MODULAR COOLING TOWER AND METHOD OF ASSEMBLING THE SAME

Abstract

A modular heat exchange system is provided. The modular heat exchange system includes an air inlet assembly, a plenum assembly, and a heat exchange assembly including at least one heat exchange module. The at least one heat exchange module includes at least one fill module. The at least one fill module includes a plurality of fill sheets arranged on at least one support member. The at least one support member includes a first end and a second end. A plurality of fill packs is also provided on the at least one support member. Each fill pack includes a plurality of bonded fill sheets. A first fill pack is coupled to the first end of the at least one support member and a second fill pack is coupled to the second end of the at least one support member.

Claims

1. A modular heat exchange system, comprising: an air inlet assembly; a plenum assembly; and a heat exchange assembly including at least one heat exchange module, wherein the at least one heat exchange module comprises at least one fill module, the at least one fill module including: a plurality of fill sheets arranged on at least one support member, the at least one support member having a first end and a second end; and a plurality of fill packs including a first fill pack and a second fill pack, wherein each fill pack comprises a plurality of bonded fill sheets, wherein the first fill pack is coupled to the first end of the at least one support member and the second fill pack is coupled to the second end of the at least one support member.

2. The modular heat exchange system of claim 1, wherein the at least one support member extends along an axis substantially perpendicular to the plurality of fill sheets.

3. The modular heat exchange system of claim 1, wherein a third fill pack is coupled to the first end of the at least one support member and is positioned adjacent to the first fill pack.

4. The modular heat exchange system of claim 1, wherein a third fill pack is coupled to the second end of the at least one support member and is positioned adjacent to the second fill pack.

5. The modular heat exchange system of claim 1, wherein the at least one heat exchange module comprises a first heat exchange module, a second heat exchange module, and a third heat exchange module, wherein the first heat exchange module is disposed adjacent to the second heat exchange module and the second heat exchange module is disposed adjacent to the third heat exchange module.

6. The modular heat exchange system of claim 5, wherein at least one of the first heat exchange module, the second heat exchange module, and the third heat exchange module comprises the at least one fill module.

7. The modular heat exchange system of claim 1, wherein the plurality of fill packs are designed to maintain the plurality of fill sheets in a predetermined orientation during transport.

8. The modular heat exchange system of claim 1, wherein the plurality of fill sheets comprise about 50 percent to about 90 percent of an overall volume of the at least one fill module.

9. The modular heat exchange system of claim 1, wherein the modular heat exchange system further includes a cold water collection basin having at least one cold water collection basin module, wherein the cold water collection basin is positioned adjacent to and below the heat exchange assembly.

10. A fill module for use in a heat exchange system, the fill module comprising: a first plurality of fill sheets provided on a first support member, the first support member including a first end positioned opposite a second end; and a plurality of fill packs, wherein each fill pack comprises a second plurality of fill sheets bonded together, wherein a first fill pack is coupled to the first end of the first support member and a second fill pack is coupled to the second end of the first support member.

11. The fill module of claim 10, wherein the first plurality of fill sheets are provided in the form of structurally-restrained fill.

12. The fill module of claim 10, wherein the plurality of fill packs are designed to stabilize the first plurality of fill sheets during transport of the fill module.

13. The fill module of claim 10 further comprising a second support member, wherein the first plurality of fill sheets are provided on the second support member.

14. The fill module of claim 10 further comprising at least one opening to receive a riser.

15. A method for assembling a modular heat exchange system comprising: assembling a fill module by: providing a plurality of fill sheets in a stack, wherein a distance between any two fill sheets in the stack is less than about 0.5 mm; providing a plurality of fill packs, wherein each fill pack comprises a plurality of bonded fill sheets; providing at least one support member having a first end and a second end; arranging the plurality of fill sheets on the at least one support member; coupling a first fill pack to the first end of the at least one support member; coupling a second fill pack to the second end of the at least one support member; and installing the fill module in a heat exchange module.

16. The method of claim 15, wherein the fill module is assembled and installed in the heat exchange module at a first location, and the heat exchange module containing the fill module is shipped to a second location for assembly into the modular heat exchange system.

17. The method of claim 15, wherein the fill module comprises a first fill module end, a second fill module end, a first fill module side, and a second fill module side.

18. The method of claim 17, wherein a plurality of fill modules are installed side by side in the heat exchange module, wherein a combination of first fill module ends of the plurality of fill modules define a first side of the heat exchange module, and wherein a combination of second fill module ends of the plurality of fill modules define a second side of the heat exchange module.

19. The method of claim 15, wherein the at least one support member extends along an axis substantially perpendicular to the plurality of fill sheets.

20. The method of claim 15 further comprising: coupling a third fill pack to the first end of the at least one support member; positioning the third fill pack adjacent to the first fill pack; coupling a fourth fill pack to the second end of the at least one support member; and positioning the fourth fill pack adjacent to the second fill pack.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0051] FIG. 1 is a schematic diagram depicting a heat transfer system having a modular counterflow cooling tower and a control system;

[0052] FIG. 2 is a bottom, isometric view of a modular counterflow cooling tower provided in accordance with the present disclosure;

[0053] FIG. 3A is an exploded view of the modular counterflow cooling tower of FIG. 2;

[0054] FIG. 3B is a partial, enlarged view of an air movement device deck assembly of the modular counterflow cooling tower of FIG. 3A;

[0055] FIG. 3C is a partial, enlarged view of a heat exchange assembly of the modular counterflow cooling tower of FIG. 3A;

[0056] FIG. 3D is a partial, enlarged view of an air inlet assembly of the modular counterflow cooling tower of FIG. 3A;

[0057] FIG. 4A is a partial, enlarged view of an air inlet assembly including a louver access door in a closed configuration;

[0058] FIG. 4B is a partial, enlarged view of the air inlet assembly of FIG. 4A with the louver access door in an open configuration;

[0059] FIG. 5A is a top isometric view of an air inlet assembly with some portions removed to show an inlet connection header including conduits designed to carry process water to be cooled to the heat transfer modules;

[0060] FIG. 5B is a partial, enlarged view of the air inlet assembly of FIG. 5A showing a flume;

[0061] FIG. 5C is another partial, enlarged view of the air inlet assembly of FIG. 5A showing a flume;

[0062] FIG. 6A is a schematic diagram depicting a top isometric view of a modular cold water collection basin provided in accordance with the present disclosure;

[0063] FIG. 6B is a schematic diagram depicting a top isometric view of another modular cold water collection basin provided in accordance with the present disclosure;

[0064] FIG. 6C is a top isometric view of the modular cold water collection basin of FIG. 6B;

[0065] FIG. 6D is a top isometric view of a modular cold water collection basin including the depressed center section of FIG. 6B with two outlets in independent modules;

[0066] FIG. 6E is a bottom isometric view of the modular cold water collection basin of FIG. 6D that shows a portion of a conduit that connects the two outlets;

[0067] FIG. 6F is a top isometric view of another modular cold water collection basin having a depressed center section and two outlets;

[0068] FIG. 6G is a schematic representation of a cross-sectional view along line 6G-6G of FIG. 6F showing each of the two outlets having a sump box, where the two sump boxes are disposed within a framed envelope of a modular heat transfer tower;

[0069] FIG. 6H is another schematic representation of a cross-sectional view along line 6G-6G of FIG. 6F showing each of the two outlets having a sump box, where the two sump boxes are disposed below a framed envelope of a modular heat transfer tower;

[0070] FIG. 6I is a top isometric view of a modular cold water collection basin with the basin modules connected through suction intake hoods and a single outlet;

[0071] FIG. 6J is a schematic representation of a cross-sectional view along line 6J-6J of FIG. 6I;

[0072] FIG. 7A is a top isometric view of a heat transfer assembly and an associated fluid header box spray system with a riser assembly for use with a modular counterflow cooling tower, such as those described herein;

[0073] FIG. 7B is a bottom isometric view of the heat transfer assembly and the associated fluid header box spray system with the riser assembly of FIG. 7A;

[0074] FIG. 7C is a bottom isometric view of the heat transfer assembly and the associated fluid header pipe spray system;

[0075] FIG. 7D is a schematic representation of a cross-sectional view taken along line 7D-7D in FIG. 7A;

[0076] FIG. 7E is another schematic representation of a cross-sectional view taken along line 7D-7D in FIG. 7A;

[0077] FIG. 8A is a top isometric view of a mixed-fill module having support members;

[0078] FIG. 8B is a top view of the mixed-fill module of FIG. 8A;

[0079] FIG. 9A is a side view of a mixed-fill module having support members;

[0080] FIG. 9B is a front view of the mixed-fill module of FIG. 9A;

[0081] FIG. 10 is a schematic diagram depicting a top view of a heat exchange assembly including three heat exchange modules, each heat exchange module containing a plurality of mixed-fill modules disposed adjacent to one another, each heat exchange module further including a mixed-fill module having an opening configured to receive a riser;

[0082] FIG. 11 is a schematic diagram depicting a top view of a heat exchange module containing a plurality of mixed-fill modules disposed adjacent to one another, the heat exchange module including a mixed-fill module having an opening configured to receive a riser;

[0083] FIG. 12 is a schematic diagram depicting a top isometric view of a mixed-fill module including an opening configured to receive a riser, where the riser is shown positioned in the opening;

[0084] FIG. 13 is a top isometric view of a heat exchange module showing a possible arrangement of fill sheets in the heat exchange module; and

[0085] FIG. 14 is a method flowchart depicting aspects of assembling a modular cooling tower, in accordance with aspects herein.

[0086] While the disclosure is susceptible to various modifications and alternative forms, a specific embodiment thereof is shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the drawings and detailed description presented herein are not intended to limit the disclosure to the particular instance disclosed, but to the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.

DETAILED DESCRIPTION

[0087] Before any embodiments are described in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings, which is limited only by the claims that follow the present disclosure. The disclosure is capable of other embodiments, and of being practiced, or of being carried out, in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of including, comprising, or having and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms mounted, connected, supported, and coupled and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, connected and coupledare not restricted to physical or mechanical connections or couplings.

