Cooling towers play a vital role in HVAC and industrial usage by transferring heat from water-cooled systems to the atmosphere. However, one of the biggest operating issues that they face is evaporation loss. While some evaporation is inevitable, since it’s the inherent cooling method, unrestrained or excessive loss of water increases operating costs, stresses water resources, and affects overall system efficiency.
That’s why we focus on smart strategies to reduce evaporation without compromising cooling tower performance. At Melfrank, part of the AadTech group, we’ve been designing cooling towers since 1991. We’ve seen firsthand how the right design, technology upgrades, and proper maintenance make a big difference.
When warm water flows into a cooling tower, it evaporates part of it along with mixing with the air. This evaporation dissipates heat and refrigerates the remaining water. In most instances, evaporation amounts to approximately 1% of the water flow for every 10°F reduction in temperature. Despite this loss being inevitable, excessive evaporation, through poor design, maintenance, or atmospheric conditions, can lead to:
Fill media in the cooling tower offers surface area for heat transfer. High-efficiency fill designs increase air-water contact while using less water to achieve the same cooling, thus reducing unnecessary evaporation.
Drift eliminators prevent tiny water droplets from exiting with the air stream. Without them, partially evaporated water gets carried out of the system along with losses. Modern drift eliminators are able to trap 99.9% of water droplets, so only vapor is released from the tower.
Fans play a crucial role in managing the evaporation rate. Ineffective or poorly designed fans often cause irregular air distribution, leading to excessive water loss. Retrofitting with advanced EC fans provides better airflow control while lowering energy consumption.
Control of correct water chemistry reduces scaling, corrosion, and fouling that otherwise decrease heat transfer efficiency. Scaling, if it decreases tower efficiency, will require extra water to cool, thus increasing the rate of evaporation. Automatic monitoring systems help maintain water balance.
Leaks, clogged nozzles, or damaged fill material will all contribute to irregular water distribution and an increase in evaporation. Frequent nozzle, basin, and drift eliminators inspections ensure free-flowing operation and prevent additional losses.
Smart controls enable control of fan speeds, ambient condition monitoring, and system performance adjustment to reduce evaporation. Utilities and industries can reduce excess water consumption by synchronizing tower operation with existing weather conditions.
Water-short locations may consider hybrid or closed-circuit cooling towers to be a better long-term investment. These designs reduce direct air-to-water contact, significantly lowering evaporation loss.
Upgrading cooling towers with energy-efficient technologies is the most effective way to reduce evaporation loss. At Aad Tech, we provide next-generation fan retrofits and system upgrades that not only reduce evaporation but also lower energy costs. By combining efficient hardware with smart automation, we help industries maximize both water and power usage.
Evaporation loss in cooling towers can’t be eliminated, but can be easily minimised using proper methods. Right from the installation of drift eliminators and fan optimisation to smart controls and efficient water treatment, facility managers have a range of methods to cut back on waste.
With the help of technology partners like us, businesses can shift to sustainable cooling operations, saving water, lowering costs, and improving system-wide efficiency. Reducing evaporation isn’t just about maximizing operations; it’s about long-term sustainability in a more resource-aware world.
