CEGB research on the effects of fouling of plastic packings on natural draught cooling tower performance

Plastic film packings were first used in CEGB natural draught cooling towers in 1985. Since then, cooling towers at seven power stations have been repacked using various commercial designs of plastic packing, with generally satisfactory results in economic terms. However, fouling of all the packings has occurred to some extent, ranging from very thin films on the surface of the sheets, which actually enhances performance, to heavy and voluminous formations which severely constrict the inter-sheet passages, causing performance loss and threatening the structural integrity of the whole fill. At CERL, methods have been developed to relate the degree of fouling to the thermal performance loss. This information is enabling accurate calculations to be made of the economics of repacking. Samples of fouled packing from operation towers are tested using the Experimental Cooling Tower at the Central Electricity Research Laboratories at Leatherhead. A systematic investigation is also underway of the changes in pressure drop and mass transfer coefficients which take place as fouling develops, using progressively-fouled packing samples from a purpose-built Packing Fouling Facility located at one of the power stations. The performance data obtained is fed-back into models by which the effect of high fouling loadings on various packings is calculated, enabling packing economic life to be predicted