[0088] The following description is presented to enable a person skilled in the art to make and use embodiments of the disclosure. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the generic principles herein can be applied to other embodiments and applications without departing from embodiments of the disclosure. Thus, embodiments of the disclosure are not intended to be limited to embodiments shown but are to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. Skilled artisans will recognize the examples provided herein have many useful alternatives and fall within the scope of embodiments of the disclosure.

[0089] Additionally, while the following discussion may describe features associated with specific devices or embodiments, it is understood that additional devices and/or features can be used with the described systems and methods, and that the discussed devices and features are used to provide examples of possible embodiments, without being limited.

[0090] The present disclosure provides a modular heat transfer tower that employs a fluid distribution system. The fluid distribution system may include a series of hot water basins or troughs, and/or a series of conduits and nozzles. Fluid may flow through the water distribution system to be cooled. During operation, hot process fluid (e.g., water) may be sprayed via the water distribution systems such that the hot process fluid travels vertically through the modular heat transfer tower. As the hot water travels along the length of the tower, the hot water is cooled by lower-temperature ambient air, which enters the tower through one or more air inlets. The modular heat transfer tower may be designed such that the ambient air flows in a first direction through the tower while the hot process fluid flows in a second, substantially opposite direction to ambient air. For example, the hot process fluid may flow vertically but counter to the direction of the flow of the ambient air (i.e., the ambient air may be counterflow relative to the hot process fluid). When the process fluid reaches the bottom of the tower, the fluid is cooled and collected in a basin. In addition, the ambient air, which has been used to cool the process fluid, is heated and drawn upwards and out of the modular heat transfer tower (e.g., by a fan that is located in the exiting air stream and draws the air through the tower).

[0091] Systems and methods disclosed herein provide a modular counterflow cooling tower with a multiple water collection basin design (e.g., a dual basin design). The multiple basin design allows for the separate basins to be pre-assembled in a factory and transported to a job site for installation into a cooling tower. Each of the basins may have dimensions that allow the basin to be economically transported to a job site. The multiple basin design allows the cooling tower to be assembled with basins and other components that are smaller than a conventional cooling tower without sacrificing cooling capacity. In fact, larger capacities than previous conventional factory assembled cooling towers can be achieved. Furthermore, power consumption per unit of cooling can be reduced with the use of larger fans previously not able to be used or provided in conventional factory assembled towers. As such, these systems and methods provide customers with a high-capacity cooling product that requires less on-site assembly time, less laydown space, and reduces transportation costs, installed product costs, safety concerns associated with on-site assembly, and downtime.

[0092] Systems and methods disclosed herein may avoid the transportation problems associated with existing cooling towers by providing a cooling tower that is assembled with various modular components that do not exceed certain transportation size limits. For example, systems and methods disclosed herein may provide a cooling tower having at least nine (9) modular components: two (2) air inlet modules (e.g., a first air inlet module and a second air inlet module), three (3) heat exchange modules (e.g., a first heat exchange module, a second heat exchange module, and a third heat exchange module), three (3) plenum modules (e.g., a first plenum module, a second plenum module, and a third plenum module), and an air current generator. In other instances, additional or fewer modular components may be provided in the cooling tower. Each of these components may have dimensions that do not exceed certain transportation size limits. Therefore, the components may be transported without special oversize load requirements, thereby reducing transportation costs.

[0093] The systems and methods disclosed herein may also provide a cooling tower having at least eleven (11) modular components: two (2) air inlet modules (e.g., a first air inlet module and a second air inlet module), two (2) water collection basin modules (e.g., a first water collection basin module and a second water collection basin module), three (3) heat exchange modules (e.g., a first heat exchange module, a second heat exchange module, and a third heat exchange module), three (3) plenum modules (e.g., a first plenum module, a second plenum module, and a third plenum module), and an air current generator. In other instances, additional or fewer modular components may be provided in the cooling tower. Each of these components may have dimensions that do not exceed certain transportation size limits. Therefore, the components may be transported without special oversize load requirements, thereby reducing transportation costs.

[0094] The systems and methods disclosed herein may also provide a cooling tower having at least ten (10) modular components: two (2) air inlet modules (e.g., a first air inlet module and a second air inlet module), two (2) water collection basin modules (e.g., a first water collection basin module and a second water collection basin module), three (3) heat exchange modules (e.g., a first heat exchange module, a second heat exchange module, and a third heat exchange module), and three (3) combined plenum and air current generator modules (e.g., a first combined plenum and air current generator, a second combined plenum and air current generator, and a third combined plenum and air current generator). In other instances, additional or fewer modular components may be provided in the cooling tower. Each of these components may have dimensions that do not exceed certain transportation size limits. Therefore, the components may be transported without special oversize load requirements, thereby reducing transportation costs.

[0095] The systems and methods disclosed herein may also provide a cooling tower having at least eight (8) modular components: two (2) air inlet modules (e.g., a first air inlet module and a second air inlet module), three (3) heat exchange modules (e.g., a first heat exchange module, a second heat exchange module, and a third heat exchange module), and three (3) combined plenum and air current generator modules (e.g., a first combined plenum and air current generator, a second combined plenum and air current generator, and a third combined plenum and air current generator). In other instances, additional or fewer modular components may be provided in the cooling tower. Each of these components may have dimensions that do not exceed certain transportation size limits. Therefore, the components may be transported without special oversize load requirements, thereby reducing transportation costs.

[0096] Systems and methods disclosed herein may also provide a cooling tower having at least eight (8) modular components: two (2) combined air inlet and water collection basin modules (e.g., a first combined air inlet and water collection basin module and a second combined air inlet and water collection basin module), three (3) heat exchange modules (e.g., a first heat exchange module, a second heat exchange module, and a third heat exchange module), and three (3) combined plenum and air current generator modules (e.g., a first combined plenum and air current generator, a second combined plenum and air current generator, and a third combined plenum and air current generator). In other instances, additional or fewer modular components may be provided in the cooling tower. Each of these components may have dimensions that do not exceed certain transportation size limits. Therefore, the components may be transported without special oversize load requirements, thereby reducing transportation costs.

[0097] Generally, very few states in the United States impose significant travel restrictions on loads that are ten (10) feet or less (or three (3) meters or less) in width. A load that is wider than eight and a half (8.5) feet may be considered oversized or wide and a standard truck bed width is eight (8) feet. Accordingly, such systems and methods disclosed herein may provide a cooling tower that can be assembled with various components that are each ten (10) feet or less (or three (3) meters or less), or 8.5 feet or less (or 2.6 meters or less), in width, thereby satisfying certain transportation size limits. While these modular components may require additional trucks for transporting to a job sitee.g., multiple trucks may be needed to carry the separate components instead of a single oversized truck for carrying an entire cooling towerthe cost savings associated with not having an oversized load (e.g., not having to pay for certain permit requirements) may outweigh the added cost of having additional trucks. Furthermore, when using larger capacity towers in larger capacity applications requiring multiple towers (e.g., cells), fewer towers or cells are required on site. Moreover, such systems and methods may provide a method for transporting and assembling cooling towers using factory-assembled components in regions that do not allow for the transportation of oversized loads.

[0098] The present disclosure also relates to a mixed-fill component (also referred to as a mixed-fill module) for use within a cooling tower, particularly a modular cooling tower or heat exchange system. The mixed-fill component may comprise both mechanically-restrained or structurally-restrained fill and one or more fill packs. The structurally-restrained fill may be supported by, coupled to, receive, or be received by one or more support members (e.g., tubes, tube sockets, rails, guides, etc.) designed to provide structural support to the fill. In addition, in some instances, the structurally-restrained fill may be supported by one or more components positioned underneath the structurally-restrained fill, where the one or more components abut a bottom surface or a bottom portion of the structurally-restrained fill. The mixed-fill and fill modules disclosed herein provide a modular fill solution that combines the benefits of structurally-restrained fill and fill packs, while minimizing the disadvantages of each type of fill. By combining structurally-restrained fill and fill packs, the mixed-fill design reduces air voids in the resultant fill module, as structurally-restrained fill has far fewer air voids or even no air voids. In addition, the fill packs also function to stabilize the structurally-restrained fill sheets and maintain the sheets in a proper orientation (e.g., a predetermined orientation), for example, during transport. Maintaining the structurally-restrained fill sheets in a proper orientation is particularly important during transportation of the fill modules, when the structurally-restrained fill sheets may be exposed to wind. Thus, the structurally-restrained fill and the fill packs may be pre-assembled together and installed in heat exchange modules in a factory and transported efficiently to a job site for construction into a cooling tower. As such, the mixed-fill design contributes to a high capacity cooling product that requires less on-site assembly time and reduces transportation costs.

[0099] The present disclosure further relates to a mixed-fill component (also referred to as a mixed-fill module) for use within a cooling tower, particularly a modular cooling tower or heat exchange system. The mixed-fill component may comprise both hanging fill and one or more fill packs. The mixed-fill and fill modules disclosed herein provide a modular fill solution that combines the benefits of hanging fill and fill packs, while minimizing the disadvantages of each type of fill. By combining hanging fill and fill packs, the mixed-fill design reduces air voids in the resultant fill module, as hanging fill has far fewer air voids or even no air voids. In addition, the fill packs also function to stabilize the hanging fill sheets and maintain the sheets in a proper orientation, for example, during transport. Maintaining the hanging fill sheets in a proper orientation is particularly important during transportation of the fill modules, when the hanging fill sheets may be exposed to wind. Thus, the hanging fill and the fill packs may be pre-assembled together and installed in heat exchange modules in a factory and transported efficiently to a job site for construction into a cooling tower. As such, the mixed-fill design contributes to a high capacity cooling product that requires less on-site assembly time and reduces transportation costs.

[0100] It is to be understood that, in some instances, the modular cooling tower or heat exchange system may utilize both the hanging fill and the structurally-restrained fill at the same time.

