From Blocks to Flute Size: Five Issues to Consider When Buying Replacement Fill for Your Cooling Tower

If you are trying to find cooling tower fill replacement, there are several decisions you will have to make. Wondering which options are available? Here are some of the elements you need to consider:

1. Original Equipment Manufacturer or New Filler 

If you like, you can order the exact same type of filler your cooling tower currently uses, and you can often order it from the original equipment manufacturer. However, if you want to try something less expensive, something that claims to work better or a different material, you may want to order a different filler than you currently have.

If you order a different type of filler, make sure it fits with your type of tower or comes with a kit for modification. Alternatively, work with a vendor who can help you with the retrofitting process. Ideally, you want an expert in cooling tower replacement fill who can advise you on exactly what you need and predict the potential results of your options.

2. Polypropylene or PVC

Cooling tower fill can be made of PVC or polypropylene (PP). PP can withstand higher heat levels than PVC, and it tends to last longer than PVC. However, PVC is more common and easier to find.

3. Welding or Glue

You also may want to consider how the filler is put together, and the two main options are welding or glue. Welding, often used with PP fillers, melds the parts of the filler together so they are unlikely to come apart or break. Glue, while totally serviceable in many applications, can break down over time, causing the filler to start to disintegrate.

4. Hanging or Block

Generally, when you buy replacement fill, it comes in block form. However, you can also buy hanging replacement filler for cooling towers. Unfortunately, block fill tends to clog more readily than hanging fill, but as block is the original filler for most towers, it can be easier to install. Conversely, however, hanging filler tends to be easier to access, once installed, for repairs.

Hanging fill can increase the cooling capacity of some towers, as it rejects heat more effectively. In addition, hanging fill returns water to the cooling tower more effectively than block filler, and that can ultimately save you on electricity costs.  

5. Flute Measurements

In addition to making all these choices, you also have to ensure the filler replacement you select comes with the right flute size. Measured in millimetres, flutes come in a range of sizes, but not every type of replacement filler accommodates every size of flute. If you cannot find the size you need, you may be able to custom order it.