QUALITY

EFFICIENCY

HYGIENE

THE COOLING TOWER COLLECTION

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For more than 50 years our company name has stood for for cooling towers of excellent quality - not just in standard sizes, but also in special builds of any dimensions.

Consistent production using high quality materials and components, constant optimisation of our equipment and processes, as well as outstanding customer focus in all corporate divisions are fundamental elements of our philosophy.

First and foremost our clients attach importance to the solid, du-rable and sustainable systems that we provide at our cooling tower manufactory.

Our founders, Dr Albert Saetzler and Rico Friedolin Kundert, were the first to have the vision of first-class performance and the highest quality.

To this day, we have been driven and guided by this claim. Since being founded we have produced over 10,000 cooling systems.

• Evaporative, re- or dry coolers • Open and closed systems • Radial and suction fan

cooling towers

These are used in more than 100 countries worldwide. Our staff meet client requirements with know-how, experience and commitment.

Our common target is: We find the right solution for our clients!

KTK KÜHLTURM KARLSRUHE

HYBRID COOLER 5

RADIAL FAN COOLING TOWERS 13

AXIAL FAN COOLING TOWERS 21

COOLING TOWER SERVICE 25

• Hygienic and biocide-free • Fresh water spraying • Very low water consumption • High changeover points • Low pressure spraying system • Low energy consumption

• Compact, strong and extremely adaptable • Easy to soundproof with inlet and outlet sound dampeners• Also suitable for internal installation • Available with fully welded wet cells• KTK design always optimised for hygiene• For open or closed circuits

• Powerful with the smallest footprint • Extremely flexible with a high output density • Fitted with high-performance axial fans • On request, particularly quiet and with gearless permanent magnet motors• KTK design always optimised for hygiene • For open or closed circuits

• Your cooling tower in good hands • Cooling towers for lease • Assembly • Maintenance • Repairs • Spare parts

TABLE OF CONTENTS

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EXPERIENCE THE HIGHEST QUALITY:

• With professional advice provided by our engineers.• Due to our staff's high-level qualifications and many years of experience.• By us carefully selecting the right system for and with you,

and bearing in mind all important criteria for you.• With the accurate and sustainable planning of your recooling projects.• With individual and reliable production of 'your' cooling system in our manufactory.• By means of comprehensive service from assembly to maintenance.

HIGH-QUALITY ENGINEERING AND DESIGN, CALCULATIONS AND KNOW-HOW

• Professional and individual advice• Durable, high-quality and bespoke solutions• Planning support is of course included• Optimum selection of product from our extensive range

HIGH-QUALITY DESIGN AND HAND-CRAFTED PRODUCTION

• High degree of impermeability• Easy accessibility to all components• Low-maintenance water distribution• Lean production from 3D design up to sheet metal working

HIGH-QUALITY MATERIALS AND ACCESSORY PARTS

• Cooling towers of corrosion- and weather-resistant stainless steel • Low-maintenance, high-quality fans and drives• High-performance packing and droplet separators• Recoolers with hygiene filters and reliable hygiene concept

QUALITY FROM OUR COOLING TOWER MANUFACTORY

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HYGIENIC AND BIOCIDE-FREE

RECOOLERS

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At our latitudes, the ambient air temperature fluctuates greatly between summer and winter.

Therefore, depending on the cool-ing task, it be economically viable to use recoolers.

In summer they exploit the water's evaporation energy, and in winter dissipate the heat via the in-creased ambient air temperature.

In winter and during the transitional period, i.e. the lion's share of operating hours, the device is operated as a pure dry cooler.

High-performance finned heat exchangers are used to achieve the highest possible dry-wet changeover points.

This saves the maximum amount of water.

The heat exchanger surface is only sprayed when ambient air temper-atures are high during the summer months.

In doing so, a mist of treated water is sprayed onto the device's fins. The water evaporates on the heat exchanger's fins.

The required evaporation energy cools the fins and as such the liquid in the heat exchanger. Spraying causes a small amount of excess water, which is not re-used.

OPERATING MODES

The higher the changeover point from dry to wet cooling, the more economic the system!

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ADVANTAGES OF OUR RECOOLER

PAY ATTENTION TO THE CHANGEOVER POINT!