[0101] Referring to FIG. 1, a schematic of a heat transfer system 90 is depicted. The system 90 is provided in the form of at least one modular counterflow cooling tower 100 designed to cool a fluid, and a central controller or control system 110 designed to be in electronic communication with and/or control one or more components of the modular counterflow cooling tower 100. The control system 110 can be communicatively coupled to the tower 100 to control, receive, and/or store data from the tower 100. For example, the control system 110 can be provided in wireless communication or wired communication with a user device 120 and/or a network 130 to directly or indirectly communicate and/or operate the tower 100 and/or one or more components of the tower 100. For example, the control system 110 can be designed to operate a fluid distribution system, a pump, a valve, a sensor, an air movement device, and/or other system components included in the tower 100, as discussed herein.

[0102] Specifically, the control system 110 can intelligently manage the fluid flow within and/or into and out of the tower 100. The control system 110 can be provided in the form of a data-processing device configured to transmit and receive data from the system 90. For example, the control system 110 can receive information at a receiver (not shown). A processor (not shown) included in the control system 110 can analyze the received data and determine instructions to be sent back to the tower 100. A transmitter (not shown) of the control system 110 can send the instructions from the processor to one or more components of the system 90. The control system 110 can further include a memory (not shown). The memory can be configured to store data received from the tower 100. The memory can be implemented as a stand-alone memory unit and/or as part of a processor included in the control system 110. Further, in some instances, the network 130 can be coupled to the memory, which can include program instructions that are stored in the memory and executable by the processor to perform one or more methods of control.

[0103] The network 130 can be provided in the form of a network interface, a local network, or other communication connection and is not limited to the plurality of communication connections. One skilled in the art will recognize that a communication connection can transmit and receive data using a plurality of communication protocols, including but not limited to wired, wireless, Bluetooth, cellular, satellite, GPS, RS-485, RF, MODBUS, CAN, CANBUS, DeviceNet, ControlNet, Ethernet TCP/IP, RS-232, Universal Serial Bus (USB), Firewire, Thread, proprietary protocol(s), or other communication protocol(s) as applicable. In some examples, the network 130 is located proximate to one or more components of the system 90. The network 130 can include the Internet, intranets, extranets, wide area networks (WANs), local area networks (LANs), wired networks, wireless networks, cloud networks, or other suitable networks, or any combination of two or more networks, Ethernet networks, and other types of networks. The network 130 can be configured to communicate directly or indirectly with the system 90 and/or a user device 120 provided in the form of a personal computer, tablet, cell phone, display, or other similar electronic device that allows a user to interface with the control system 110 (e.g., using an application on the device).

[0104] Although FIG. 1 depicts the control system 110 in communication with the user device 120 and the network 130, various communication methodologies and connections may be implemented to work in conjunction with, or independent from, one or more local controllers associated with one or more individual components associated with the towers 100 as discussed herein.

[0105] FIG. 2 depicts a modular counterflow cooling tower 200. In some instances, the tower 200 may be the tower 100 of FIG. 1. In counterflow towers like the tower 200, ambient air and a process fluid to be cooled (e.g., water) flow in opposite directions. For example, hot process fluid (e.g., hot water from an industrial process or a HVAC system) may enter the top of the tower via a fluid inlet and may then be distributed over fill media. Cool ambient air may be drawn upwards through the fill media from the bottom of the tower. As the cool air flows upwardly and the hot process fluid flows downwardly through the tower, the cool air may absorb heat from the hot process fluid via evaporation and convection. Thus, the temperature difference between the descending hot process fluid and the rising cool air at any point along the counterflow tower is maximized, which leads to a higher rate of heat transfer.

[0106] The tower 200 may include an air inlet assembly 210 and a heat exchange assembly 220. The air inlet assembly 210 may be designed to permit ambient air to enter the tower 200 (e.g., the interior of the tower 200) and may be in fluid communication with the outside environment. The air inlet assembly 210 may include at least one air inlet module 212 or a plurality of air inlet modules 212a, 212b. As shown in FIG. 2, the tower 200 includes two air inlet modules 212a, 212b. The number of air inlet modules in a tower (e.g., the tower 200) may be selected based on the needs of the system. When a tower includes more than one or a plurality of air inlet modules, the air inlet modules may be identical or different. In some instances, as described herein, the air inlet modules can be mirror images of each other. In still other instances, as described herein, each air inlet module of the plurality of air inlet modules may have a different structure.

[0107] The air inlet assembly 210 may further include a cold water collection basin 214 designed to collect a cooled process fluid that passes through the tower 200. The cold water collection basin 214 may include at least one cold water collection basin module 216 or a plurality of cold water collection basin modules 216a, 216b. The air inlet modules 212a, 212b may be disposed above, or directly above, the cold water collection basin modules 216a, 216b. The air inlet assembly 210 may further include one or more louvers designed to control fluid splash out and/or promote uniform airflow through the tower 200. The louvers can be provided in the form of glued PVC corrugated sheets, although the louvers may also be provided in the form of other materials.

[0108] The heat exchange assembly 220 may include a plurality of heat exchange modules 222. As shown, the tower 200 includes three heat exchange modules, specifically, heat exchange modules 222a, 222b, 222c. The number of heat exchange modules in a tower may be selected based on the needs of the system. When a tower includes more than one or a plurality of heat exchange modules, the heat exchange modules may be identical or different. In some instances, each heat exchange module of the plurality of heat exchange modules may have the same design or structure. The heat exchange assembly 220 and/or each heat exchange module can include fill or fill media, which may be designed to enhance heat transfer between the process fluid flowing down through the tower 200 and the air flowing up through the tower 200 by increasing the surface area of the process fluid exposed to the air. Fill can be provided in the form of splash-type fill or film-type fill, among others. Splash-type fill may break up the process fluid and interrupts its vertical flow, for example, by causing it to cascade through successive offset levels of parallel splash bars. Film-type fill may cause water to spread into a thin film, for example, by flowing over large vertical areas.

[0109] In some instances, the fill is provided as a splash-type fill that includes a plurality of elongated, horizontally arranged, and staggered splash bars supported at spaced intervals by an upright grid structure or frame assembly. In certain instances, the fill may be provided as a film-type fill that includes a series of fill packs or fill packing composed of a number of film fill sheets. During assembly of the evaporative cooling towers, an outer shell or support structure may be constructed first and then the fill media may be installed. In the case of splash-type fill, a rack or grid support may be affixed to the support shell and splash bars may then be threaded into the rack. The splash bars provide a surface for consistent, predictable dispersal and breakup of the water droplets over a range of water loadings typically encountered during operation of the cooling tower. Typically, the splash bars are long and thin, and the fill structure includes a large number of them. In the case of film fill, fill packs may be employed and installed into the support structure of the cooling tower. Fill packs may consist of individual sheets glued or attached by some other means to one another to make blocks. Alternatively, fill packs may consist of sheets hung from support members. Successive sheets may be placed on support members from one end and pushed down the support member until the support member is populated with the desired number of sheets. The fill packs are then placed in the support structure. Suitable fill packs include, for example, a counterflow film fill having crossed corrugations and uniform fill sheet spacing. In some instances, the fill may be provided in the form of a mixed-fill module, such as the mixed-fill modules discussed with reference to FIG. 8A-14.

[0110] Still referring to FIG. 2, in some cases, the tower 200 can be elevated above the ground on grillage or risers 240. In some cases, the cold water collection basin 214 may rest on the risers 240. The risers 240 may provide space for piping (e.g., an inlet water conduit 250 and/or an outlet water conduit 260).

[0111] The tower 200 includes a plurality of openings designed to control fluid (e.g., water, air, etc.) flow into and out of the system. For example, the inlet water conduit 250 may be designed to deliver hot process fluid to the fluid distribution system. In addition, the outlet water conduit 260 may be designed to remove cooled process fluid from the cold water collection basin 214. The inlet water conduit 250 and the outlet water conduit 260 may be run beneath the tower 200, although the inlet water conduit 250 and the outlet water conduit 260 may also be provided in other positions relative to the tower 200. In some instances, as discussed in detail below, piping and/or other fluid distribution components can be disposed below the tower 200. In general, as one skilled in the art would appreciate, the piping and/or fluid distribution components may have multiple configurations (e.g., side discharge or individualized piping per spray system).

[0112] FIG. 3A illustrates an exploded view of the modular counterflow cooling towers 100, 200 of FIGS. 1 and 2. The exploded tower provided in FIG. 3A is labeled as a tower 300. As shown in the exploded view of FIG. 3A, the tower 300 may include a plenum assembly 330. The plenum assembly 330 may include at least one or a plurality of plenum modules (e.g., plenum modules 332a, 332b, 332c), an air current generator 334 (e.g., an impeller/impeller assembly or a fan/fan assembly), and an optional air current generator cylinder or an optional air current generator cylinder stack 336 that houses the air current generator 334. The air current generator 334 may be defined by a fan assembly having at least one fan blade. The plenum modules 332a, 332b, 332c may be designed to retain and/or support the air current generator 334. As shown, the tower 300 includes three plenum modules 332a, 332b, 332c. However, the tower 300 can have a greater or fewer number of plenum modules depending on the needs of the system, and the plenum modules provided may be the same or different. In some instances, as shown and described in more detail with reference to FIG. 3A, each plenum module 332a, 332b, 332c can have a different structure or shape. The plenum assembly 330 and/or each plenum module 332a, 332b, 332c may be shaped and configured to accommodate or support the air current generator 334. In some examples, the plenum assembly 330 includes the air current generator stack 336, which may be designed to enhance the efficiency of the air current generator 334 by directing airflow induced by the air current generator 334 upwards, which can reduce energy losses in the tower 300. In some instances, at least one of the plenum modules 332a, 332b, 332c comprises at least a portion of the air current generator 334. In some instances, at least one fan blade extends from one of the plenum modules over another (e.g., adjacent) plenum module.

