Hybrid cooling tower combines wet cooling (evaporative) and dry cooling (air-cooled) to efficiently manage heat by switching between modes or operating both simultaneously, often using a closed heat exchanger design to protect the process fluid. In drier conditions, the tower operates in dry mode, using ambient air over finned tubes to cool the process fluid. During high heat, the system wets the coils or fills, initiating evaporation to supplement the cooling and provide higher heat removal capacity. This dual-mode operation reduces water consumption and visible steam plumes, optimizing performance based on ambient temperature and humidity. 

How it Works

1. Dry Cooling (Air-Cooled Heat Exchanger):

Hot process fluid flows through a heat exchanger composed of finned tubes.

A fan draws ambient air over these finned tubes, absorbing heat from the fluid through direct air-to-tube contact.

This is the primary mode in cooler weather, conserving water.

2. Wet Cooling (Evaporative Cooling):

When the ambient temperature rises, the dry cooling alone may not be enough.

A fine mist of water is then sprayed onto the coils or wet the fill material.

This water then evaporates from the surfaces, using the latent heat of vaporization to cool the air significantly.

The now cooler, saturated air flows over the finned tubes, enhancing the heat transfer and cooling the process fluid further.