Cooling towers are a special type of heat exchanger that reduce the temperature of hot water using water and air. During the operation of these towers, a small amount of water evaporates, which results in a decrease in the circulating water temperature. Therefore, cooling towers are directly exposed to humidity, extreme temperature changes, and water impacts.
All mechanical structures deteriorate and break down over time, and cooling towers are no exception. These damages lead to significant financial and time costs for industrial units. Traditionally, the common solution to this problem was the replacement of the entire tower or the damaged area, which required shutting down the production line. Today, with the advancement of science and technology, innovative methods have replaced the old ones.
With the introduction of advanced materials, especially composites, into the cooling tower repair industry in developed countries, very beneficial results have been achieved. In response to the pressing needs of industrial units in the country, the technical and engineering research and development team at Farasath Zarfam has successfully localized this knowledge and technology in the country.
As we know, concrete is very weak against impacts, corrosive materials, temperature, and water, which requires reinforcement. In the Basin area of these towers, which are usually made of concrete, concrete gradually deteriorates due to water splashing, high temperature gradients, impacts, etc. Over time, the rebar inside the concrete also corrodes. The following images show examples of concrete and rebar deterioration in these towers.
The experienced technical and engineering team at Farasath Zarfam can assist you in determining the best methods and selecting materials for repairing, replacing, or reconstructing damaged structures, regardless of the cooling tower’s manufacturer or its age.
The repair and reinforcement methods used by Farasath Zarfam involve fiber-reinforced polymer composites (CFRP, CRP, FRP, GRE, GRP, CFRTP). Due to the variety of resin and fiber options, the most important challenge is choosing the correct materials. The fibers used for repairing these towers are typically made of fiberglass and carbon.
Carbon fibers are only justified in cases where very high strength is required due to their high cost. The use of composites in the repair of these towers offers numerous advantages, some of which are as follows:
- No rusting
- High mechanical strength (flexural, shear, and torsional reinforcement)
- Ability to enhance mechanical properties in the desired direction
- High tolerance for temperature gradients
- Resistance to water impact
- Insulation properties
- Fire resistance
- Resistance to corrosion and moisture
- Impermeability to insects and water
It is worth mentioning that the repair methods designed by Farasath Zarfam comply with the latest global standards.