[0113] FIG. 3B-3D illustrate additional views of components of the modular counterflow cooling tower 300. More particularly, FIG. 3B further illustrates the plenum assembly 330, FIG. 3C further illustrates the heat exchange assembly 320, and FIG. 3D further illustrates the air inlet assembly 310. As shown in the exploded view of FIG. 3A, the components of the tower 300 (e.g., the air inlet assembly 310, the heat exchange assembly 320, and the plenum assembly 330) are disposed on top of each other in the Y-direction to form the tower 300. Specifically, the air inlet assembly 310 includes a first air inlet module 312a and a second air inlet module 312b positioned parallel to or along the X-axis and parallel to each other. The second air inlet module 312b may be positioned adjacent to the first air inlet module 312a. The heat exchange assembly 320 includes a first heat exchange module 322a, a second heat exchange module 322b, and a third heat exchange module 322c positioned parallel to or along the Z-axis. The second heat exchange module 322b may be positioned between the first heat exchange module 322a and the third heat exchange module 322c. Accordingly, each of the heat exchange modules 322a-322c are positioned over at least a portion of each of the first air inlet module 312a and the second air inlet module 312b. In other words, the heat exchange modules 322a-322c are positioned perpendicular to the air inlet modules 312a, 312b. The plenum assembly 330 may include a first plenum module 332a, a second plenum module 332b, and a third plenum module 332c, parallel to or along the Z-axis. The second plenum module 332b may be positioned between the first plenum module 332a and the third plenum module 332c. Accordingly, the first plenum module 332a may be positioned over the first heat exchange module 322a, the second plenum module 332b may be positioned over the second heat exchange module 322b, and the third plenum module 332c may be positioned over the third heat exchange module 322c. The air current generator 334 may be disposed in or on one or more of the plenum modules 332a-332c. In some instances, at least one of the plenum modules 332a, 332b, 332c comprises at least a portion of the air current generator 334 or the fan assembly. In some instances, at least one fan blade extends from one of the plenum modules over an adjacent plenum module. In instances where the tower 300 includes the air current generator stack 336, such as a fan stack, the air current generator stack 336 may be disposed on one or more of the plenum modules 332a-332c.

[0114] In some aspects, the heat transfer system may include two modular counterflow cooling towers, such as a first cooling tower and a second cooling tower (not shown). The first and/or second cooling tower can be the tower 100 of FIG. 1 and/or the tower 200 of FIG. 2 and/or the tower 300 of FIG. 3A. In some instances, the towers can be serially arranged. In other words, the cold process fluid (e.g., the process fluid from the cold water basin) of the first cooling tower can be the hot process fluid (e.g., the process fluid distributed over the fill media by the fluid distribution system) of the second cooling tower. In other instances, the first cooling tower and the second cooling tower can be in a parallel arrangement. In other words, each of the towers may act as an independent cell or independently of each other. Further, it is to be understood that the system can include more modular cooling towers (in either a serial or parallel arrangement) depending on the needs of the system.

[0115] FIG. 4A and FIG. 4B depict a louver door 400 included in an air inlet assembly 410 in a closed configuration and open configuration, respectively. The air inlet assembly 410 may be the air inlet assembly 210 and/or 310. The louver door 400 can be provided in the form of a hinged, full-height door. The height of the door may range from about 72 inches to about 85 inches, or about 80 inches to about 85 inches (e.g., about 83 inches), and the width of the door may range from about 30 inches to 35 inches (e.g., 33 inches). In certain cases, the height of the door may range from about 1.8 meters to about 2.2 meters, and the width of the door may range from about 0.8 meters to about 0.9 meters. The door may be designed to provide walk-in access to an interior of the air inlet assembly (e.g., the first or second air inlet module) and allow a person to access the internal components of the air inlet assembly 410, including, e.g., the cold water collection basin. The louver door 400 may include a steel frame (composed of, e.g., 304 stainless steel) and one or more louvers disposed in the frame. The one or more louvers may be designed to allow air to enter through the closed door during operation of the tower, which may reduce an air-side pressure drop near the louver door 400. In some instances, the door includes one or more cellular air inlet louvers or louver packs disposed in the frame. Suitable cellular air inlet louvers have a structure similar to the cellular drift eliminator described in U.S. Pat. No. 4,514,202, the disclosure of which is hereby incorporated by reference in its entirety. A cellular air inlet louver can be described as having a major flow axis across its width. The cellular air inlet louver may exit air at an upward angle compared to its major flow axis, e.g., at an upward angle of about 10 to about 60 (or 10 to 60), or about 30 (or 30), as described in U.S. Pat. No. 4,514,202, the disclosure of which is also hereby incorporated by reference in its entirety. Cellular air inlet louvers may be made of PVC thermoformed sheets that are glued or otherwise attached together to make blocks or packs, where individual sheets may range in thickness from about 12 mm to about 15 mm (or 12 mm to 15mm) and packs of sheets may have uniform sheet spacing.

[0116] In some aspects, the louver door 400 allows air through but is substantially water-tight or is water-tight. In certain aspects, a perimeter of the louver door 400 may have a seal or flange to help prevent water from leaking out of the air inlet assembly 410. In some aspects, the louver door 400 may include a flanged steel frame, where a flange extends around at least portion of or the entire perimeter of the frame. In some aspects, the louver door 400 extends entirely between an upper edge and a lower edge of the air inlet assembly 410. In some examples, the height of the louver door 400 may be about 60% to about 95% (or 60% to 95%) of the height of the air inlet assembly 410, although the height of the louver door 410 may be less than or greater than these values. In some instances, one or more steps (e.g., two steps) may be provided below a lower edge of the louver door 400. The louver door 400 may be in a closed configuration while the tower is in use as depicted in FIG. 4A. The louver door 400 may be opened inwardly toward the internal components of the air inlet assembly 410 or toward the interior of the cooling tower (e.g., the tower 100, 200, 300 of FIGS. 1, 2, 3A) during a maintenance period and/or when the tower is not operating. In other instances, the louver door 400 may be opened outwardly and away from the internal components of the air inlet assembly 410 or away the interior of the cooling tower (e.g., the tower 100, 200, 300 of FIGS. 1, 2, 3A) during a maintenance period and/or when the tower is not operating.

[0117] FIG. 5A-5C illustrate various internal components of an air inlet assembly 510. The air inlet assembly 510 may be the air inlet assembly 210, 310, 410 of FIGS. 2, 3A, 4A, and 4B. As shown in FIG. 5A, the air inlet assembly 510 can be provided in the form of a first air inlet module 512a and a second air inlet module 512b. The air inlet assembly 510 may include a flume 550 that defines a flow path to allow fluid to pass from one cold water collection basin module 516a, 516b (e.g., the cold water collection basin module 516a) to another cold water collection basin module 516a, 516b (e.g., the cold water collection basin module 516b), and to an outlet 530. Thus, the flume 550 may have two primary purposes: to transfer water from the cold water collection basin modules 516a, 516b to the outlet 530 and/or to equalize the liquid levels between the cold water collection basin modules 516a, 516b. The flume 550 may be coupled to the cold water collection basin modules 516a, 516b to form a fluid-tight (e.g., watertight or substantially watertight) connection. In some instances, the flume 550 may be welded to the cold water collection basin modules 516a, 516b and the welding may be performed on-site. Alternatively, the flume 550 may be coupled to the cold water collection basin modules 516a, 516b with a waterproof sealant that may be applied to one or more mating surfaces of the flume 550 and/or the cold water collection basin modules 516a, 516b. As shown in FIG. 5B, one or more bolts 556 or other attachment mechanisms may also be used to secure the flume 550 to the cold water collection basin modules 516a, 516b, although the one or more bolts 556 may also be omitted (e.g., when the flume 550 is welded to the cold water collection basin modules 516a, 516b). As best shown in the enlarged views of FIGS. 5B and 5C, the flume 550 may be imparted with a trapezoidal shape. The flume 550 may comprise a base 552 and a pair of sidewalls 554a, 554b extending therefrom. Each sidewall 554a, 554b may be sloped at an angle. In some instances, the base 552 and opposing sidewalls 554a, 554b are provided as a unitary, one-piece construction.

[0118] The air inlet assembly 510 may further include a header assembly 560 (which may also be referred to as an inlet connection header). The header assembly 560 may further include a header box 562 in fluid communication with the heat transfer modules (not shown) via at least one conduit 564a, 564b, 564c (which may also be referred to as header inlet riser piping or header inlet riser conduits). The header inlet riser conduits 564a-564c carry process water to be cooled and are fluidly connected to pipes or conduits within the heat transfer modules, where the water will be distributed through spray nozzles onto heat transfer media (e.g., fill). As illustrated in FIG. 5A, the header assembly 560 is provided in the form of three conduits 564a-564c. However, it is to be understood that the header assembly 560 can include greater or fewer conduits depending on the needs of the system and/or the number of heat transfer modules. In some instances, the number of conduits may be the same as the number of heat transfer modules provided in the system. The air inlet assembly 510 may optionally include more than one header assembly (e.g., one header assembly per fluid distribution assembly).

[0119] FIG. 6A-6J depict various components of a cold water collection basin 614 for use in a modular heat transfer tower (e.g., the towers 100, 200, 300 of FIGS. 1, 2, and 3A). The cold water collection basin 614 may be provided in the form of a modular cold water collection basin 614 defined by at least one cold water collection basin module 616a, 616b (or a plurality of cold water collection basin modules 616a, 616b) and a flume 650, which may be coupled to the cold water collection basin modules 616a, 616b so as to connect the cold water collection basin modules 616a, 616b (see, e.g., FIG. 6A-6D). In some instances, the flume 650 may be welded to the cold water collection basin modules 616a, 616b. In certain instances, the welding may be performed on-site. Thus, the modular cooling tower may include one or more cold water collection basin modules 616a, 616b, which may be joined together to collectively form the cold water collection basin 614.

[0120] In instances where multiple cold water collection basin modules are joined together, not every cold water collection basin module may include a fluid outlet 630. For example, as shown in FIG. 6A-6C, only a first cold water collection basin module 616a includes a fluid outlet 630. A second cold water collection basin module 616b (which may not include a fluid outlet 630), may be fluidly connected, e.g., via a flume or a conduit, to the first cold water collection basin module 616a. The first cold water collection basin module 616a may be proximate or adjacent to the second cold water collection basin module 616b. Fluid in the second cold water collection basin module 616b may flow through the flume 650 to the fluid outlet 630 in the first cold water collection basin module 616a. One or more of the cold water collection basin modules may comprise a depressed floor section 640 (see FIG. 6a).

