Knowledge Hub

Field-tested cooling tower engineering, shared openly.

Case studies, technical downloads, blogs and FAQs from 30+ years of cooling tower projects across India.

Case Studies

Selected work, by industry

Power

Power plant cooling tower revamp — timber to FRP

18% power saving, 25-year extended life

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HVAC

EC fan retrofit at a Mumbai commercial complex

32% fan power reduction across 6 cells

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Chemical

Counterflow tower upgrade for a chemical major

Approach improved by 1.8°C, 22% energy savings

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Pharma

AMC contract for multi-site pharma manufacturer

0 unplanned shutdowns over 3 years

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Steel

Pre-fabricated tower for a steel rolling mill

Installed and commissioned in 21 days

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Downloads

Get the documents you need

Company Profile (PDF)

Capabilities, certifications and reference projects.

Product Brochure (PDF)

Pultruded FRP, crossflow, counterflow and prefab towers.

EC Fan Retrofit Whitepaper

How EC fans cut cooling tower power by 20–35%.

Audit Request Checklist

Data we need to scope your performance audit.

BLOGS

From the Melfrank engineering desk

FAQs

Frequently asked questions

What is a cooling tower?
A cooling tower is a heat rejection device, which extracts waste heat to the atmosphere though the cooling of a water stream to a lower temperature. The type of heat rejection in a cooling tower is termed “evaporative” in that it allows a small portion of the water being cooled to evaporate into a moving air stream to provide significant cooling to the rest of that water stream. The heat from the water stream transferred to the air stream raises the air’s temperature and its relative humidity to 100%, and this air is discharged to the atmosphere. Evaporative heat rejection devices such as cooling towers are commonly used to provide significantly lower water temperatures than achievable with “air cooled” or “dry” heat rejection devices, like the radiator in a car, thereby achieving more cost-effective and energy efficient operation of systems in need of cooling. Think of the times you’ve seen something hot be rapidly cooled by putting water on it, which evaporates, cooling rapidly, such as an overheated car radiator. The cooling potential of a wet surface is much better than a dry one.
Common applications for cooling towers are providing cooled water for air-conditioning, manufacturing and electric power generation. The smallest cooling towers are designed to handle water streams of only a few gallons of water per minute supplied in small pipes like those might see in a residence, while the largest cool hundreds of thousands of gallons per minute supplied in pipes as much as 15 feet (about 5 meters) in diameter on a large power plant.

Years ago you might have purchased a cooling tower satisfying your plant needs at that particular time .Over the years , your plant needs would have undergone tremendous change . You may have improved enhanced your process . But the cooling tower may have deteriorated in its performance . As a result, your process may not be optimum. It may be affecting your plants yields , quality or may be consuming more power . Ask your operator/engineer to check the cooling tower .Ask if the cold water temperature in the cooling tower was 10 centigrade lower ,will it help the yield , quality and save power. If the answer is yes ,then the solution to your problem is your cooling tower needs a repair.

MELFRANK will collect data about your cooling tower and evaluate its performance .MELFRANK will give you suggestions how to improve your tower ,save energy and continueto maintain your tower in best condition.
BETTER COMPONENTS
MELFRANK has developed highly efficient cooling tower components which will improve the tower performance and thermal efficiency .
Beside Improving the performance of the tower , MELFRANK service ensure that there is
  • Proper distribution of water from hot water basin over the fills.
  • Proper and efficient Air Intakes.
  • Proper Air Locking.
  • Optimum Water Loading.
  • Elimination of Channeling Effect.
  • Extra Structure strength for a long-lasting tower.
  • Upgarditation of RCC cooling tower from 1000m3/hr. to 2000 m3/hr . This saved an additional investment for cooling tower.
  • Improved thermal efficiency of the towers by 60% .The company could now increase the production by more that 2 crores.
  • Improved approach from designed 40C to 20C , thus reducing the evaporating losses of the company’s product by Rs. 60 Lakhs Per Year.
  • Increase Capacity of tower by 40%. Thus saving the need for investment for more towers.
  • Converted existing cross flow tower to counter flow tower for better performance and increased capacity.
  • Saved power consumption by more than 45% which meant to some customers Rs.6 Lakhs per year.