Cooling Tower Distribution Nozzles

Cooling tower water distribution nozzles are components that spray warm condenser water evenly over the fill media so the air-water contact is maximized. Good nozzle performance is essential for tower efficiency, heat transfer, and avoiding dry spots on the fill.

Below is a clear, practical overview.

1. Purpose of Cooling Tower Distribution Nozzles

* Ensure uniform water distribution across the fill.

* Maintain droplet size ideal for heat transfer.

* Prevent splash-out, dry zones, and scaling.

* Operate effectively at a range of flow rates and pressures (usually low-pressure gravity or pressurized systems).

2. Types of Cooling Tower Nozzles

A. Gravity-Flow (Low Pressure) Nozzles

Used in counterflow towers with hot water basins.

Common types:

* ABS or PP Target Nozzles (Round or Square)

* Most common in package towers.

* Simple design: water falls through a throat and hits a spreader/target.

* Easy to clean and inexpensive.

* Spray Deck / Orifice Nozzles

* Usually used in larger field-erected towers.

* Distribution based on a drilled orifice plate.

B. Pressurized Spray Nozzles

Used in crossflow towers or systems with pump-fed headers.

Common types:

* Full Cone Spray Nozzles

* Produce a cone-shaped spray pattern.

* Good coverage and droplet uniformity.

* Hollow Cone Nozzles

* Lower droplet density; used in specific applications.

* Spiral Nozzles

* Wide-angle spray; good for lower-pressure systems with clog-tolerant design.

3. Common Materials

* ABS – Most common for package counterflow towers; economical.

* Polypropylene (PP) – Better temp & chemical resistance.

* Glass-filled nylon – Stronger, used in high-temp systems.

* PVC – Affordable, usable in non-high-temp towers.

* Stainless steel – High durability; mostly for industrial or high-temp process towers.

4. Signs Your Nozzles Need Attention

* Uneven fill wetting

* Reduced cooling performance

* Visible dry streaks in fill

* Scaled or clogged nozzles

* Broken splash/target pieces

* Reduced pump pressure or flow imbalance

5. Maintenance & Cleaning Tips

* Remove and soak in descaling solution if scaling is heavy (vinegar or inhibited acid).

* Inspect for cracks or brittle plastic (common in older ABS).

* Clean or replace orifice inserts.

* Ensure headers are flushed to avoid debris accumulation.

* Replace nozzles periodically (typical: every 3–5 years depending on water quality).

6. Well-Known Nozzle Manufacturers

* SPX Marley

* Baltimore Aircoil (BAC)

* EVAPCO

* Brentwood Industries

* Harrington Industrial Plastics (distributor for many brands)

* DYNAIR

* Koolant Koolers / Recold