[0121] As shown in FIG. 6A, the first cold water collection basin module 616a includes the depressed floor section 640, whereby fluid may flow from the second cold water collection basin module 616b, through the flume 650, and to the fluid outlet 630. After being provided to the fluid outlet 630, the fluid may flow out of the cooling tower. In some instances, the flume 650 may be fluid (e.g., water) tight and not allow fluid to leak where the flume 650 connects or couples to the cold water collection basin modules 616a, 616b.

[0122] In some instances, it may be advantageous to limit or reduce the amount or length of welding that joins cold water collection basin modules 616a, 616b. For example, providing a fluid tight (or substantially fluid tight) seal between the flume 650 and the cold water collection basin modules 616a, 616b along the entire length of the cold water collection basin 614, as shown in FIG. 6A, may involve significant time and effort. Moreover, the more welding or the longer the length of the welded connection, the greater the potential for leaks, particularly if the welding is performed on-site in difficult conditions (e.g., extreme temperatures).

[0123] FIGS. 6B, 6C, and 6D show the modular cold water collection basin 614 imparted with depressed floor sections 640 that are turned 90 relative to the depressed floor section 640 shown in FIG. 6A. The first and second cold water collection basin modules 616a, 616b in FIGS. 6B and 6C share a flume 650, but the flume 650 does not span the entire length (L.sub.C) of the cold water collection basin 614. In some aspects, as shown in FIGS. 6B, 6C, and 6D, a cold water collection basin 614 may be defined by first and second cold water collection basin modules 616a, 616b and first and second depressed floor sections 640a, 640b, which extend along a Y-axis and together span the width of the first and second cold water collection basin modules 616a, 616b. A flume 650 connects the cold water collection basin modules 616a, 616b, extends along an X-axis, and spans less than the length (L.sub.C) of the cold water collection basin 614, as shown in FIGS. 6B and 6C. In certain aspects, fluid may flow from a second depressed floor section 640b in a second cold water collection basin module 616b to a first depressed floor section 640a in a first cold water collection basin module 616a, through the flume 650, which extends along an X-axis and spans the width (W.sub.F) of the first and second depressed floor sections 640a, 640b, to the fluid outlet 630, where the fluid may exit the cooling tower. In certain cases, the length of the flume 650 (L.sub.F) may be less than the length (L.sub.C) of the collection basin, although the length of the flume 650 (L.sub.F) may be substantially equal to or equal to the length (L.sub.C) of the collection basin. In some cases, the length of the flume 650 may be about 5% to about 90%, or about 10% to about 80%, or about 20% to about 70%, or about 30% to about 60% of the length of the cold water collection basin 614. In other cases, the length of the flume 650 may be 5% to 90%, or 10% to 80%, or 20% to 70%, or 30% to 60% of the length of the cold water collection basin 614. The first and second cold water collection basin modules 616a, 616b may be joined by a seal plate 652 that connects the module interface above the waterline. The seal plate 652 may be bolted, welded, or otherwise coupled to the first and second cold water collection basin modules 616a, 616b. It may be advantageous to reduce or avoid welding, which can be costly and time-consuming. The length (L.sub.F) of the flume 650 may be less than the length of the seal plate 652.

[0124] Turning to FIGS. 6D and 6E, in some instances, a cold water collection basin 614 may be provided in the form of a first cold water collection basin module 616a fluidly coupled to a second cold water collection basin module 616b, where the first cold water collection basin module 616a comprises a first outlet 630a and the second cold water collection basin module 616b comprises a second outlet 630b. The first and second outlets 630a, 630b may be connected or coupled by a conduit 660 disposed below the cold water collection basin 614 or below the first and second cold water collection basin modules 616a, 616b. In some instances, the cold water collection basin 614 may be defined by first and second cold water collection basin modules 616a, 616b and the first and second depressed floor sections 640a, 640b, which extend along a Y-axis and together span the width (W.sub.C) of the first and second cold water collection basin modules 616a, 616b. The first and second outlets 630a, 630b may optionally comprise sump boxes 632a, 632b disposed below the first and second outlets 630a, 630b. One or more of the first and second outlets 630a, 630b or sump boxes 632a, 632b may include a fluid outlet or outlet pipe through which the fluid may exit the cooling tower. The first and second cold water collection basin modules 616a, 616b may be joined by a seal plate 652 that connects the module interface above the waterline. The seal plate 652 (see FIG. 6D) may be bolted, welded, or otherwise coupled to the first and second cold water collection basin modules 616a, 616b. By utilizing piping disposed below the collection basin to fluidly connect the first and second collection basin modules, welding can be reduced or avoided altogether, as the first and second collection basin modules may be joined or connected by a seal plate that connects or extends along the module interface and above the waterline.

[0125] Turning to FIG. 6F, in some instances, a cold water collection basin 614 may be provided in the form of a first cold water collection basin module 616a fluidly coupled to a second cold water collection basin module 616b. The first cold water collection basin module 616a may comprise a first outlet 630a positioned proximate or adjacent to an inner wall 618a of the first cold water collection basin module 616a and the second cold water collection basin module 616b may comprise a second outlet 630b positioned proximate or adjacent to a sidewall or an inner wall 618 of the second cold water collection basin module 616b. As shown in FIGS. 6G and 6H, the first and second outlets 630a, 630b may each comprise a sump box (e.g., a sump box 632a for the first outlet 630a and a sump box 632b for the second outlet 630b). The sump boxes 632a, 632b may be disposed below the first and second outlets 630a, 630b, respectively, and the sump boxes 632a, 632b may be connected by a conduit 660. In some instances, each of the sump boxes 632a, 632b may be coupled to an outlet conduit that is designed to remove fluid from the tower (e.g., the outlet water conduit 260 of FIG. 2). In other instances, only one of the sump boxes 632a, 632b may be coupled to an outlet conduit that is designed to remove fluid from the tower. In such instances, as fluid exits a first sump box (e.g., the sump box 632a) via the outlet conduit, the fluid provided from a second sump box (e.g., the sump box 632b) may exit the cooling tower by flowing through the conduit 660, to the first sump box, and then the provided outlet conduit. In instances of a tower including more than two cold water basin modules, water may similarly exit a single cold water collection basin module via an outlet conduit by placing each of the cold water collection basin modules into fluid communication with each other.

[0126] As shown in FIG. 6G, the sump boxes 632a, 632b and the conduit 660 connecting the sump boxes 632a, 632b may be disposed within the framed envelope 622 of the cold water collection basin 614. For example, the sump boxes 632a, 632b and the conduit 660 connecting the sump boxes 632a, 632b may be positioned within a volume defined by the framed envelope 622. In other words, the sump boxes 632a, 632b may not extend below or outside of the dimensions of the tower when the tower is assembled. As such, the tower may be erected directly on the ground and need not be raised above the ground in order to avoid the sump boxes 632a, 632b. Alternatively, as shown in FIG. 6H, the sump boxes 632a, 632b and the conduit 660 connecting the sump boxes 632a, 632b may be disposed outside of (e.g., outside the volume of) or below the framed envelope 622 of the cold water collection basin 614. Thus, because both the sump boxes 632a, 632b and the conduit 660 connecting the sump boxes 632a, 632b are disposed below the framed envelope 622, the conduit may be coupled or connected (e.g., via welding) directly to the sump boxes 632a, 632b. In contrast to the example of FIG. 6G, as shown in FIG. 6H, the conduit 660 need not pass through the inner walls 618a, 618b of the first and second cold water collection basin modules 616a, 616b to reach the sump boxes 632a, 632b. However, the tower may be raised above the ground (e.g., with risers or grillage) to provide the appropriate clearance for the sump boxes 632a, 632b. When the water level in a sump box may be low relative to the flow rate, a vortex may occur. In some instances, an anti-vortex plate or fitting may be disposed over the sump box outlet to help prevent vortexing.

[0127] The cold water collection basin 614 may be provided in the form of a first cold water collection basin module 616a fluidly coupled to a second cold water collection basin module 616b via one or more suction intake hoods 620a, 620b, as shown in FIGS. 6I and 6J. The one or more suction intake hoods 620a, 620b may be connected at a flow opening through the inner walls 618a, 618b of the first and second cold water collection basin modules 616a, 616b. In some instances, the conduit 660 may be welded to the suction intake hoods 620a, 620b.

[0128] The modular tower (e.g., the tower 100, 200, 300 of FIGS. 1, 2, and 3A) may further employ a fluid distribution system (e.g., a fluid distribution system 750 of FIG. 7A-7E). The fluid distribution system may comprise a hot fluid basin or trough (e.g., a series of fluid basins or troughs) and one or more conduits and/or a nozzle (e.g., a series of conduits and nozzles) through which process fluid (e.g., process fluid to be cooled) flows. The fluid distribution system may be designed to distribute the process fluid over the fill media disposed within the tower. The fluid distribution system may be defined by a first fluid distribution assembly disposed in a first heat transfer module, a second fluid distribution assembly disposed in a second heat transfer module, and a third fluid distribution assembly disposed in a third heat transfer module. More specifically, the first fluid distribution assembly may be disposed in a top portion of the first heat transfer module, the second fluid distribution assembly may be disposed in a top portion of the second heat transfer module and the third fluid distribution assembly may be disposed in a top portion of the third heat transfer module. Each of the liquid distribution assemblies may comprise a plurality of nozzles configured to spray liquid into lower regions of the modular heat transfer tower, specifically, into fill portions or sections disposed in the heat transfer modules. A plurality of fluid distribution assemblies may be coupled together on-site to form a unified fluid distribution system with one fluid inlet connection.

[0129] As shown in FIG. 7A-7E, a heat transfer assembly 770 may be designed to include one or more heat transfer modules 722a, 722b, 722c and a fluid distribution system 750. The fluid distribution system 750 may comprise a hot fluid basin (not shown), a header assembly 771, which includes a header 772 and a header box 773a, 773b, 773c, in fluid communication with the hot fluid basin, one or more distribution pipes or conduits 776 in fluid communication with the header assembly, and a plurality of spray nozzles 774 in fluid communication with the one or more conduits 776. In a counterflow cooling tower, high temperature fluid may be distributed vertically through the tower via gravity and/or a spray system (e.g., under pressure).

