Wet & Hybrid Cooling Towers

Critical thermal performance for optimal plant efficiency

wide range of project requirements

Wet Cooling Towers

SPIG natural draft and induced or forced draft wet cooling towers are designed for a wide range of project requirements such as high seismic and wind loads, vibration control, corrosion resistance, low-noise emission, sub-freezing operation and fresh, geothermal, sewer or sea water applications. Cooling tower structures can be customized using fiber reinforced polymer (FRP), precast or cast in situ concrete, steel or wood.

dry and wet cooling in a single structure

Hybrid Cooling Towers

SPIG hybrid cooling towers offer an environmentally friendly solution for plume abatement and water conservation. Specifically designed to eliminate visible plumes in cold, humid conditions and meet local regulatory requirements, such as at airports or residential areas, these towers excel in cost-effectiveness and performance. By integrating wet cooling tower technology with dry heat exchangers, SPIG’s hybrids effectively minimize environmental impact.
The dry sections, featuring conventional air-cooled heat exchangers positioned above drift eliminators, use triangular pitch tube bundle designs with fins for optimal efficiency.

This hybrid design combines dry and wet cooling within a single structure. Hot water flows through the system sequentially, starting hot in the external dry section above the drift eliminators, then pre-cooled before distribution onto the wet section’s fill media. A skid vacuum system ensures the siphon effect in the tube bundles (dry section), reducing the workload on circulating water pumps.
Hybrid cooling towers are particularly advantageous where water usage must be minimized and visible plumes avoided, which can be disruptive in sensitive environments like air traffic or residential areas. While wet cooling towers may offer initial cost savings, hybrids provide long-term environmental benefits by reducing water consumption and plume emissions. In many cases, the water savings achieved with hybrid technology outweighs the initial construction costs.

Our Products

Explore a wide range of services tailored to your needs.

Mechanical Draft Cooling Towers

Mechanical draft field-erected cooling towers cater to diverse cooling needs, from power plants to refining, from pulp and paper to petrochemical, from renewable energy to HVAC. Utilizing large mechanical fans, they efficiently move air through the tower, where water is sprayed over the fill surface. Based on fan position, these towers are classified as induced or forced draft, with configurations as counterflow or crossflow, depending on air and water direction. SPIG counterflow towers deliver top-notch thermal performance cost-effectively, while our crossflow towers prioritize lower energy use and ease of maintenance, all contributing to sustainable, efficient operations.

FRP Cooling Towers

FRP cooling towers, favored for their environmental benefits, offer a superior alternative to wood, concrete, or steel. Their structures feature a framework of fiberglass composite structural shapes, reinforced with diagonal braces to handle wind, earthquake, and other loads effectively. The fan deck is spacious and designed for easy maintenance, making FRP cooling towers ideal for demanding environments like oil refineries and petrochemical facilities. Key advantages include high strength, weather resistance, long-term durability, lightweight construction, dimensional stability, and excellent noise and vibration absorption.

Concrete Cooling Towers

Concrete cooling towers feature a robust structure of reinforced concrete, crafted to withstand aggressive water conditions. Precast designs ensure timely project completion while adhering to stringent deadlines. The shell and structure are engineered to meet local wind load codes and can be reinforced for seismic resilience if necessary. Whether precast or cast in situ, prefabricated elements are preferred for accelerated project timelines.

Wooden Cooling Towers

SPIG’s wooden cooling towers utilize pressure-treated timber selected for durability in cooling applications. Structural integrity is enhanced with FRP corrugated panels. The fan deck is engineered to support normal operational loads effectively.

Sea Water Cooling Towers

SPIG’s environmentally responsible cooling towers play a vital role in marine ecosystem conservation and reducing environmental impact. Our seawater cooling towers help conserve valuable desalinated water and minimize carbon emissions. Material selection is critical for seawater applications; we utilize corrosion-resistant FRP structures, high-resistance steelworks, and protective coatings on mechanical equipment. According to the Cooling Tower Institute Journal (Vol. 24, No. 2), seawater cooling towers are both technically and economically viable, effectively meeting the cooling demands of industries like petrochemicals. They demonstrate minimal operational and maintenance challenges compared to once-through systems, offering favorable economics.

Low-Noise Cooling Towers

SPIG designs customized cooling towers to mitigate noise pollution, meeting stringent local noise level regulations. Our expertise lies in sound-attenuation technologies, incorporating low noise and ultra-low noise fans for minimal sound emission. Additionally, we offer various noise-abatement solutions such as water impact attenuation systems, inlet/outlet silencers, motor soundproofing boxes, and noise attenuation walls.

Hybrid Cooling Systems & Special Applications

Crossflow Cooling Towers

In crossflow cooling towers, water flows perpendicularly to the air stream, achieving high thermal efficiency through a unique distribution system. Louvers enhance airflow direction, and the tower design is especially compatible with splash fills. A fixed water distribution tray covers a large section of the fan deck area. Depending on specific thermal requirements, crossflow towers can provide a compact footprint compared to counterflow models. Additionally, the basin design in crossflow towers allows for easier access, making inspections more convenient.

Natural Draft Cooling Towers

SPIG specializes in the service and refurbishment of Natural Draft Cooling Towers (NDCTs), both Crossflow and Counterflow.
Natural draft cooling towers, also known as hyperbolic cooling towers, are ideal for high-volume water processing, commonly used in power plants. Operating on the principle of hot air rising and cool air drawn in from bottom air inlets, these towers offer several advantages. They eliminate the need for fans, reducing power consumption and noise emissions. With minimal moving parts, maintenance is low and longevity is extended.

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SPIG features

With over 85 years of experience, our company’s expertise in wet and dry applications spans more than 85 countries, showcasing our commitment to excellence and innovation. Each installation is a testament to the skill and dedication of our engineers, who design solutions that perform reliably across diverse industries, including power generation, petrochemicals, and manufacturing. Our global presence reflects our ability to meet the most demanding challenges, delivering high-performance systems that enhance thermal efficiency and sustainability. These references underscore our enduring legacy of quality, innovation, and long-term partnerships with clients worldwide.

Our experience includes wet cooling (mechanical and natural draft) systems, dry cooling systems and hybrid cooling solutions as dictated by site-specific requirements. We design plants for a wide range of project requirements such as high seismic and wind loads, vibration control, corrosion resistance, low-noise emission, sub-freezing operation, and seawater applications. Specialized services include preventive maintenance, equipment upgrades, replacement and spare parts, online performance monitoring, and a commitment to research and develop efficient cooling system solutions.