1. Introducing AQUAFAN+
Hydro-Powered Cooling Tower Technology

2. AQUAFAN+ Turbine Powered Cooling Tower with Backup Motor

3. Main Characteristics – AQUAFAN+
Uses system residue pressure of the cooling water to drive the fan via special design turbine.
Makes sure these residue pressures built-into system design as “engineering cushions” are put to use, no energy goes to waste
Forced Draft Cooling Tower Principle:
Moving water and air are in contact in the tower to allow cooling through evaporation of a small %-age of the water.
The tower infill increases retention time of water in the tower to facilitate the evaporation. Electric pumps and fan motors are required in conventional systems.

4. Key data / Power saving
Cell modules of 3.6 meter (12’) with 2.4 meter fans
Rotation generated by turbine up to RPM ( t-RPM [turbine RPM] depending on water pressure available)
Total rotation required up to 400 RPM
Typical total fan shaft power required up to 7.5 kW
“Safe” system design leaves up to 0.5b residue pressure at top of cooling tower
250 m3 water over 12’ cell
Water energy  3.3 kW
Turbine efficiency = 50%  1.65 kW turbine contribution to system
On total requirement of 6.5 kW  >20% energy saving

5. Principles of Operation
Residue water pressure from system pump gives basic rotation to the fan
Water pressure will vary over time (between turn around moments)
Electromotor brings up fan RPM to required level
Spin from pressure relieves the motor current demand and saves energy.

6. Synergy effect in Combination EQOBRUSH on condenser / HE cleaning
Condensers and heat exchangers co-operating with cooling towers are designed on bar on pressure loss.
Fouled units generate a pressure loss of up to 1 bar. System needs to be able to overcome this.
In systems with fouling-free Condensers / HE’s (due to EQOBRUSH on-line brush cleaning system) additional residue pressure is available. Result: less energy consumption in the cooling tower fan motor.

7. Engineering aspects AQUAFAN

8. Modular Systems
Flexible in capacity and construction by a applying a modular system.
Extension of existing cooling towers is possible by simply adding modules.
Cell sizes:
4 ft (prefab): up to 30 m3/hour
8 ft: up to 150 m3/hour
10 ft: up to 200 m3/hour
12 ft: up to 260 m3/hour
No back-up units required for fail safe operations, Reduce system footprint

9. Construction Information
Cooling Tower part
Material
Turbine
Nylon and Stainless Steel
Fan
ABS
Structural Parts
Pultruted FRP
Cladding
FRP
Fasteners
Stainless Steel 304/316
Piping
PVC
Drift eliminator
Infill
PVC or ABS
Motor Support
Motor
IP56

10. Structure All FRP with Stainless Steel Fasteners
FRP meets CTI 137 standard with UV protection and 20+ yrs lifetime. Colors on demand
Basins optional in FRP
Components can be hand carried for easy assembly on site

11. Architecture Friendly
Drift eliminator is placed above fan stack: no visible fan cones
The box-shaped the structure is easy to fit into architecture for buildings
Possible variations in cover (= drift eliminator) of the installation offers a pleasant sight when viewed from above

12. Construction Turbine Light weight non corrosive materials only:
Aluminum Turbine House
Stainless steel Turbine Ring and Hub Plate
ABS / FRP / Alu fan
PA6 molded turbine scoops and nozzles
All parts can be assembled with simple wrench key
On site repairs within 15 minutes and with 1-cell / lane shut down
No vibration switches needed (total weight of 12 kg all centered in hub)
(Plays in Power Point Show)

13. Water Distribution system
Add-on for critical selections
FRP collector dome guides water over low pressure spray nozzle system
Guarantee optimal distribution over CT surface
Dome design variable to water volume and cell size

14. Variables in turbine control
Water pressure / volume
Nozzle size
Number of blades
Angle of blades
All variables extensively tested and documented for selection purposes.

15. Selection Calculation Approach
Required exchange surface
Enthalpy balance  Optimal L/G ratio
Pressure Losses over different stages of Tower
Check fan diagram for required RPM at air movement level
Select pump pressure and nozzle configuration at given water volume

16. AQUAFAN+ Variation Hybrid with motor backup
For critical water cooling jobs (low approach) and maximum flexibility
Ensures that all cushion safety margins on hydraulic engineering of the system are put to use (in energy conversion)
Typical: 0.5 bar equals to 25% of fan energy requirement
Geared motor backup kicks in when needed. Guarantees performance and offers extreme flexibility over a wide cooling spread with minimum energy use.

17. AQUAFAN+ with VFD control
When energy savings on the cooling tower become possible and interesting due to variable WBT or thermal load.
Principles:
VFD on the backup motor with following functions:
Reduce fan speed to save electricity
Switch off motor support and run fan at water pressure only
For extended flexibility and savings:
VFD on system pump
VFD's in communication: pump VFD only reduces volume/pressure when fan VFD is fully scaled down (eg fan powered by water pressure only).

18. AQUAFAN allows…
>25% reduction of investments and operational cost of cooling tower operation
Reduction of your footprint (carbon and physical)
Substantial reduction of maintenance cost on the power system of your cooling towers

19. Application Areas Diary Industries Paper Mills Steel & Non-Ferro Mills
Power Stations
HVAC - Comfort Cooling (hotels-office-hospitals)
Pharmaceutical Industries
Contaminant removal processes
Chemical and Petrochemical Industries
Casting & Die Casting Industries
Plastics Industries
Mining Industries
Semi Conductor Industries
Sugar Industries