The following are important when selecting a recooler with regard to its efficiency

• the changeover point at which the system switches from dry to evaporative cooling.

• Due to their high changeover point KTK recoolers can be operated for most of the year as dry coolers, with the heat exchange surface only being sprayed at the height of sum-mer. This saves the maximum amount of water.

• The higher the changeover point, the more economic the system!

Comparing the wet/dry operating hours and the annual water con-sumption at the Essen site with differ-ent changeover points clearly shows how high the cost saving can be with a high changeover point (Saving here: over 125,000 e/year)!

Fresh water spraying

High changeover points

Very low water consumption

Low cooling water temperature

Low energy consumption

Hygiene certified

Hygienic

Low-pressure spraying system

No vapour formed

Changeover point 13 °C

Dry mode hours

Wet mode hours

Annual water consumption with different changeover points

Changeover point 19 °C

Dry mode hours

Wet mode hours

33 %

67 %

9 %

91 %

40,000

30,000

20,000

10,000

m3/aChangeover point 13 °C Changeover point 19 °C

177,382 E/a

50,976 E/a

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INCLINED TRAY BOTTOMS

With KTK cooling towers, the bottom of the collection tray is always sloped so that residual emptying is always at the lowest point of the basin.

The channels for removing water are also covered with a protec-tive grate.

This allows complete draining and makes cleaning substantially easier.

HYGIENE DETAILS

Air intake filter optional

EASY ACCESSIBILITY

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QUALITY CHARACTERISTICS

FANS AND DRIVES

The axial fans arranged for suction are intended for stepless speed regulation using a frequency con-verter. Compact fans with geared motors, slow-turning permanent magnet motors, or fans with exter-nal rotor motors are used.

As standard the motors receive motor protection using thermal contacts, are provided with corro-sion protection for external instal-lation, and can be operated with outlet air temperatures of -40 °C to +60 °C.

Sophisticated three-dimensionally curved wing shapes are used that are very quiet.

The low-pressure spraying system for direct moistening of the fins in wet mode at KTK are of height-ad-justable stainless-steel tubes and easy-to-change plastic spray nozzles.

Low-pressure spray systems are significantly more economic and quieter than high-pressure spray systems.

LOW-PRESSURE SPRAY SYSTEM

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BIOCIDE-FREE

With KTK recoolers, extremely pure osmosis water is provided for spraying, which almost completely evaporates. This completely eradicates the need to treat water with anti-corrosion agents, hardness stabilisers and biocides.

Spraying creates a minimum amount of excess water. This excess water is not re-used.

FRESH WATER SPRAYING

Not recycling the spray water prevents micro-organisms from reproducing in this area.

The amount of spray water is automatically optimised by the control unit integrated into the switch cabinet depending on the load on the device and the state of the ambient air.

BIOCIDE-FREE RECOOLERS

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HYGIENE FILTER

The hygiene filter with a filter mesh of 0.2 µm holds back any bacteria in the spray water.

In addition, for reasons of hygiene the spraying system is operated in such a way that even in low spraying periods, fresh water is repeatedly flushed through.

INCLINED WATER DISTRIBUTION PIPES

The inclined design of the spray-ing pipes provides complete draining of the entire spraying system. This structural measure acts to prevent stagnant water encouraging the build up of germs and represents an additional hygiene detail.

HYGIENE DETAILS

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GREATEST PRACTICAL COOLING TOWER KNOW-HOW

The five high-performance fans with a 3m diameter are located 15m above the ground. Around 300 m2 of sound dampening equipment ensures quiet in front of the shopping centre.

The complete system delivers 9 MW of cooling capacity and extends over three stories. It runs completely without recirculating the evaporation water. The hybrid operation allows the systems to be operated at cooler ambient air temperatures like a dry cooler. In comparison to wet cooling, this leads to more appreciable water savings.

SPECIAL HYBRID PROJECT: SHOPPING CENTRE

HEAT EXCHANGERSINSTALLATION: BESPOKE!

