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Views: 0 Author: Site Editor Publish Time: 2025-11-20 Origin: Site
During high-temperature seasons, industrial cooling systems face multiple challenges such as high operating loads, reduced cooling margins, and accelerated scaling or corrosion. As a professional cooling-solution provider, Mach Cooling (www.machcooling.com) offers practical optimization guidelines to help facilities maintain stable, efficient cooling tower performance even under extreme heat.
This article analyzes the critical issues during hot weather and provides actionable techniques, monitoring strategies, maintenance practices, and water-treatment guidance for operators and project managers.
When ambient dry-bulb and wet-bulb temperatures rise, the cooling tower’s thermal performance drops because the cooling effect depends on the temperature difference between circulating water and wet-bulb temperature.
A higher wet-bulb temperature results in a higher achievable cold-water temperature, reducing the cooling margin and making heat rejection more difficult.
In hot seasons, industrial equipment often operates at higher loads, increasing heat-rejection demand and causing supply-water temperatures and flow rates to fluctuate.
Without timely adjustments, this may lead to elevated temperatures, equipment safety shutdowns, or reduced production capacity.
High temperatures accelerate evaporation, increasing concentration cycles and promoting scaling, algae growth, corrosion, and microbial activity.
These significantly reduce heat exchange efficiency and shorten the lifespan of internal components.
More airflow and higher circulation rates are required to maintain performance under heat, which increases the load on fans and pumps.
Non-variable-speed motors may experience efficiency drops or higher power consumption.
Variable-frequency fans and pumps are recommended for dynamic adjustment to match fluctuating loads.
Fixed-speed systems should consider slightly increasing fan speed or deploying auxiliary fans during heat waves.
Pumps must maintain stable flow at high loads to ensure proper water circulation.
During high-temperature seasons, output temperature targets should be adjusted slightly higher to avoid fan/pump overload.
Example: ΔT of 5°C during normal seasons may be adjusted to 6–7°C during peak heat.
Monitor water-flow rates to prevent under-flow or over-flow conditions that reduce cooling efficiency.
Keep air inlets/outlets unobstructed and prevent hot-air recirculation around the tower.
Clean intake louvers and maintain good ventilation around the tower.
Check and eliminate any hot-air return paths.
| Indicator | Typical Value / Target | Optimization Note |
|---|---|---|
| Inlet water temp (°C) | Depends on process | High → check load & pump flow |
| Outlet water temp (°C) | System target | Higher → airflow or fill issue |
| Wet-bulb temp (°C) | Ambient parameter | Higher → reduced cooling margin |
| Approach (Outlet temp – Wet-bulb) | 4–6°C typical | Higher → performance declining |
| Water flow (m³/h) | Within ±5% of design | Deviation → pump/pipe problems |
| Fan power (kW) | Rated value | Increase → heavy load or fault |
Set alarms for key parameters (e.g., Approach > 6–7°C).
Review daily/weekly trend charts to detect performance decline (e.g., fouled fill or decreased fan efficiency).
Combine analysis with maintenance logs to guide future optimization.
Activate additional fans or increase pump flow before peak heat periods (13:00–16:00).
If cooling demand spikes, consider switching in standby cooling towers.
Reduce fan/pump speed at night to save energy when temperatures are lower.
Ensure proper water distribution to avoid inlet/outlet mixing or short-circuiting.
Rising outlet temperature with normal flow may indicate obstruction in fill or heat-exchange surfaces.
Check water-side pressure drop and fill temperature differences.
High temperatures increase evaporation, so timely makeup is essential.
Increase blowdown frequency or concentration-ratio control to prevent scale formation.
Combine with proper water-treatment dosing.
Heat accelerates fouling and stress on fill media; inspect monthly for scaling, clogging, or damage.
Ensure uniform spray distribution to avoid dry spots that reduce thermal performance.
Clean or replace impaired fill modules as needed.
Check fan blades for wear, dirt buildup, or deformation.
Monitor motor temperature, vibration, and bearing condition under high load.
Consider upgrading fixed-speed motors to VFD systems for better adaptability.
Hot weather accelerates algae and bacterial growth—enhance microbial control and chemical dosing.
Regularly test pH, hardness, alkalinity, corrosion rate, and iron/copper ion levels.
Use proper inhibitors and filtration systems to maintain water quality.
High-temperature seasons pose significant challenges to cooling tower operation—reduced thermal margin, increased system load, faster water deterioration, and heavier mechanical stress. To maintain peak cooling performance, facilities must strengthen five key areas:
Design adaptability, operational monitoring, dynamic adjustments, preventive maintenance, and strong water-treatment management.
As a professional manufacturer, Mach Cooling (www.machcooling.com) recommends preparing early for high-temperature periods, establishing a monitoring system, adjusting operations dynamically, and closely tracking the condition of equipment and water quality. By applying the optimization strategies above, you can maintain efficient cooling, reduce energy consumption, stabilize production, and extend equipment service life.
