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Design Methodology:

1. Thermal Load Distribution:

   • Split the cooling duty between the dry section (air cooler) and the wet section (cooling tower).
   • The dry cooler handles sensible heat removal using ambient air, reducing water usage.
   • The wet section polishes the final temperature drop, leveraging evaporative cooling.

2. Configuration Options:

   • Series Configuration: Air cooler first, followed by a cooling tower.
   • Parallel Configuration: Both units operate simultaneously on separate loops or stages.
   • Choose configuration based on climate, cooling range, and process requirements.

3. Materials & Components:

   • Use galvanized steel or stainless steel for dry cooler coils.
   • Select corrosion-resistant fill and efficient drift eliminators in the wet section.
   • Fan systems must be optimized for both air velocity and energy consumption.

4. Control System Integration:

   • Implement smart controls to adjust fan speeds and bypass valves based on ambient temperature and cooling demand.
   • Automated switching between dry and wet modes can drastically reduce water and power consumption.

5. Water Management:

   • Design water circuit with minimal blowdown and make-up needs.
   • In some designs, adiabatic cooling (mist pre-cooling for air) is added to further reduce tower water use.

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Retrofit & Optimization:

1. Dry Add-on to Existing Tower:
   Retrofit an air-cooled coil bank upstream of an existing wet cooling tower to reduce plume and water load.

2. Energy Efficiency Improvements:
   Add VFDs to fan motors and install real-time control systems for dynamic operation based on process load and climate.

3. Plume Abatement:
   In cold climates or urban zones, hybrid towers help eliminate visible plume without sacrificing thermal performance.

4. Water Savings:
   Operate in dry mode during winter or low load periods to significantly cut water consumption.

5. Performance Monitoring:
   Use IoT sensors for predictive maintenance, water chemistry tracking, and optimization of hybrid mode switching.

technical info