EASY ACCESSIBILITY

3.00 m

View of the 15m high ceiling

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COMPACT, STRONG AND EXTREMELY ADAPTABLE

RADIAL FAN COOLING TOWERS

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FOR OPEN CIRCUIT• The circulation water

comes into direct contact with the ambient air

• The type of cooling tower with the highest output density

• Output per cooling tower cell: up to 2,000 kW

FOR CLOSED CIRCUIT• No direct contact with

the ambient air

• Hydraulic simple connection by the closed circuit

• Output per cooling tower cell: up to 800 kW

EXCELLENT RANGE - EXTREMELY ADAPTABLE

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RADIAL FAN EVAPORATIVE COOLING TOWERS

with soundproofing aspirating at the top - blowing out at the top

Fan below the packing with small footprint (here with soundproofing)

Single-cell cooling tower

with soundproofing aspirating at the top - blowing out at the top

Fan below the packing (here for closed circuit)

Multiple cell cooling tower

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BLOW-VENTILATED EVAPORATIVE COOLING TOWERS

Open cooling towers have the maximum output density.

Due to its uncomplicated design and very low space requirement, the open cooling tower with radial fans is suited for nearly all areas of cooling in industry demanding coolant temperatures below the ambient air temperature.

Open KTK cooling towers are suit-ed for the free cooling in the cold times of the year even with tem-peratures below zero by bypassing the cooling unit.

This provides an additional energy saving

SOUNDPROOFING

Radial fan cooling towers are very good sound insulators. With high noise requirements the devices are fitted with additional sound insulators, with retrofitting also possible.

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Radial fan heating tower with plate heat exchangers

Stainless-steel water distribution with hollow-cone spray nozzles

COMPACT, STRONG AND EXTREMELY ADAPTABLE

Radial fan cooling towers require a relatively small footprint, are flexible to adjust, and can be fitted with inlet and outlet air soundproofing. They are also suited for internal installation.

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INCLINED TRAY BOTTOMS

With KTK cooling towers, the bot-tom of the collection tray is always sloped so that residual emptying and the return flow is always at the lowest point of the basin.

This allows complete draining and makes cleaning substantially easier.

The entire wet cell can be exposed for cleaning or maintenance in just a few steps. The light-weight plastic water distribution pipes are particu-larly easy to dismantle, for example when changing nozzles.

HYGIENE DETAILS

WATER DISTRIBUTION MADE FROM PLASTIC OPTIMISED FOR HYGIENE AND FLOW AS AN ALTERNATIVE.

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SEPARATE DRIVE FOR EACH FAN

EASY ACCESSIBILITY

OPERATIONAL SECURITY

Each fan is driven by a separate motor.

The individual powering of fans leads to optimum operational security with multi-cell cooling towers. In the event of a motor failing, only the affected cooling tower cell would be taken out of service.

These are easier to replace due to the low weight of the motors used by us.

QUALITY FITTIINGS

The heat exchanger bodies used are of resistant plastic. For most cases, packing with 12-15mm channel widths of polypropylene resistant up to 80°C is used.

For specific applications, in par-ticular with heavily fouled circula-tion water, we use appropriately suited special packing, e.g. resist-ant up to 100°C.

KTK only uses Eurovent-certified droplet separators.

QUALITY CHARACTERISTICS

MIRRORED DESIGN

COMPLETELY WELDED WET CELLS

Fully welded cooling tower wet cells (optional) meet the most rig-orous of demands of durability and hygiene thanks to being made en-tirely of stainless steel, their straight-forward full-chemical cleaning and superheated steam cleaning. They are the first choice among evapo-rative cooling towers for hospitals, clean rooms or the food & bever-age industry.

The structural combination of 2 to 6 cells in a mirrored assembly in one device allows additional space saving and simplified connection to the water with radial fan cooling towers.

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POWERFUL WITH THE SMALLEST OF FOOTPRINTS

AXIAL FAN COOLING TOWER

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Axial cooling towers require the smallest footprints. For the open circuit, they represent the design with the greatest output density.

Due to its uncomplicated design and very low space requirement, the open cooling tower with axial fans is suited for nearly all areas of cooling in industry demanding coolant temperatures below the ambient air temperature.

Open KTK cooling towers are suited for the free cooling in the coldest times of the year even with temperatures below zero by bypassing the cooling unit. This provides an additional energy saving.

HIGHEST PERFORMANCE WITH THE SMALLEST OF FOOTPRINTS

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QUALITY CHARACTERISTICS

The high-performance fans used stand out for their very low power consumption, which leads to lower operating costs.

