How to clean cooling tower fill

Cooling towers play a crucial role in industrial, commercial, and HVAC systems, and the filling material, as a core component that promotes water air exchange and improves heat dissipation efficiency, directly affects the performance, energy consumption, and lifespan of the cooling tower due to its cleanliness. As the running time increases, the surface of the fill is prone to accumulate scale, algae, sediment, and biofilms. If not cleaned in time, it not only reduces cooling efficiency, but may also lead to equipment corrosion, increased noise, and even the growth of Legionella bacteria and other risks. Therefore, regular cleaning of the cooling tower fill is crucial.

Preparation before cleaning

Before carrying out cleaning operations, the following preparations should be made to ensure project safety and efficiency:

1. Shutdown and power outage

Ensure that the cooling tower is completely shut down and cut off the power supply to the fan and water pump to avoid danger during operation.

2. Evacuate the system

Drain the circulating water in the cooling tower, especially the accumulated water near the packing area, for easy disassembly and cleaning.

3. Check the status of the fill material

Confirm the fill material (PVC, PP, etc.) and the aging and damage situation;

If brittle cracking or deformation occurs, replacement should be considered instead of cleaning.

4. Prepare tools and cleaning agents

1）Soft bristle brush or low-pressure water gun

2）Non corrosive cleaning agent (acid pickling agent should be used in moderation)

3）Protective equipment (gloves, protective goggles, masks, anti slip shoes)

4）Water gun with a pressure not exceeding 100 psi to prevent damage to the fill

Cleaning method for cooling tower fill

According to the degree of pollution, cleaning methods can be divided into physical cleaning and chemical cleaning, and the combination of the two is most effective when necessary.

Method 1: Physical cleaning (suitable for mild and moderate pollution)

1.Dismantle the fill (if removable)

Gently remove the filler, being careful not to break it.

2.Low pressure flushing

Use a low-pressure water gun to rinse from top to bottom to avoid damage or detachment of the packing caused by high-pressure impact.

3.Brush the surface

Use a soft bristled brush to remove stubborn dirt. Do not use hard brushes or metal brushes to avoid damaging the filling structure.

4.Air-dry naturally

After rinsing clean, let the packing air dry naturally, and then reinstall it into the cooling tower.

Method 2: Chemical cleaning (suitable for severe scaling, water scale, and algae growth)

When the scale on the surface of the fill is thick or there is obvious biofilm, chemical cleaning is more effective.

The steps are as follows:

1.Configure cleaning agents

Use specialized cooling tower fill cleaning agent

If using acidic cleaning agents (such as diluted citric acid or phosphoric acid), the concentration must be strictly controlled to avoid corrosion and secondary pollution

2.Soak filling material

Soak the filler in the cleaning solution for 30-60 minutes to soften the scale.

3.Brush and rinse

Remove the fill and scrub it thoroughly, then rinse with clean water to ensure there are no residual cleaning agents.

4.Neutrality treatment

If acidic cleaning agents are used, a weak alkaline solution (such as sodium carbonate) should be added for neutralization treatment before final washing.

Method 3: In situ cleaning inside the tower (without dismantling the fill)

Suitable for systems with large cooling towers or fill structures that are difficult to disassemble:

1.Drainage after shutdown

2.Spray specialized fill cleaning agent onto the surface of the fill

3.Allow to react for 30-60 minutes

4.Use low-pressure water gun to rinse layer by layer

5.Drain, replenish, and circulate for 10-15 minutes before emptying

Cleaning frequency and daily maintenance recommendations

1. Cleaning frequency

1）Commercial cooling tower: Clean at least once every 6 months

2）Industrial cooling tower: Clean every 3-6 months

3）Areas with high dust or hard water: Clean more frequently, even quarterly

2. Daily maintenance suggestions

1）Maintain good water quality and install an automatic dosing system

2）Regularly check water quality (hardness, pH, colony count)

3）Keep the water collection tray and sprinkler system clean

4）If necessary, add a side filter system (such as a sand filter)