[0130] A fluid distribution system 750 comprising a centerline header assembly 771, and a fluid distribution system 750 comprising an off-center header assembly 771, are shown in FIG. 7D and FIG. 7E, respectively. The header 772 may optionally be centered such that the header bisects the width (W.sub.H) of the heat transfer assembly 770. The header box 773a, 773b, 773c can be provided in the form of steel or PVC, although other materials may also be used. The header 772 can also be provided in the form of steel or PVC, although other materials may also be used. The spray nozzles 774 may be arranged or designed to evenly distribute (or substantially evenly distribute) the fluid over the fill media 778, as shown in FIGS. 7D and 7E. Once the fluid travels through the fill media 778, the fluid may be collected at the bottom of the tower in a cold liquid collection basin assembly (not shown). The spray nozzles 774 and conduits 776 may be made of PVC or polypropylene. Each spray nozzle of the plurality of spray nozzles 774 can be spaced apart about 15 inches to about 30 inches (or about 38 centimeters to about 76 centimeters) from each adjacent spray nozzle. In other instances, each spray nozzle of the plurality of spray nozzles 774 can be spaced apart 15 inches to 30 inches (or 38 centimeters to 76 centimeters) from each adjacent spray nozzle. In some cases, the plurality of spray nozzles 774 may be positioned about 5 inches to about 20 inches (or about 13 centimeters to about 50 centimeters) above the fill media 778. In other cases, the plurality of spray nozzles 774 may be positioned 5 inches to 20 inches (or 13 centimeters to 50 centimeters) above the fill media 778. In yet other cases, the space between the individual spray nozzles, and the distance the plurality of spray nozzles 774 are positioned above the fill media 778, may be less than or greater than the values recited herein.

[0131] The fluid distribution system 750 may further include a riser assembly provided in the form of piping that provides fluid communication between the circulating fluid supply line, from the level of the base of the tower or the supply header, to the tower's distribution system, as shown in FIG. 7Aand 7B. A supply piping arrangement in a counterflow tower may position the supply line proximate or adjacent to the long side of the tower and run the full length of the tower, with a vertical riser (e.g., one vertical riser per cell) connecting the supply line to inlet connections at the elevation of the fluid distribution system of the tower. As shown in FIGS. 7B and 7C, the fluid distribution system 750 comprises a riser assembly 779, which includes one or more riser headers 777a, 777b, 777c and one or more vertical risers 775a, 775b, 775c. Each vertical riser may be coupled to a riser header. In some instances, each heat transfer module 722a, 722b, 722c comprises a vertical riser 775a, 775b, 775c coupled to a riser header 777a, 777b, 777c. The fluid distribution system 750 may also comprise one or more distribution pipes or conduits 776 (see FIGS. 7A, 7D, and 7E). The risers may carry water from the header assembly 560 of the air inlet assembly 510 (see FIG. 5A) through fill media to a distance above the fill media, where the water may then be distributed through the one or more distribution pipes or conduits 776. Each distribution pipe or conduit 776 may have one or more holes, e.g., a series of holes, for water to flow through or one or more nozzles, e.g., a series of nozzles, mounted thereon to distribute water. The water may be evenly distributed on top of the fill. In some instances, the fluid distribution system 750 includes a centerline header assembly 771 made of steel (as shown in FIG. 7A) and a riser assembly 779.

[0132] Turning now to FIGS. 8A, 8B, 9A, and 9B, a mixed-fill module 800, 900 for use in a cooling tower (such as the modular counterflow cooling towers 100, 200, 300 depicted in FIGS. 1, 2, and 3A) is illustrated. FIGS. 8A, 8B, 9A, and 9B illustrate various internal components of the mixed-fill module 800, 900. As shown in FIGS. 8A and 8B, the mixed-fill module 800 includes at least one support member provided in the form of a first support member 802, a second support member 803, an optional third support member 805, and an optional fourth support member 807. Alternatively, as shown in FIGS. 9A and 9B, the mixed-fill module 900 may comprise fewer support members, such as a first support member 902 and a second support member 903. It is to be understood that the mixed-fill module 800 may also comprise more than four support members or fewer than four support members in certain instances. In some aspects, each support member may have a first end 802a, 803a, 805a, 807a, 902a, 903a and a second end 802b, 803b, 805b, 807b, 903b. In certain aspects, the ends 802a, 803a, 805a, 807a, 902a, 903a, 802b, 803b, 805b, 807b, 903b of the at least one support member may be capped, e.g., with a retainer cap. The at least one support member may take the form of a pipe or a tube, and thus have a substantially round cross-section (as depicted in FIGS. 8A, 8B, 9A, and 9B). In other aspects, the at least one support member 802, 803, 805, 807, 902, 903 may alternatively comprise a non-round cross-section, such as a square shape, a rectangular shape, or other polygonal shape. In some cases, the at least one support member 802, 803, 805, 807, 902, 903 may comprise a non-circular round shape, such as an oval shape or elliptical shape. In addition, the mixed-fill module 800, 900 may comprise a plurality of fill sheets 804, 904. The individual fill sheets in the plurality of fill sheets 804, 904 may have the same dimensions, substantially the same dimensions, or different dimensions. In some aspects, the individual fill sheets in the plurality of fill sheets 804, 904 have the same dimensions.

[0133] In some aspects, the individual sheets in the plurality of fill sheets are loose, unbonded, or not bonded together. In certain aspects, the plurality of fill sheets 804, 904 are arranged on the at least one support member (e.g., the support members 802, 803, 805, 807, 902, 903). As used herein, the phrase arranged on includes direct or indirect coupling or attaching, hanging, mounting, or otherwise suspending the fill sheets from the at least one support member. In some aspects, the plurality of fill sheets 804, 904 may be arranged on the at least one support member 802, 803, 805, 807, 902, 903 by way of hanging, e.g., to provide a hanging fill configuration or, in some instances, a structurally-restrained fill configuration. It is to be understood that both the structurally-restrained fill and the hanging fill configurations may utilize the at least one support member 802, 803, 805, 807, 902, 903. However, compared to the hanging fill configuration and as previously described, bottom surfaces or bottom portions of the fill in the structurally-restrained fill configurations may be supported to provide additional stability to the fill. Additionally, in some instances, the structurally-restrained fill configurations may utilize guides, rails, and other similar structures in addition to, or in the place of, the at least one support member 802, 803, 805, 807, 902, 903. In certain aspects, each individual fill sheet of the plurality of fill sheets 804, 904 may comprise openings sized and/or shaped to allow the at least one support member 802, 803, 805, 807, 902, 903 to pass through the openings in each fill sheet of the plurality of fill sheets 804, 904. Alternatively, the at least one support member 802, 803, 805, 807, 902, 903 may be sized and/or shaped to pass through openings provided in each fill sheet of the plurality of fill sheets 804, 904.

[0134] In some aspects, the at least one support member 802, 803, 805, 807, 902, 903 may extend entirely or at least partially along the length L.sub.F of the mixed-fill module 800, 900. In certain aspects, the at least one support member 802, 803, 805, 807, 902, 903 may be substantially perpendicular or perpendicular to the plurality of fill sheets 804, 904. That is, as shown in FIGS. 8A, 8B, and 9B, the plurality of fill sheets 804, 904 may hang downwardly from the at least one support member 802, 803, 805, 807, 902, 903, where the at least one support member 802, 803, 805, 807, 902, 903 may be substantially parallel or parallel to the base of the cooling tower and/or the ground. In some cases, the ends 802a, 803a, 805a, 807a, 902a, 903a, 802b, 803b, 805b, 807b, 903b of the at least one support member may extend beyond the length L.sub.F of the mixed-fill module 800, 900 (e.g., a length of the at least one support member may be greater than the length L.sub.F of the mixed-fill module 800, 900). Any and all aspects of arranging the plurality of fill sheets 804, 904 on the at least one support member 802, 803, 805, 807, 902, 903 are contemplated herein.

[0135] In some aspects, the distance between each fill sheet of the plurality of fill sheets 804, 904 may be about 0.5 millimeters (or 0.5 millimeters) when the plurality of fill sheets are arranged on the at least one support member 802, 803, 805, 807, 902, 903, although the distance between each fill sheet of the plurality of fill sheets 804, 904 may be somewhat less or even greater than about 0.5 millimeters (or 0.5 millimeters). In some cases, the distance between adjacent fill sheets of the plurality of fill sheets 804, 904 may be no more than about 1 millimeter, or no more than about 0.9 millimeters, or no more than about 0.8 millimeters, or no more than about 0.7 millimeters, or no more than about 0.6 millimeters, or no more than about 0.5 millimeters, or no more than about 0.4 millimeters, or no more than about 0.3 millimeters, or no more than about 0.2 millimeters, or no more than about 0.1 millimeters. In other cases, the distance between adjacent fill sheets of the plurality of fill sheets 804, 904 may be no more than 1 millimeter, or no more than 0.9 millimeters, or no more than 0.8 millimeters, or no more than 0.7 millimeters, or no more than 0.6 millimeters, or no more than 0.5 millimeters, or no more than 0.4 millimeters, or no more than 0.3 millimeters, or no more than 0.2 millimeters, or no more than 0.1 millimeters.

