BAC Closed Circuit Cooling Towers

Baltimore Aircoil Company (BAC) is the world’s largest manufacturer of cooling towers. With over 75 years of experience and over 100 patents in the field, BAC offers reliable and efficient cooling technologies for industrial, HVAC and refrigeration processes.

Closed circuit cooling towers or fluid coolers operate just like the open type, but dissipate the process fluid heat load into the ambient air via a heat exchange coil. This isolates the process fluid from the outside air, keeping it clean and free of contamination in a closed loop and creating 2 separate fluid circuits:

1. An external circuit, in which spray water circulates over the coil and mixes with the outside air.
2. An internal circuit, in which the process fluid circulates inside the coil.

During the evaporative cooling operation, heat goes from the internal circuit, via the coil to the spray water, and then to the open air as a portion of the evaporating water.

The key benefits of closed circuit cooling towers are

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Contaminant-free cooling circuit

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Dry operation in winter

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Reduced system maintenance

economy-saver

Lower overall system costs thanks to year-round savings on maintenance, water, energy and water treatment

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The patented Baltibond hybrid coating

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Eurovent certification

Cooling tower
VXI

Overview

Reliable operation guaranteed

Since 1978, thousands globally installed, proving the VXI coolers reliability

Fans, motor and drive system (V-belt) are located in the dry air, preventing moisture and condensation.  No external moving parts, helping it withstand the toughest weather.

Various corrosion-resistant materials, including the unique Baltibond hybrid coating for guaranteed long service life.

Optional extended surface coil with steel fins for dry operation


Ideal for a quiet operation

VXI closed circuit cooling towers include quiet internal centrifugal fans for minimal surrounding noise.

Single-side air inlet, and a quieter tower rear for more noise-sensitive areas.

Cut operation noise still further with factory-designed and tested sound attenuators.


More compact

Compact design for confined spaces,

Single-side air inlet lets you install next to solid walls,

Units housable indoors thanks to centrifugal fans allowing intake or discharge ductwork.


Reduced shipping, rigging and installation costs

VXI units are factory-assembled. We ship larger models in 2 sections to reduce the size and weight of the heaviest section for easy on-site assembly with smaller cranes

VXI offers high capacity and minimal operating weight. Save on steel supports, both underneath the equipment and in the building itself for rooftop installations.

VXI-C models can be container-shipped (in 12’ containers). Fan enclosures shippable loose in the tower bottom section for easy on-site assembly.

Principle of Operation

Warm process fluid (1) enters through a heat exchange coil (2) and gets water sprayed on by the spray system (3) at the top of the cooling tower. At the same time the centrifugal fan (4), located at the bottom of the unit, blows ambient air upwards (5) through the tower. During operation, heat is transferred from the internal circuit coil to the water, and then to the atmosphere as a portion of the water that evaporates. The cooled down fluid then exits the unit (6). The tower sump (7) or basin collects the remaining water. The spray water pump (8) recirculates the water up to the water spray system. The warm saturated air (9) leaves the tower through the drift eliminators (10), which remove water droplets from the air.

Key benefits

  • Reliable
  • Quiet
  • Compact

Typical applications

  • Small to medium HVAC and industrial applications
  • Tight enclosures and installations requiring a single air inlet
  • Indoor installations
  • Sound critical installations
  • High temperature industrial application
  • Dry operation in winter time
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Cooling tower
VFL

Overview

Low height

Very low height: fits perfectly on roof tops or tight enclosures.


Easy installation

VFL towers are factory-assembled. We ship in one piece for easy on-site lifting and installation.

VFL offers high capacity and minimum operating weight. Save on steel supports, both underneath the equipment and in the building itself for rooftop installations.

Single-side air inlet lets you install next to solid walls.

Units housable indoors thanks to centrifugal fans allowing intake or discharge ductwork.


Ideal for a quiet operation

VFL units include quiet internal centrifugal fans for minimal surrounding noise.

Single-side air inlet, and a quieter tower rear for more noise-sensitive areas.

Cut operation noise still further with factory-designed and tested sound attenuators or silencers.


Year-round reliable operation

Various corrosion-resistant materials, including the unique Baltibond hybrid coating for guaranteed long service life.

Optional Baltiguard Drive System for energy savings and less noise during low load (night). A perfect stand-by system in case of motor failure

Optional extended surface coil with steel fins for dry operation.

