Cooling towers
Our fill wets like a pad. It works well at low water flow.
How a tower works
Cooling tower fill
Everything interesting happens on the inside.
Cooling tower fill hasn’t changed in decades. Our evaporative media goes into the tower you already have and moves the same air and water for less fan work.
Video: iStock.com/dongfang zhao
Evaporative media
Cooling towers and evaporative air coolers both cool with a wet material called evaporative media.
Air moves through the wet media, and a little of the water evaporates. That carries the heat away. In a cooling tower the media is called fill. In an air cooler it is called a pad. We developed a new manufacturing platform that makes both.
Air coolers
Our pads are built from fill DNA: the same material as our fill. So they last longer than standard pads, and they work well at low water flow.
Ask us about padsCooling towers
A cooling tower cools water by letting a little of it evaporate.
A cooling tower cools water for a building or a plant. Warm water pours down through the tower while big fans move air through it. A little of the water evaporates, and that carries the heat away. On the way down, the water runs over the fill, which spreads it out so the air can touch as much of it as possible.
The problem
The fill is what the fans work against, every hour the tower runs.
The harder it is for air to get through the fill, the more work the fans do. Over the life of a tower, that adds up to a lot of electricity.
Does it fit
You keep the tower. We change what is inside it.
It is a drop-in replacement for the fill. It handles the same air and water, and the fans do less work to move the air through it. Whether it suits your tower is the first thing we will talk through.
How we do it
We develop the material, design the shape and test it.
Geometry is the shape of the media. Ours is a lattice: an open, repeating 3D pattern that the water runs over and the air moves through.
A test block on our bench. The colors are a brand treatment.
The material
We develop and test the materials the media is made of. We print samples, wet them, load them and repeat that many times, until we know where they fail.
The shape
We design the lattice for the job. It holds a thin film of water, lets air through and carries its own weight.
From test bench to your site
We test full-size parts on our own test bench. Then we run a pilot at your site. We install it and stay with it while it runs.
Founded by chemical engineers Matthew Pearlson (MIT) and David Walker (PhD Northwestern, co-founder of Azul 3D). About us
Next step
Get in touch for a technical discussion.
Tell us about your cooling tower or air cooler: where it is, what kind it is, and what fill or pads are in it now, if you know. We read every message and will get back to you.