Introduction Of Bac Cooling Tower Fill Material

BAC (Baltimore Aircoil Company) cooling tower fill is designed to maximize heat transfer while resisting fouling, UV exposure, and chemical attack. BAC selects fill material based on tower type, water quality, temperature, and application.

Standard Bac Cooling Tower Fill Materials

1. PVC (Polyvinyl Chloride) – Most Common

Used in: BAC Series 1500, Series V, FXV, FXVS, VXT

Key properties

* Excellent heat transfer efficiency

* Corrosion resistant

* Smooth surface reduces scale adhesion

* Cost-effective

Typical limits

* Max continuous water temperature: ~55 °C (131 °F)

* Not suitable for very hot process water

2. High-Temperature PVC (HT-PVC)

Used when: Hot condenser or process water

Key properties

* Higher temperature resistance than standard PVC

* Same performance as standard PVC

Typical limits

* Max water temperature: ~60–65 °C (140–149 °F)

3. PP (Polypropylene) Fill

Used in: Industrial, dirty water, high-temperature applications

Key properties

* High chemical resistance

* Better fouling tolerance than PVC

* Stronger at elevated temperatures

Typical limits

* Max water temperature: ~80–90 °C (176–194 °F)

4. Splash Fill (PP or PVC Bars / Grids)

Used in: Very dirty water or high solids

Key properties

* Large open structure

* Easy to clean

* Lower thermal efficiency than film fill

Common BAC use

* Series FXV (splash configuration)

* Steel or FRP-supported splash grids

Bac Cooling Tower Fill Material Types by Tower Design

BAC Tower Type	Fill Style	Material
Crossflow	Film fill sheets	PVC / HT-PVC
Counterflow	Film or splash fill	PVC / PP
Closed-circuit towers	PVC / PP	Coil + fill combination
Hybrid / plume abatement	Film fill	PVC / PP

BAC Film Fill Characteristics

* Sheet thickness: typically 0.15–0.20 mm

* Flute angle: optimized for low pressure drop

* Surface texture: enhanced wetting

* UV inhibitors: added for outdoor durability

Bac Cooling Tower Fill Material Selection Guidelines (BAC Practice)

Choose **PVC film fill** when:

* Clean to moderately clean water

* Standard HVAC condenser duty

* Lowest fan power desired

Choose **PP film or splash fill** when:

* High water temperature

* High TDS, oil, or suspended solids

* Industrial or process cooling

Common BAC Fill Problems & Solutions

Problem	Cause	Solution
Scaling	High hardness	Water treatment / periodic cleaning
Fouling	Dirty water	Switch to PP or splash fill
Brittleness	UV + heat aging	Replace with HT-PVC or PP
Collapse	Overtemperature	Upgrade material

BAC Replacement Fill Notes

* Always match BAC model & serial number

* Fill geometry is model-specific

* Mixing different fill materials is not recommended

* Use OEM or BAC-approved equivalent fill

BAC vs Other Brands (Material Comparison)

Brand	Common Fill Material
BAC	PVC, HT-PVC, PP
Marley	PVC, PP
EVAPCO	PVC, PP
Hamon	PVC, PP, stainless splash