Principle of Operation

Warm process fluid (1) enters through a heat exchange coil (2) and gets water sprayed on by the spray system (3) at the top of the cooling tower. At the same time the centrifugal fan (4) blows ambient air upwards (5) through the tower. During operation, heat is transferred from the internal circuit coil to the water, and then to the atmosphere as a portion of the water that evaporates. The cooled fluid then exits(6) the unit. The tower sump (7) or basin collects the remaining spray water. The spray water pump (8) recirculates the water up to the water spray system. The warm saturated air (9) leaves the tower through the drift eliminators (10), which remove water droplets from the air.

Key benefits

  • Low height
  • Easy installation
  • Quiet

Typical applications

  • Small to medium HVAC and industrial applications
  • Low height requirements
  • Tight enclosures and installations requiring a single air inlet
  • Indoor installations
  • Sound critical installations
  • High temperature industrial application
  • Dry operation in winter time
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Cooling tower
HFL

Overview

Unrivalled water-saving

Patented intelligent flow control system!
With a 3-way valve for precise setting of outlet fluid temperature and unrivalled annual water-saving.

Load profile-adaptable to dry, adiabatic or combined wet-dry operation.


Compact

Side by side installation for double cell towers. Water basin access is at tower connection end.

Very low height. Fits perfectly on roof tops or tight enclosures.

Low operating weight. Water basin contains only 1/4 of the water of conventional evaporative fluid coolers.


Superb hygiene control

Dry-running for 10 months per year possible depending on application and weather conditions.

Self-cleaning auto-drain sump to prevent stagnant water.

Basin for water outside air stream and accessible during operation


For reduced noise

Low noise centrifugal fans for a quieter environment.

Single-side air inlet, and a quieter tower rear for more noise-sensitive areas.


Easy to install

Single-side air inlet lets you install next to solid walls.

Units housable indoors thanks to centrifugal fans allowing intake or discharge ductwork.


Guaranteed year-round reliable operation

During dry winter operation, no extra sump drainage needed. With HFL water basin outside airstream, and heaters to prevent basin water freezing, even with fans at top speed.

Non-plume wet operation thanks to optional dry finned coil: it reduces humidity of discharge air from the prime surface coil.


Various corrosion-resistant materials, including the unique
Baltibond hybrid coating for guaranteed long service life.

Principle of Operation

Dry operation

The spray water pump (1) and spray system (2) are turned off and the modulating flow control valve (3-way valve) (3) remains fully open. The warm process fluid (4) flows both through the finned discharge coil (5) and the prime surface coil (6). A fan (7) blows the ambient air (8) over the coil and cools the fluid (9) inside the coil. In this mode neither water consumption nor plume occurs.

Key benefits

  • Unrivalled water savings
  • Compact
  • Superb hygiene control

Typical applications

  • Medium to large HVAC and industrial applications
  • Low height requirements
  • Water saving requirements
  • Plume reduction requirements
  • Tight enclosures and installations requiring a single air inlet
  • Indoor installations
  • Sound critical installations
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Cooling tower
FXVS

Key benefits

  • Star in energy efficiency
  • Low maintenance and easy inspection
  • Unmatched hygiene control

Typical applications

  • Small to medium HVAC and industrial applications such as water source heat pump loops and air compressor cooling.
  • Tight enclosures and installations requiring a single air inlet.
  • Ideal for unit replacement
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Cooling tower
PFI

Overview

Lowest energy consumption and total cost of ownership

Evaporative cooling for system-wide energy saving at lower operating temperatures.

The highly efficient OptiCoil System increases thermal performance up to 30% for the same coil volume lowering the installed fan power by up to 50%.

Elimination of potentially excessive operating costs. PFI is Eurovent-CTI certified for both water and glycol. This guarantees thermal performance and it eliminates field thermal performance testing costs.

System pump energy savings obtained through shorter coil circuits resulting in lower coil pressure drops.

Savings on maintenance and water treatment because the closed loop in PFI cooling towers ensures a contaminant-free cooling circuit.

Lower installed costs. PFI has a lower weight, reducing structural and vibration isolation costs. Less glycol is required to achieve the same or higher heat transfer.

Water and chemical savings up to 33% because Baltibond Hybrid Coating allows higher cycles of concentration.


Year round reliable operation

Trouble free process operation – The closed loop in PFI cooling towers protects the process fluid and equipment from external contaminations.

The thermal performance of PFI closed circuit cooling towers is tested and certified by Eurovent.

For extremely cold weather operation, switch off the spray system during periods of reduced load and operate dry.

Optimal thermal performance through lifetime. Lab tests have proven that the OptiCoil System reduces scale formation on the coil.

Minimum maintenance and downtime- Complete and easy access to all critical components, including coil.

Easy-clean and easy-inspect PFI towers reduce hygiene risks from bacteria (e.g. Legionella) or biofilm inside. 

Self-cleaning cold water basin sloping towards drain, to prevent sediment build up.

