The invention relates to a heat exchanger apparatus comprising at least one metal sheet (10) (e.g. aluminium), and preferably a plurality in a stack. Each metal sheet (10) has a corrugated surface, with fabric covering at least a portion of one surface of the metal sheet to promote evaporation. A wetting agent (e.g. LiCl/Polyvinyl-Alcohol (PVA) solution) is provided in the fabric to promote wetting of the fabric, and also acts as an anti-microbial agent. The fabric preferably covers all of the corrugated surface, and two planar portions are provided above and below the corrugated surface respectively. In use, the heat exchanger apparatus is disposed with a long side vertical and the corrugated surface is disposed on a middle portion, the upper planar portion is contiguous with an air outlet, and/or the lower planar portion is contiguous with an air inlet. In a preferred embodiment, the corrugated surface has in cross-section a profile of a periodic waveform, wherein the peak-to-peak distance is 11.6 mm, the amplitude is 2.5 mm, and corrugations intersect the plane of the heat exchanger apparatus at an angle to that plane of 50 degrees. Also disclosed are a cooling system incorporating the heat exchanger apparatus and methods of operating the cooling system, involving intermittently operating a water supply system for the application of water to the fabric, and/or, recirculating water from a water sump using the water supply system.

An air transfer apparatus being made as a monolithic or an integral structure or enclosure. The air transfer apparatus is made from a non-porous material and is made from any of the manufacturing methods of molding, injection molding, gas assisted injection molding, liquid/water assisted injection molding, blow molding, extruding, electrofusion or 3-D printing. The air transfer apparatus can be any of a cooling tower, a swamp cooler or a cooling Indirect Direct Evaporative Cooler. The air transfer apparatus has at least one integral cavity manufactured therein and at least one heat exchanger pad can be attached to the air transfer apparatus or made integral with the air transfer apparatus.

A fill sheet and a fill pack manufactured from a plurality of fill sheets for cooling a cooling medium in a cooling tower, each fill sheet having a plurality of flutes extending diagonally from top to bottom of the fill sheet, the diagonal orientation of the flutes resulting from a plurality of alternating longer diagonal flute segments and shorter vertical flute segments, each of the plurality of flutes having the microstructure comprising a plurality of alternating rounded mounds and rounded depressions extending between flat ridge edges and flat valley edges of said flutes.

Methods and apparatus for shredding cooling tower debris are provided herein. In some embodiments, a method of preparing debris for disposal includes: receiving debris from a cooling tower; processing the received debris through a low RPM shredder to reduce the size of the debris; depositing the reduced size debris onto a conveyor; and moving the debris along the conveyor and depositing the debris into a receptacle.

A water redistribution system for adiabatically pre-cooled dry coolers having stacked adiabatic panels, the water redistribution system located between upper and lower adiabatic panels and having a plurality of alternating baffles arranged to reduce water free-fall height and resultant splashing. Upwardly turned flanges at the top of each baffle inhibit the travel of water out of the interior water channel.

A fill sheet for cooling heat transfer fluid in a cooling tower includes an air intake end, an air outlet end, a top edge and a bottom edge. The air outlet end is positioned opposite the air intake end along a lateral axis. The top edge connects the air intake end and the air outlet end and the bottom edge also connects the air intake end and the air outlet end. The bottom edge is positioned opposite the top edge along a vertical axis. A plurality of flutes extends generally parallel to the lateral axis between the air intake end and the air outlet end. An offset extends generally parallel to the vertical axis. A first flute of the plurality of flutes transitions from a first peak at a first side of the offset to a first valley at a second side of the offset.

A pre-evaporative system used with an evaporative cooling apparatus is provided. The system may include a pre-evaporative media and a cooling media, each having a fiber pad with an edge coating and a distribution plate. The distribution plate operates to evenly distribute water over the entire surface. The system includes a shield with a mounting plate. The shield with the mounting plate operate to retain the pre-evaporative media and the cooling media adjacent each other; to form a seal with the distribution plate of the pre-evaporative media and with the distribution plate of the cooling media; and to shield a first water distribution pipe and a second water distribution pipe that supply water to the pre-evaporative media and the cooling media.

A cooling tower splash bar hanger assembly includes a grid comprised of a plurality of wires, including vertical and horizontal wires, defining a plurality of slots. The plurality of vertical wires includes a first vertical wire and a second vertical wire. The plurality of slots includes a first slot. The first slot defines a first slot width. A first splash bar defines a first bar width and is configured for positioning in the first slot supported by one of the plurality of horizontal wires. A second splash bar defines a second bar width. The second splash bar is supported by the one of the plurality of horizontal wires. The first slot width is greater than the first bar width and the second bar width. The first slot width and the first bar width define a size ratio of approximately two to one or greater than two to one.

An open mesh member for insertion into a cooling tower utilizing polluted or clean water and counterflow or crossflow airflow includes a plurality of corrugations including upper support frames, lower support frames and a wall strand. The upper and lower support frames extend at a corrugation angle relative to a height axis. The corrugations have a plurality of openings through a thickness of the mesh member. A planar edge positioned at a first end of the mesh member. A beveled edge positioned at a second end of the mesh member. The beveled edge includes a first bevel extending distally from one of the upper support frames. The bevel includes first and second legs and a distal end. The first and second legs extend substantially parallel relative to the associated upper support frame.

A cooling apparatus for cooling a waterflow is provided. Cooling apparatus includes a first evaporative cooler adapted to cool the waterflow therethrough, a second evaporative cooler adapted to receive and cool the waterflow from the first evaporative cooler therethrough, wherein the second evaporative cooler is adapted to receive an airflow therethrough to cool the waterflow therethrough and the first evaporative cooler is adapted to receive the airflow therethrough from the second evaporative cooler to cool the waterflow therethrough, and a deflector adapted to deflect the waterflow from the first evaporative cooler to the second evaporative cooler and allow the airflow from the second evaporative cooler to the first evaporative cooler therethrough. A cooling method for cooling a waterflow is also provided.