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Dry Cooling Towers

Water-saving dry cooling towers designed to cool and maintain process-water temperature through extended-surface heat exchange, without the continuous water consumption associated with evaporative cooling towers.
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Introduction

Atcorp offers dry cooling tower solutions for industrial applications where process water needs to be cooled without evaporative water loss. The system uses copper-tube heat-transfer coils with extended fins and forced airflow from low-noise axial fans to reject heat directly to the atmosphere, helping reduce water consumption, scaling, contamination and routine maintenance.

Key Benefits

No Evaporative Water Consumption
No Scale Formation
Low Noise Operation
Reduced Maintenance
Clean Process Water
Corrosion-Resistant Enclosure

Why Choose Dry Cooling Towers?

Conventional evaporative cooling towers consume water through evaporation, drift and blowdown, while exposed cooling-water systems can require treatment and frequent cleaning. A dry cooling tower uses atmospheric air and extended-surface heat-transfer coils instead, keeping the process water in a closed circuit and rejecting heat without evaporative water consumption.
Specification Details
Cooling Principle Air-to-Water Heat Exchange
Cooling Type Dry / Non-Evaporative
Process Circuit Closed Loop
Heat Exchanger Extended-Fin Copper Tube Coil
Tube Size 5/8″ OD Copper Tube
Coil Construction Level-Wound Coil with Hairpin Bends
Tube Arrangement Staggered in Airflow Path
Fan Type Axial Flow
Fan Design Aerodynamically Balanced
Fan Drive Electric Motor
Motor Protection IP55
Motor Shaft Extended Stainless Steel
Enclosure Fibreglass / GI Panels
Base Frame Heavy-Duty Channel Frame
Structural Frame Die-Formed Galvanized Steel
Water Connections Inlet & Outlet on Same End
Coil Protection Factory Pressure Tested
Venting High-Point Vent Connection
Drainage Low-Point Drain Connection
Expansion Integrated Expansion Tank Arrangement

A dry cooling tower removes heat from process water by transferring it through extended-surface coils to atmospheric air.

 

Step 1 – Hot Water Entry
Hot process water enters the copper heat-transfer coils.

 

Step 2 – Heat Transfer
Heat moves from the circulating water through the copper tube walls and extended fins.

 

Step 3 – Airflow Generation
Low-speed axial fans draw or move atmospheric air across the finned coils.

 

Step 4 – Heat Rejection
The heat transferred to the fins is carried away by the passing air.

 

Step 5 – Process Water Cooling
The cooled water exits the coil and returns to the connected process or equipment.

 

Step 6 – Continuous Circulation
The closed-loop cycle continues as the process generates additional heat.

 

Unlike evaporative cooling towers, the cooling process does not rely on evaporation, spray water or cooling-water blowdown.

Water-Free Cooling

The dry cooling principle eliminates evaporative water consumption, making it suitable for locations where water availability is limited.

 

No Scale Formation

Because the process water remains isolated within the heat-transfer circuit, the system avoids the scale-related problems associated with exposed evaporative cooling water.

 

Clean Process Water

The closed circuit prevents atmospheric dust, dirt, fly ash and biological contaminants from mixing with the process water.

 

Low Maintenance

The system has no water spray pumps, sprinkler nozzles or evaporative fill requiring routine cleaning. The primary moving components are the fans and motors.

 

Efficient Heat Transfer

Staggered copper tubes and extended fins increase the available heat-transfer surface while supporting efficient airflow.

 

Low-Noise Fans

Aerodynamically balanced axial fans operate at relatively low speed to reduce noise while maintaining effective airflow.

 

Harsh-Environment Construction

IP55 motors with extended stainless-steel shafts are designed to withstand moisture, rain and dust.

 

Flexible Plant Location

Because the system does not require a continuous supply of cooling water, plant-location constraints associated with water availability are reduced.

Heat Transfer Coils

  • Imported 5/8″ OD copper tubes
  • Level-wound coil construction
  • Hairpin bends for fewer joints
  • Uniform tube-wall thickness
  • Staggered tube arrangement
  • Mechanically expanded tubes
  • Improved tube-to-fin bonding
  • Pressure-tested after manufacture

 

Headers & Connections

  • Heavy-wall steel inlet and outlet headers
  • Reinforced brazed connections
  • Inlet and outlet connections on the same end
  • Convenient high-point vent
  • Low-point drain
  • Expansion-tank arrangement

 

Fan & Motor Assembly

  • Aerodynamically balanced axial fans
  • Low-speed operation
  • Adjustable fan pitch
  • High-efficiency airflow
  • IP55 weatherproof motors
  • Extended stainless-steel motor shafts
  • Moisture-, rain- and dust-resistant construction

 

Tower Construction

  • Heavy-duty channel base frame
  • Fibreglass/GI enclosure panels
  • Die-formed galvanized steel structural frame
  • Corrosion-resistant construction
  • Easy access for installation and maintenance

Industrial Applications

Dry cooling towers are particularly suitable for industrial processes where water conservation, clean process water and low-maintenance heat rejection are important.
Automotive Manufacturing
Provides closed-loop cooling for diesel engines and generator sets by circulating cooled process water back through the engine.
Gas Generator Cooling
Supports heat rejection from gas-engine generator systems without the continuous water consumption of evaporative cooling.
Power Generation
Provides dry heat rejection for selected power-generation and utility applications.
Industrial Process Cooling
Maintains process-water temperature for machinery and equipment generating continuous heat.
Manufacturing Plants
Provides an alternative to evaporative cooling where water availability, contamination or maintenance is a concern.

Frequently Asked Questions

Find answers about dry cooling towers, water-free cooling, heat-transfer coils, maintenance, fan operation and industrial applications.
A dry cooling tower is a heat-rejection system that cools process water by transferring heat through extended-surface coils to atmospheric air. Unlike an evaporative cooling tower, it does not rely on evaporation to remove heat.
The dry cooling process itself does not consume water through evaporation, drift, spray loss or blowdown. The process water remains within the closed heat-transfer circuit.
Hot process water flows through copper tubes equipped with extended fins. Axial fans move atmospheric air across the coils, transferring heat from the water through the tube and fins into the air.
Yes. The referenced system describes an application in which hot water from a diesel engine is circulated through the dry cooling tower, cooled and returned to the engine to remove heat continuously.
Maintenance is generally lower than an evaporative tower because there are no cooling-water spray pumps, sprinkler nozzles or evaporative fill requiring regular cleaning. Routine inspection of fans, motors, coils, connections and the process-water circuit is still recommended.
Selection should consider process heat load, water flow rate, hot-water inlet temperature, required outlet temperature, ambient air temperature, altitude and available installation space. Atcorp can evaluate these parameters to help identify an appropriate dry cooling tower configuration.

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