Splash Fill Vs Film Fill Cooling Tower

In the cooling tower system, the filling material is the core component that affects heat exchange capacity, operating costs, and overall efficiency. This article will delve into the structural differences, advantages and disadvantages, applicable scenarios, and issues that enterprises should pay attention to when selecting or renovating cooling towers between splash fill vs film fill cooling tower from a professional perspective.

What is the function of a cooling tower fill?

The cooling tower fill is the "core heat exchange zone" of the cooling tower, which increases the contact area between water and air, prolongs the residence time, and thus improves the efficiency of evaporative cooling. Common cooling tower fills can be divided into two categories:

1.Splash Fill

2.Film Fill

The two types of fill structures and working methods are completely different, so the correct choice must be made in the design and renovation of cooling towers.

The core difference between Splash Fill vs Film Fill Cooling Tower

What is Splash Fill?

Splash Fill is a multi-layer grid or Flat noodles structure that allows the water flow to be continuously "broken" into drops, increasing the area of contact with the air.

Features:

1）Low water quality requirements, almost no blockage

2）Low cleaning and maintenance costs

3）Suitable for circulating water systems with high turbidity, high solid content, and high temperature

4）The cooling efficiency is slightly lower than that of thin film fillers

Applicable scenarios:

1）Power plant cooling tower

2）Chemical plants, refineries

3）Steel and metallurgical industry

4）High temperature waste heat cooling tower

What is Film Fill?

Film Fill uses regular corrugated PVC sheets to form a thin film of water on the surface, improving heat exchange efficiency.

Features:

1）High cooling efficiency, it is the most common type of cooling tower fill

2）Low wind resistance and good energy-saving performance

3）High requirements for water quality, prone to scaling and blockage

4）Not suitable for water systems with high levels of oil or particulate matter

Applicable scenarios:

1）Hotel and office building air conditioning cooling tower

2）Commercial HVAC system

3）Cleaner circulating water system in industry

Splash Fill vs Film Fill Cooling Tower: Selection Suggestions

If the water quality is poor → choose Splash Fill

For example:

1）Supplement water to surface water and river water

2）Containing suspended solids, oil stains, algae, etc

3）There is high-temperature water present

The structure of Splash Fill is naturally resistant to dirt, non clogging, and has higher reliability.

If pursuing high efficiency and clean water quality → Choose Film Fill

For example:

1）Commercial air conditioning cooling tower

2）Low pollution circulating water

3）Film Fill has low loss and large heat transfer area, which can achieve lower cooling water outlet temperature.

Summary of the advantages and disadvantages of two cooling tower fills

Advantages of Splash Fill

1）Not easy to block (resistant to oil stains/suspended solids)

2）Not prone to scaling and biofilm formation

3）Easy maintenance

4）Long lifespan

Disadvantages of Splash Fill

The cooling efficiency is slightly lower than that of thin film fillers

Advantages of Film Fill

1）The highest heat transfer efficiency

2）The tower structure is more compact

3）High energy efficiency, saving operating costs

Disadvantages of Film Fill

1）Need clean water quality

2）Easy to clog, requiring more maintenance