Equipment model: FMT-500 square counterflow fiberglass cooling tower

Medium: air conditioning and process circulating water

Quantity: 3 units

Project description: Provide three FMT-500 square counterflow fiberglass cooling towers for a commercial and cold chain project in a Southeast Asian country to provide large-flow circulating water cooling services. In response to the high temperature, high humidity, and high salt spray environment of the local climate, the project uses high-strength anti-corrosion fiberglass materials and a counter-flow efficient heat transfer structure to ensure long-term stable operation of the system and demonstrate excellent corrosion resistance and energy-saving performance.

Situation

A country in Southeast Asia is located in the tropics, with high temperatures, rain, and humidity all year round. The cooling systems of its industrial and large commercial projects are in high-load operation all year round. What is even more challenging is that the project is close to the coastal zone, and the salt spray content in the air is extremely high, which is extremely corrosive to conventional metal structural equipment. This multinational customer is building a large-scale commercial complex and food cold chain base locally. The central air-conditioning and cold storage systems have strict requirements on the flow rate and temperature control stability of circulating cooling water. Traditional metal structure cooling towers are easily rusted and perforated in the local high salt spray, high humidity and heat environment, resulting in high maintenance costs and significantly shortened service life.

Task

The core mission of this project is to build a high-flow cooling water system with high weather resistance, long life and low operating cost in a coastal environment with extreme heat and humidity and high salt spray.

Extreme anti-corrosion and wind resistance: The equipment shell and structure must have top-level resistance to salt spray corrosion, and at the same time be able to withstand frequent strong typhoons in the Philippines.

Heat dissipation redundancy in high humidity and heat environments: In the local climate with high humidity (high wet bulb temperature) all year round, the moisture absorption capacity of the air is weak, so the heat transfer design must be optimized to ensure that the cooling capacity of a single 500-ton unit is not compromised.

Space matching and continuous and stable production: Three large-flow equipment operate in parallel and need to adapt to the limited installation space on the roof or ground. They must ensure 24-hour uninterrupted operation to ensure the safe storage of cold chain food at the bottom.

Action

After in-depth technical demonstration, the expert team of Shandong Kaisen Heat Transfer Solutions has customized a system integration solution for 3 FMT-500 square counterflow fiberglass cooling towers:

Full fiberglass anti-corrosion body design: The tower shell and main structural parts are made of high-strength high-quality fiberglass (FRP) composite materials, with a UV-resistant gelcoat layer added to the surface. The material itself is naturally resistant to acid, alkali and salt spray corrosion, completely getting rid of the pain points of traditional steel plates that are easy to rust.

Square counter-flow efficient heat transfer structure: Using a square counter-flow design, air enters evenly from all four sides of the lower part of the tower, forming an all-round reverse heat exchange with the top spray water. Coupled with Kaisen's optimized high-efficiency flame-retardant PVC filler, the heat exchange area is expanded and extremely high heat dissipation efficiency can be maintained even in tropical high-humidity environments.

Structural reinforcement and typhoon-resistant design: In response to the country's frequent typhoons, the internal skeleton of the equipment has been structurally strengthened, using hot-dip galvanized steel or stainless steel reinforcements. The overall wind pressure resistance design standards have been greatly improved to ensure structural safety in severe typhoon weather.

Low-noise energy efficiency control and one-stop cross-border delivery: The selection of aluminum alloy fans with large diameter, wide blades and low rotation speed can not only ensure large air volume, but also significantly reduce the noise requirements of the commercial area. Overcoming the constraints of cross-border shipping and rainy seasons on islands, a digital team was dispatched to remotely guide on-site assembly and rapid debugging.

Key Results

• Three FMT-500 fiberglass cooling towers were successfully put into production on site in a Southeast Asian country and are operating at high standards:

• Perfect weather-resistant performance: Since the project was put into operation, it has experienced multiple typhoon seasons and long-term high-salt fog and sea breezes. The fiberglass body is as good as new, without any rust or deformation, and the equipment structure is stable.

• The heat exchange efficiency fully meets the standard: In the extremely hot and humid weather in summer, the outlet water temperature is always accurate and stable within the set process range, and the overall heat exchange efficiency is increased by more than 12%, effectively ensuring the full-load uninterrupted operation of the commercial central air-conditioning and cold storage systems.

• Significant reduction in overall costs: Thanks to the maintenance-free nature of FRP, customers do not need to carry out tedious maintenance such as rust removal and painting on a regular basis. Annual equipment maintenance costs are reduced by more than 30%. Its high-energy-efficiency fans also bring significant reductions in electricity bills for the factory.

Numerical core KPI data indicators

3 sets of FMT-500 large fiberglass cooling towers are delivered to the grid at one time with high standards

Salt spray rust rate of tower shell and core structure: 0%

System heat exchange efficiency improvement: more than 12%

Comprehensive equipment maintenance and service cost reduction: 30%

Structural design wind resistance: perfect to withstand strong local typhoon environment

Reusability Takeaways

Full glass fiber reinforced plastic (FRP) anti-corrosion cooling technology: It is the preferred solution for replication and promotion of cooling projects in coastal industrial areas, high salt spray island environments, chemical industry and acid-base corrosive factories.

Square counter-current large flow standardized module: The square design is easy to arrange multiple units in parallel and has high space utilization. It is suitable for the standardization promotion of medium and large commercial and industrial cold chain projects.

Experience in contract performance in tropical island climates in Southeast Asia: accumulated experience in wind-resistant design of special equipment and delivery management of transnational logistics supply chains for Southeast Asia’s rainy, typhoon, high-humidity and heat environments.