[0136] With continued reference to FIGS. 8A, 8B, 9A, and 9B, the mixed-fill module 800 may further comprise a plurality of fill packs 806a, 806b, 906a, 906b. Each of the plurality of fill packs 806a, 806b, 906a, 906b may comprise a plurality of fill sheets bonded together. In other words, the difference between the plurality of fill sheets 804, 904 arranged on the at least one support member 802, 803, 805, 807, 902, 903 and the plurality of sheets forming each of the plurality of fill packs 806a, 806b, 906a, 906b is that the sheets in the fill packs are bonded together, as described above. The plurality of fill packs 806a, 806b, 906a, 906b may have varying dimensions, including a height, width, and length, which may be selected to optimize the efficiency of the mixed-fill module 800, 900. In some aspects, the mixed-fill module 800, 900 may include any number of fill packs of the plurality of fill packs 806a, 806b, 906a, 906b, where one or more of the fill packs are imparted with different dimensions relative to the other fill packs. For example, the mixed-fill modules 800, 900 may include one or more fill packs 806a, 906a imparted with first set of dimensions and one or more fill packs 806b, 906b imparted with a second set of dimensions. As shown in FIGS. 8A, 8B, and 9B, the mixed-fill modules 800, 900 may include two fill packs (the first and second fill packs 806a, 906a) that have substantially the same dimensions, where the first fill pack 806a, 906a is coupled to the first ends 802a, 803a, 805a, 807a, 902a, 903a and the second fill pack 806a, 906a is coupled to the second ends 802b, 803b, 805b, 807b, 903b of the respective support member 802, 803, 805, 807, 902, 903. In addition, as shown in FIGS. 8A, 8B, and 9B, the mixed-fill modules 800, 900 may include a third fill pack 806b, 906b, which have dimensions that are different from the dimensions of the first and second fill packs 806a, 906a. For example, as shown in FIG. 9B, the third fill pack 906b may be imparted with a thickness and a height that is less than the first and second fill packs 906a. It is to be understood that any of the individual dimensions of the third fill pack 806b, 906b (e.g., a width, a length, a height) may be less than, equal to, or greater than the respective individual dimensions of the first and second fill packs 806a, 906a. In addition, the third fill pack 806b, 906b may be coupled to the first end 802a, 803a, 805a, 807a, 902a, 903a of the respective support member 802, 803, 805, 807, 902, 903 and be positioned proximate or adjacent to the first fill pack 806a, 906a. In certain instances, the third fill pack 806b, 906b may abut the first and second fill pack 806a, 906a. In some aspects, the at least one support member 802, 803, 805, 807, 902, 903 may be substantially perpendicular to the plurality of fill packs 806a, 906a, 806b, 906b. That is, as shown in FIGS. 8A, 8B, and 9B, the plurality of fill packs 806a, 906a, 806b, 906b may hang downwardly from the at least one support member 802, 803, 805, 807, 902, 903, where the at least one support member 802, 803, 805, 807, 902, 903 may be substantially parallel or parallel to the base of the cooling tower and/or the ground.

[0137] Coupling the fill packs 806a, 906a, 806b, 906b to the first ends 802a, 803a, 805a, 807a, 902a, 903a and the second ends 802b, 803b, 805b, 807b, 903b of the respective support member 802, 803, 805, 807, 902, 903 may surround the plurality of fill sheets 804, 904, thereby forming a bounded configuration of the mixed-fill module 800, 900. Thus, the mixed-fill module 800, 900 may comprise a plurality of fill packs 806a, 906a, 806b, 906b at the ends 802a, 803a, 805a, 807a, 902a, 903a, 802b, 803b, 805b, 807b, 903b of the at least one support member 802, 803, 805, 807, 902, 903 and a plurality of fill sheets arranged on the at least one support member 802, 803, 805, 807, 902, 903 between the fill packs 806a, 906a, 806b, 906b. As discussed above, the bounded configuration of the mixed-fill module 800, 900 may be advantageous over existing structurally-restrained or hanging fill configurations that are open or unbounded on the ends of the modules. For example, transporting heat exchange modules containing structurally-restrained or hanging fill configurations alone may be challenging, as the individual fill sheets may shift or move or otherwise not maintain the proper orientation during transport. Indeed, in some cases, the individual fill sheets may detach from their respective support member during transportation. The mixed-fill described in the present disclosure (e.g., the mixed-fill modules 800, 900) addresses this challenge by bounding the structurally-restrained or hanging fill with one or more fill packs on each end of the structurally-restrained or hanging fill, thereby stabilizing the plurality of fill sheets in the structurally-restrained or hanging fill.

[0138] Referring still to FIGS. 8A, 8B, 9A, and 9B, in some aspects, the plurality of fill sheets 804, 904 may form the largest segment or section of the mixed-fill module 800, 900. The mixed-fill modules 800, 900 may be provided in or as part of any of the heat exchange modules described herein. In such instances, the plurality of fill sheets 804, 904 may be positioned or provided in a central segment or section of the mixed-fill module 800, 900. Similarly, the plurality of fill packs 806a, 906a, 806b, 906b may form smaller segments or sections of the mixed-fill module 800, 900. In such instances, the plurality of fill packs 806a, 906a, 806b, 906b may be positioned or provided at end segments or end sections of the mixed-fill module 800, 900. In certain aspects, the plurality of fill sheets 804, 904 may form about 50 percent to about 90 percent (or 50 percent to 90 percent) of the overall volume of the mixed-fill module 800, 900, while the plurality of fill packs 806a, 906a, 806b, 906b may form about 10 to about 50 percent (or 10 percent to 50 percent) of the overall volume of the mixed-fill module 800, 900. For example, the plurality of fill sheets 804, 904 may form or occupy at least about 50 percent, or at least about 60 percent, or at least about 70 percent, or at least about 80 percent, or no more than about 90 percent of the overall volume of the mixed-fill module 800, 900. As a further example, the plurality of fill packs 806a, 906a, 806b, 906b may form at least about 10 percent, or at least about 20 percent, or at least about 30 percent, or at least about 40 percent, or no more than about 50 percent of the overall volume of the mixed-fill module 800, 900. As a further example, the plurality of fill sheets 804, 904 may form at least 50 percent, or at least 60 percent, or at least 70 percent, or at least 80 percent, or no more than 90 percent of the overall volume of the mixed-fill module 800, 900. As an additional example, the plurality of fill packs 806a, 906a, 806b, 906b may form at least 10 percent, or at least 20 percent, or at least 30 percent, or at least 40 percent, or no more than 50 percent of the overall volume of the mixed-fill module 800, 900. It is to be appreciated that the plurality of fill sheets 804, 904 and the plurality of fill packs 806a, 906a, 806b, 906b may comprise different percentages of the overall volume of the mixed-fill module 800, 900 than those percentages explicitly recited herein.

[0139] Referring to FIG. 10, a heat exchange assembly 1000 including three heat exchange modules 1010a, 1010b, 1010c is shown. Each heat exchange module 1010a, 1010b, 1010c may include a plurality of fill modules 1008a-1008r. As shown in FIG. 10, the heat exchange modules 1010a, 1010b, 1010c may be disposed proximate or adjacent to one another, and, in some instances, may abut one another. In some aspects, a first heat exchange module 1010a may be disposed proximate or adjacent to a second heat exchange module 1010b, and the second heat exchange module 1010b may be disposed proximate or adjacent to a third heat exchange module 1010c. Each heat exchange module 1010a, 1010b, 1010c may comprise a plurality of fill modules 1008a-1008r, such as from one to ten fill modules of the plurality of fill modules 1008a-1008r, or more. By way of example, each of the heat exchange modules 1010a, 1010b, 1010c of FIG. 10 include six fill modules of the plurality of fill modules 1008a-1008r. FIG. 13 shows a heat exchange module 1310 without any fill modules provided therein. At the same time, FIG. 13 illustrates a potential arrangement of fill sheets 1304a-1304f (the fill sheets 1304a-1304f shown in FIG. 13 using broken lines), where each fill sheet 1304a-1304f represents a fill module. In some instances, the fill sheets 1304a-1304f may be provided in a hanging fill configuration when coupled to at least one support member and provided in the heat exchange module 1310. In other instances, the fill sheets 1304a-1304f may be provided in a structurally-restrained fill configuration where a bottom surface or bottom portion of the fill sheets 1304a-1304f are supported by one or more supporting structures positioned underneath the fill sheets 1304a-1304f and/or an inner surface of the heat exchange module 1310. In addition, when provided in the heat exchange module 1310, the structurally-restrained fill configuration may utilize guides, rails, and other similar structures in addition to, or in the place of, the at least one support member. In some aspects, each of the first heat exchange module 1010a, the second heat exchange module 1010b, and the third heat exchange module 1010c comprises six fill modules 1008a-1008r, although the first, second, and third heat exchange modules 1010a, 1010b, 1010c may each also comprise a different number of fill modules.

[0140] Referring again to FIG. 10, in certain aspects, a first plurality of fill modules 1008a-1008f may be installed in the first heat exchange module 1010a, a second plurality of fill modules 1008g-1008l may be installed in the second heat exchange module 1010b, and a third plurality of fill modules 1008m-1008r may be installed in the third heat exchange module 1010c. As shown in FIG. 10, a first plurality of fill modules 1008a-1008f may be installed side-by-side in the first heat exchange module 1010a, with the collective first ends 1014a-1024a of the first plurality of fill modules 1008a-1008f defining a first side 1026a of the first heat exchange module 1010a. Further, the collective second ends 1014b-1024b of the first plurality of fill modules 1008a-1008f may similarly define a second side 1026b of the first heat exchange module 1010a. In addition, each of the first and second sides 1026a, 1026b may define the length L.sub.M of the first heat exchange module 1010a. Similarly, a second plurality of fill modules 1008g-1008l may be installed side-by-side in the second heat exchange module 1010b, with the collective first ends of the second plurality of fill modules 1008g-1008l defining a first side of the second heat exchange module 1010b and the collective second ends of the second plurality of fill modules 1008g-1008l defining a second side of the second heat exchange module 1010b. In addition, a third plurality of fill modules 1008m-1008r may be installed side-by-side in the third heat exchange module 1010c, with the collective first ends of the third plurality of fill modules 1008m-1008r defining a first side of the third heat exchange module 1010c and the collective second ends of the third plurality of fill modules 1008m-1008r defining a second side of the third heat exchange module 1010c. Similarly, FIG. 11 shows a plurality of fill modules 1108a-1108f installed side-by-side in a heat exchange module 1110, where each of the first side 1126a and the second side 1126b of the heat exchange module 1110 defines the length L.sub.M of the heat exchange module 1110.