As standard the motors receive motor protection using thermal contacts, are provided with corrosion protection for external installation, and can be operated with exhaust air temperatures of -40 °C to +60 °C.

With higher noise requirements, the devices are fitted with special low-noise fans and additional impact dampers.The heat exchanger bodies used are of resistant plastic. For most

cases, packing with 12-15mm channel widths of polypropylene resistant up to 80°C is used.

For specific applications, in particular with heavily fouled circulation water, we use appropriately suited special packing, e.g. resistant up to 100°C.

FANS AND DRIVES EASY ACCESSIBILITY

QUALITY FITTINGS

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KTK AXIAL FAN COOLING TOWERS

When designing and constructing axial fan cooling towers, our engi-neers also respond flexibly to our clients' wishes.

Axial cooling towers of various dimensions and outputs, with muf-flers if desired, for open or closed circuits.

ASSEMBLY, MAINTENANCE, REPAIRS, SPARE PARTS, COOLING TOWERS FOR LEASE

COOLING TOWER SERVICE

... REGARDLESS OF YOUR COOLING TOWER'S AGE AND MANUFACTURER

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WE PERFORM THE FOLLOWING SERVICES FOR YOU

- REGARDLESS OF THE MANUFACTURER AND AGE OF YOUR COOLING TOWER -

• Assembly and commissioning

• Individual service and maintenance agreements

• Performance measurement

• Checking your water values

• Chemical and mechanical cleaning

• Delivery and installation of spare parts

• General overhaul at fixed price and with warranty

• Retrofitting of mufflers and air filters

KTK COOLING TOWER SERVICE

COOLING TOWERS FOR LEASE

For your system security in emergencies or for short-term use we are happy to also provide you with equipment for lease from all areas of system solutions - wet, dry and recooling.

• On-site replacement of motor and fan bearings on site

• Waterproofing of recoolers by welding or renewal of flexible joints

• Documentation of all maintenance work

• Advice on technical innovations

• Energy optimisation

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Over 55 parameters are evaluat-ed at KTK to find the cooling tower most suited to you specific case. Examples of these are:

• different performance profiles,

• consideration with and without cooling units,

• varying costs for water and power,

• depending on where installed, varying meteorological data (DIN 4710)

FINDING THE RIGHT SYSTEM

Would you like to know which is the right system, and which is the most favourable cooling tower under the given framework conditions for a specific project?

This tool allows you to compare different KTK cooling towers and comparable types of cooling tower from other manufacturers.

The KTK efficiency calculation shows:

• Which system has the lowest in-vestment?

• Which system has the lowest op-erating costs?

• Which system demonstrates the lowest CO2 emissions in opera-tion?

Consumer refrigeration capacity kW 1,000

Annual operating hours h/a 6,000

Quality of the cooling unit – very good

Representation in accordance with DIN 4710 Mannheim

Load profile 50 % Basic load + air conditioning as of

Design output kW 1,147 1,246

max. operating output kW 1,147 1,246

Surface reserve % 0

Inlet temperature °C 33.0 46.0

Outlet temperature °C 27.0 40.0

Air temperature °C 34.0 34.0

Wet bulb temperature °C 22.0

Device typeOpen cool-ing tower

RecoolerClosed cool-

ing towerDry cooler

Changeover temperature °C 18.0 -10.0

Ethylene glycol % 34.0 34.0 34.0

Annual costs E/a 108,649 99,613 115,285 148,663

20.0 °C

De

sign

da

ta

Sole

The KTK efficiency calculation cor-responds to the recommends of the VDMA unit sheet 24659.

The findings help you make the right decision.

THE KTK EFFICIENCY CALCULATION

"QUALITY BEGINS BY PLACING CUSTOMER SATISFACTION AT THE CENTRE OF OUR THINKING."

John Fellows Akers (1934-2014),

CEO at IBM (1984-1993)

GOHL-KTK GmbH · Schlosserstraße 5 · 76448 Durmersheim

Telephone +49 - 72 45 - 9 19 16-0 · Fax +49 - 72 45 - 9 19 16-11

kuehlturm@kuehlturm.de · www.kuehlturm.de

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