Cooling tower fill media increase the contact area between water and air, supporting heat and mass transfer. Selecting the right fill affects cooling performance, air-side pressure drop and maintenance requirements. PVC and PP identify the construction material, while film and splash describe how the fill promotes air–water contact.
PVC Film Fill: Large Surface Area and High Thermal Performance
Corrugated PVC sheets distribute water as a thin film across their surfaces. Cross-fluted designs provide a large contact area per unit volume for effective heat transfer. Airflow resistance depends on channel geometry, fill depth and operating flow rates.
PVC film fill is commonly used in HVAC systems and clean industrial processes with controlled water quality. Using mains water does not eliminate the need to control scale and biofilm.
Polypropylene (PP) Grid Fill: Temperature and Chemical Compatibility
Appropriately selected PP fill can serve applications requiring higher temperatures than standard PVC fill. However, continuous operating limits differ from the limits permitted during brief temperature excursions. Applications at or above 80 °C require verification against the manufacturer’s technical data.
Chemical resistance must be assessed according to the substance, concentration and temperature. Grid geometry also influences fouling behaviour and thermal performance.
Splash Fill: Fouling Resistance for Contaminated Water
Splash fill repeatedly breaks falling water into smaller droplets as it strikes successive surfaces, increasing contact with air. Its open construction can offer greater resistance to clogging than narrow-channel film fill when circulating water contains high levels of suspended solids.
Typical applications include steel production, petrochemical plants and other heavy industries. Water containing oil or heavy sediment requires a separate suitability assessment, along with continued cleaning and water treatment.