Combined inlet shields block sunlight to prevent biological growth in the tower, filter the air and stop water splashing outside.


Ideal replacement unit with certified thermal performance

Same or higher capacity. Ideal like-for-like solution, performing per published ratings. The PFI is independently Eurovent-CTI certified for various process fluids.


Low noise

A variety of fans is available to offer the perfect solution for every sound challenge.

Water silencers achieve noise levels close to those of crossflow towers. Water silencers come always with Whisper Quiet fans.

Factory designed, tested and rated sound attenuation is available on the discharge for further noise reduction.


Easy to maintain

The PFI closed circuit cooling tower is easier to maintain than other induced draft counterflow cooling towers.

Optional coil inspection hatches allow complete and easy access to heat transfer section

BranchLok water distribution – each branch removable for easy cleaning.

Combined inlet shields for easy no-tool removal.

Motor adjusters: externally accessible and locking wrench for easy motor alignment and belt tensioning.

Full cold water basin access when removing the combined inlet shields.

Fans easy accessible via sliding access door.

Optional clean out port helps remove silt and sludge from the cooling tower basin.

Removable suction strainer anti-vortex hood.


Ship and install PFI easily

Guide pins mean swift PFI cooling tower on-site assembly. The guide pins help reduce section assembly time by up to 75 %!

Compact PFI footprint – perfect for confined spaces.

Container shipment often possible!

Principle of Operation

The PFI features the OptiCoilTM System, which includes the BAC Versapak spray water cooling medium (1). This improves the overall cooling efficiency and ensures an optimal cooling of the warm process fluid (2) inside the coil (3), which is wetted by the spray system (4). The Versapak is inserted within the coil structure, engineered for easy inspection. The axial fan (5) draws ambient air (6) upwards through the tower. Combined inlet shields (7) protect the tower from debris being drawn into the unit. During operation, heat is transferred to the spray water, and then to the atmosphere as a portion of the water that evaporates. The cooled process fluid then exits the unit (8). The sloping sump (9) or basin collects the remaining water. The spray pump (10) recirculates the cooled water to the top of the tower. The warm saturated air leaves the tower through drift eliminators (11) which remove water droplets from the air.

Key benefits

  • Lowest energy consumption and total cost of ownership
  • Year round reliable operation
  • Ideal replacement unit with certified thermal performance

Typical applications

  • Medium to large HVAC and industrial applications
  • Dry operation requirement in winter time
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Cooling tower
HXI

Overview

No plume

Non-plume wet operation thanks to dry finned coil: it reduces humidity of discharge air from the prime surface coil.


Superb water saving

Patented intelligent flow control system!
With a 3-way valve for precise setting of outlet fluid temperature and unrivalled annual water-saving.

Load profile-adaptable to dry, adiabatic or combined wet-dry operation.


Cost-saving

Evaporative cooling PLUS unique combined heat transfer system for minimized system-wide energy consumption. 

Axial fan – half the consumption of rivals and huge single cell capacity: saving you more!

Less water usage = less water costs = less water treatment expenses


Low maintenance and easy inspection

Inspect and maintain safely HXI towers with unrivalled comfort, while standing inside.

The HXI has a spacious plenum (internal area) and easy inspection/maintenance access.

Access via large hinged door to internal walkway: no basin draining needed for unit interior inspection.

Easy to inspect the coil during operation from the outside or from the inside via the removable drift eliminator modules.

Easy to inspect the fill from the inside and via the removable combined inlet shields from the outside.

The patented Bacross fill sheets reduce fouling, allowing an easy inspection of the fill core without dismantling. Optional BACross fill bundles for quick and easy removal and cleaning of the fill.

Self-cleaning cold water basin and fill above sloped basin to flush out dirt and debris.

Removable suction strainer anti-vortex hood.

Make-up, drain and overflow easily accessible from the outside for inspection and cleaning.


Flexible operation

Multiple fan motor system covers independent fan motor and drive assembly per fan with a plenum partition for independent fan operation. For extra capacity control or stand-by fan in case of fan failure.

Various corrosion-resistant materials, including the unique Baltibond hybrid coating for guaranteed long service life.

Single-side air inlet and discharge, fits in most enclosures.

Unique and patented heat transfer system: featuring combined flow via heat exchange coil and fill pack, for fine temperature applications and thermal challenges.

Patented intelligent flow control system!


Maximum operational safety

Easy-clean and easy-inspect HXI units reduce hygiene risks from bacteria or biofilm inside.

Combined inlet shields block sunlight to prevent biological growth in the tower, filter the air and stop water splashing outside.

The patented BACross fill reduces fouling.

