water more finely dispersed, increase the uniformity and sufficiency of contact, but too small unit size may increase water flow resistance and air flow resistance. It is necessary to comprehensively consider the specific operating parameters of the cooling tower (such as water pump head, fan power, etc.) to determine the appropriate unit size to optimize the heat dissipation performance.

4. Installation method

Arrangement and layout: The arrangement of the packing in the cooling tower is very important. The neat and reasonable arrangement helps the air and water to pass through the packing layer evenly and achieve uniform heat exchange. For example, the multi-layer staggered packing method allows water to contact with air at different levels many times during the falling process, avoiding the "dead corner" area where local heat exchange is insufficient, thereby improving the overall heat dissipation efficiency. If the packing is installed unevenly or there are blockages, vacancies, etc., the flow of air and water will be disordered, seriously affecting the heat dissipation performance.

Coordination with other components: The coordination between the packing and the air inlet, outlet, water distribution system and water collector of the cooling tower also affects the heat dissipation. For example, the water distribution system should be able to spray cooling water evenly on the packing. If the water distribution is uneven, there will be too much water in some areas and too little water in other areas, which will lead to uneven heat exchange in various parts of the packing and affect the overall heat dissipation. For another example, if the water collector cannot effectively intercept the water droplets brought out by the air, the water loss of the cooling tower will increase, which will affect the flow rate and heat exchange effect of the circulating water, and indirectly affect the heat dissipation performance of the packing.

V. Operating conditions

Water temperature difference: The temperature difference of the cooling water entering and flowing out of the packing has a direct impact on the heat dissipation performance. The larger the water temperature difference, the more heat the packing takes away in this process, and the better the heat dissipation effect, but the water temperature difference is also limited by the heat load of the equipment and the overall design and operation capacity of the cooling tower. For example, the cooling tower corresponding to the equipment with large heat load in industrial production has a high inlet water temperature. If the packing can effectively reduce the outlet water temperature and produce a large water temperature difference, it means that its heat dissipation performance is good. Otherwise, it may be necessary to check whether there are problems with the packing or other related components that affect the heat dissipation.

Air flow and flow rate: Sufficient air flow and appropriate flow rate are important external conditions to ensure the heat dissipation of the packing. Larger air flow means more cold air participates in heat exchange and can take away more heat; and moderate flow rate can ensure that air and water have sufficient contact time in the filler. Factors such as the fan power and shutter opening of the cooling tower will affect the air flow and flow rate. When the fan fails or the shutter is improperly adjusted, resulting in insufficient air flow and unreasonable flow rate, the filler itself cannot fully exert its heat dissipation effect even if it has good performance.

6. Use environment

Ambient temperature and humidity: In a high temperature environment, the temperature difference between the filler and the outside air becomes relatively small, and the heat dissipation difficulty increases. At this time, the heat dissipation performance of the filler is required to be higher, and it is required to be able to exchange heat as efficiently as possible under unfavorable temperature conditions. A high humidity environment will affect the evaporation rate of water. Since part of the heat dissipation of the cooling tower depends on the absorption of heat by water evaporation, the evaporation amount decreases when the humidity is high, and the filler needs to strengthen the conduction and convection heat exchange between air and water to compensate for the weakening of the evaporative cooling effect. Therefore, the ambient temperature and humidity have a restrictive or promoting effect on the heat dissipation performance of the filler.

Corrosive substances: If there are corrosive gases (such as acidic and alkaline gases in chemical production areas) or liquid droplets in the environment where the cooling tower is located, if the filler material is not corrosion-resistant, it will gradually be corroded, the surface structure will be destroyed, the specific surface area will be reduced, the pores will be blocked, etc., which will seriously affect its heat dissipation performance. For example, ordinary plastic fillers may experience surface aging, brittleness, pore deformation, etc. in an environment with high concentrations of acidic gases for a long time, reducing the efficiency of heat exchange.

In summary, the heat dissipation performance of cooling tower fillers is the result of the interaction of multiple factors. In the design, selection and daily operation and maintenance of cooling towers, these factors need to be comprehensively considered to ensure that the fillers can achieve the best heat dissipation effect.