The drift eliminators certified by Eurovent, to prevent droplets escaping into the air.

Principle of Operation

Water saver mode

The spray water pump (1) is turned off and the modulating flow control valve (3-way valve) (2) remains fully open. The warm process fluid (3) flows both through the finned discharge coil (4) and the prime surface coil (5).

An axial fan (6) draws the ambient air (7) over the coil and the heat is rejected from the fluid inside the coil. In this mode neither water consumption nor plume occurs.

Key benefits

  • No plume
  • Superb water savings
  • Cost saving

Typical applications

  • Medium to large HVAC and industrial applications
  • Water saving requirements
  • Plume reduction requirements
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Cooling tower
NEXUS

Overview

Maximum Uptime

Units are CTI-Eurovent certified which guarantees thermal performance and eliminates field thermal performance testing costs.

Independent individual modules that guarantee redundancy.

Corrosion-resistant materials come standard for maximum equipment life: stainless steel hCoreTM Heat Transfer Techonology combined with Baltibond hybrid coating on all structural components, with corrosion resistance equivalent to SST 304L.

The cold water basin of the patent-pending DiamondClearTM Design can be inspected while the unit is in operation.

EC Fan Systems are located inside the unit, in the dry air, preventing condensation and eliminating corrosion issues and premature failures.

Direct driven fans eliminate potential mechanical failures.


Lowest operating costs

Innovative iPilotTM Control System with patented intelligence operates in multiple modes to optimize both water and energy savings based on your needs and preferences.

Patented hCoreTM Heat Transfer Technology delivers high thermal efficiency (wet and dry) in a compact footprint, maximizing both water and energy savings.

Patent-pending DiamondClearTM Design optimizes air distribution over the heat exchanger, provides continuous self-cleaning, reduces spray water volume by up to 60%, reduces water treatment and spray pump energy costs.

EC Fan System has a superior efficiency that exceeds the requirements of efficiency class IE4. Integrated electronics of EC motors permit variable speed control for maximum system efficiency, at a significantly reduced power consumption.

Energy efficient radial fans give up to 40% savings versus standard centrifugal fans and provide high external static capability.


Lowest environmental impact

Patent-pending DiamondClearTM Design offers a continuous self-cleaning operation. During standstill the sloping surfaces fully drain hence avoiding stagnant water inside the unit and the risk of sedimentation of impurities.

External collection basin with its 80% lower water volume reduces the chemical usage and eliminates the need to access the interior for cleaning.

Possibility to use water treatment systems that allow drainage from the hybrid cooler to surface water.

Completely encased collection basin eliminates any sunlight ingress, preventing biological growth.

Baltibond hybrid coating for a smooth surface finish that reduces biofilm development.

Guarantee operational safety through the optional factory installed chemical free UV biocide system.


Lowest installation costs

Can be installed as a single piece or as individual modules that fit in a freight elevator.

Up to 35% less weight, 40% smaller footprint and 1,5 m lower height.

Plug & Play design with innovative iPilotTM Control System and integrated electronics of EC motors, which eliminate external VFD’s, electronic filters and on-site shielded cable wiring.

Modular header included as standard for single point process fluid connections.

No passivation required due to fully corrosion-resistant structure and hCoreTM Heat Transfer Technology.

Pressure capability of fans allows indoor installation with ductwork.

Lowest maintenance

Patent-pending DiamondClearTM Design offers a continuous self-cleaning operation through fully sloping surfaces, a constant impact of falling spray water, high water velocities and 80% lower water volume (with no stagnant water inside the unit) minimizing the need for maintenance by reducing scale build-up and biological growth.

The external cold water basin with spray pump, the direct drive fan in the dry system, the water distribution system and drift eliminator are all easily accessible from the outside without the need for any permanent ladders or elevated platforms.

Swing-out EC Fan System allows easy inspection and requires no maintenance whatsoever.

Inspection and maintenance of critical parts is possible during operation.

Baltibond hybrid coating and stainless steel for a smooth surface finish that facilitates internal cleaning.

Principle of Operation

Nexus mode

In the revolutionary Nexus mode, you can prioritize water and energy savings to achieve the right balance of both. Your climate, cooling load profile and the rates you pay for water and energy will determine your specific settings, which can be easily adjusted as needed. You can specify the importance of water versus energy savings to automatically achieve the right balance for your specific situation.

Key benefits

  • Maximum Uptime
  • Lowest operating costs
  • Lowest environmental impact

Typical applications

  • Small to medium HVAC and light industrial applications with focus on reliability, efficiency and minimal maintenance
  • Tight enclosures and projects with height limitations
  • Indoor installations
  • Water saving requirements
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