[0141] In some cases, each of the plurality of fill modules 1008a-1008r comprises a plurality of structurally-restrained fill sheets or hanging fill sheets 1004 (hereinafter referred to as hanging fill sheets 1004) arranged on at least one support member 1002, 1003 and a plurality of fill packs 1006a, 1006b. In such cases, the at least one support member 1002, 1003 may extend along a length L.sub.F of each of the plurality of fill modules 1008a-1008r and each of the plurality of fill packs 1006a, 1006b may extend along a width W.sub.F of each of the plurality of fill modules 1008a-1008r. As shown in FIG. 10, the fill modules 1008a-1008r may include first and second fill packs 1006a that are imparted with substantially the same dimensions and coupled to the first ends 1002a, 1003a, and the second ends 1002b, 1003b of the respective support member 1002, 1003. The fill modules 1008a-1008r may also include a third fill pack 1006b, which may be imparted with dimensions that are different from the dimensions of the first and second fill packs 1006a. The third fill pack 1006b may also be coupled to the first end 1002a, 1003a of the respective support member 1002, 1003 and positioned proximate or adjacent to the first fill pack 1006a. In some aspects, the fill modules, such as the fill modules 1008g-1008l in the second heat exchange module 1010b, may include third and fourth fill packs 1006b, which have dimensions that are different from the dimensions of the first and second fill packs 1006a, where the third and fourth fill packs 1006b are coupled to the first end 1002a, 1003a and the second end 1002b, 1003b, respectively, of the respective support member 1002, 1003 and positioned proximate or adjacent to the first and second fill packs 1006a, respectively. In certain aspects, the at least one support member 1002, 1003 may be positioned or arranged substantially perpendicular to the plurality of fill packs 1006a, 1006b, although the at least one support member may be alternatively positioned or arranged with respect to the plurality of fill packs 1006a, 1006b.

[0142] As discussed in detail above, the heat transfer assembly may include a fluid distribution system (e.g., the fluid distribution system 750 of FIG. 7A-7E), which may include one or more vertical risers. For example, a supply piping arrangement in a counterflow tower (e.g., the towers 100, 200, 300 of FIGS. 1, 2, and 3A) may position the supply line proximate or adjacent to the long side of the tower running the full length of the tower, with at least one vertical riser (e.g., one vertical riser per cell or heat transfer module) connecting the supply line to inlet connections at the elevation of the distribution system of the tower. In some aspects, the heat exchange assembly 1000 of FIG. 10 may include the three heat exchange modules 1010a, 1010b, 1010c, in which each heat exchange module 1010a, 1010b, 1010c includes a vertical riser (not shown in FIG. 10) and the plurality of fill modules 1008a-1008r. For example, a first riser may be disposed in the first heat exchange module 1010a, a second riser may be disposed in the second heat exchange module 1010b, and a third riser may be disposed in the third heat exchange module 1010c. In some aspects, the first plurality of fill modules 1008a-1008f includes a fill module 1008d having an opening 1012 for receiving a riser, the second plurality of fill modules 1008g-1008l includes a fill module 1008j having an opening 1012 for receiving a riser, and/or the third plurality of fill modules 1008m-1008r includes a fill module 1008p having an opening 1012 for receiving a riser. For example, the openings 1012 of the fill modules 1008d, 1008j, 1008p may be designed to receive the first, second, and third risers of the first, second, and third heat exchange modules 1010a, 1010b, and 1010c, respectively. In certain aspects, at least one fill module 1008d within the first heat exchange module 1010a, at least one fill module 1008j within the second heat exchange module 1010b, and at least one fill module 1008p within the third heat exchange module 1010c comprises an opening 1012 to receive a riser. It is to be appreciated that the risers of the heat exchange module 1000 may be alternatively positioned (e.g., within different fill modules) than described herein. Referring to FIG. 11, the heat exchange module 1110 may include the plurality of fill modules 1108a-1008f in which the fill module 1108d is imparted with or has an opening 1112 for receiving a riser 1114. In some aspects, the opening 1012, 1112 may be partially surrounded, substantially surrounded, entirely surrounded, and/or reinforced with one or more fill packs 1006c, 1006d, 1106a. It is to be understood that the opening 1112 may be sized, shaped, and/or designed to receive a riser (e.g., the dimensions of the opening 1112 may be selected to accommodate a riser).

[0143] As shown in FIGS. 10, 11, and 12, the openings 1012, 1112, 1212 for receiving the riser may be partially, substantially, or entirely surrounded and/or reinforced with one or more fill packs 1006c, 1006d, 1106a, 1206b. The dimensions of the fill packs 1006c, 1006d, 1106a, 1206b surrounding the opening 1012, 1112, 1212 may be selected based on the dimensions of the opening 1012, 1112, 1212 and the dimensions of the riser. For example, as shown in FIG. 10, the dimensions of a first fill pack 1006c that partially surrounds the opening 1012 are different from the dimensions of a second fill pack 1006d that partially surrounds the opening 1012. Alternatively, the opening 1012, 1112, 1212 may be partially or substantially surrounded by one or more fill packs, where each fill pack of the one or more the fill packs is imparted with the same dimensions or, alternatively, different dimensions. As shown in FIG. 12, the opening 1212 may optionally be reinforced with a frame 1216, such as a steel frame, although frames comprising other materials may also be used. A fill pack may be placed around the frame 1216. In some instances, the fill pack may substantially surround the frame 1216. As shown in FIGS. 10, 11, and 12, the fill module 1008d, 1008j, 1008p, 1108d, 1208 that includes the opening 1012, 1112, 1212 for receiving a riser (e.g., the riser 1214) may be formed from a reduced percentage of the plurality of structurally-restrained or hanging fill sheets 1004, 1104, 1204 and an increased percentage of the fill pack 1006a, 1006b, 1006c, 1006d, 1106a, 1106b, 1106c, 1106d, 1206a, 1206b, 1206c. The frame 1216 may surround the riser in the longitudinal direction, or in the transverse direction. Furthermore, in other aspects, the frame 1216 may surround the riser in all directions. The reduction of the percentage of the plurality of structurally-restrained or hanging fill sheets 1004, 1104, 1204 may be due to the fill pack 1006c, 1006d, 1106a, 1206b that may be used to substantially surround the opening 1112, as compared to the other fill modules 1008a-1108c, 1008e-1008i, 1008k-1008o, 1008q, 1008r, 1108a-1108c, 1108e, 1108f in the heat exchange module 1010a, 1010b, 1010c, 1110. In some aspects, the composition of the fill module 1008d, 1008j, 1008p, 1108d, 1208 that has an opening 1012, 1112, 1212 for receiving a riser 1214 may be different from the composition of the other fill modules 1008a-1108c, 1008e-1008i, 1008k-1008o, 1008q, 1008r, 1108a-1108c, 1108e, 1108f.

[0144] Referring again to FIGS. 10 and 11, the dimensions of the fill packs 1006c, 1006d, 1106a surrounding each of the openings 1012, 1112 may be selected based on the dimensions of the opening 1012, 1112 and the riser. As shown in FIG. 10, the dimensions of a first fill pack 1006c that partially surrounds the opening 1012, 1112 are different from the dimensions of a second fill pack 1006d that partially surrounds the opening 1012, 1112. Alternatively, each of the openings 1012, 1112 may be partially or substantially surrounded by one or more fill packs, where the one or more the fill packs have the same dimensions. As shown in FIG. 11, the fill module 1108d having an opening 1112 for receiving a riser may be formed from a reduced percentage of the plurality of structurally-restrained or hanging fill sheets 1104 and an increased percentage of fill pack 1106a, which substantially surrounds the opening 1112, as compared to the other fill modules 1108a-1108c, 1108e, 1108f. In some aspects, the composition of the fill module 1108d having an opening 1112 for receiving a riser may be different than the composition of the other fill modules 1108a-1108c, 1108e, 1108f.

[0145] Generally, the dimensions of the mixed-fill modules disclosed herein may be selected based on the dimensions of the corresponding heat exchange module or heat exchange assembly. For example, the mixed-fill modules disclosed herein may be sized, shaped, and/or designed to be received in the corresponding heat exchange module or heat exchange assembly. In addition, the number of mixed-filled modules provided within a heat exchange module or a heat exchange assembly may partially depend on the dimensions of the provided heat exchange module or heat exchange assembly. In some instances, the number of mixed-fill modules provided in the heat exchange module or the heat exchange assembly may be different than the number of mixed-fill modules explicitly disclosed herein.

[0146] In some aspects, the plurality of fill sheets and the bonded fill packs disclosed herein are manufactured at a first location and then shipped to a second location, where the various modules of a modular cooling tower may be manufactured. As discussed above, shipping bonded fill packs may involve shipping a significant amount of air, as air may get trapped in the gaps between fill sheets in the pack. Advantageously, the use of hanging fill sheets avoids the problem of shipping air, as the individual sheets can be packed tightly together, minimizing or eliminating air gaps, thereby reducing shipping costs. Thus, the mixed-fill modules described herein allow a reduction in shipping costs, due to the proportion of hanging fill utilized in the mixed-fill module. In addition, the fill pack in the mixed-fill module bounds the hanging fill sheets and maintains the hanging fill sheets in a proper orientation or position. The mixed-fill modules may be constructed at the same location where the cooling tower modules are constructed and installed into the heat exchange modules, which may then be shipped to the field site of the cooling tower. During transportation, the heat exchange modules and the fill modules contained inside of them may be open to the elements. As such, the bounding of the hanging fill by the fill packs may be particularly beneficial during transport.

[0147] Referring to FIG. 14, a flowchart for an exemplary method 1400 of manufacturing a modular cooling tower is depicted. Block 1402 describes an aspect of the method 1400 involving providing a plurality of fill sheets in a stack, where the distance between any two fill sheets in the stack may be less than about 0.5 mm (or less than 0.5 mm). In some cases, the distance between adjacent fill sheets of the plurality of fill sheets may be no more than about 1 millimeter, or no more than about 0.9 millimeters, or no more than about 0.8 millimeters, or no more than about 0.7 millimeters, or no more than about 0.6 millimeters, or no more than about 0.5 millimeters, or no more than about 0.4 millimeters, or no more than about 0.3 millimeters, or no more than about 0.2 millimeters, or no more than about 0.1 millimeters. In other cases, the distance between adjacent fill sheets of the plurality of fill sheets may be no more than 1 millimeter, or no more than 0.9 millimeters, or no more than 0.8 millimeters, or no more than 0.7 millimeters, or no more than 0.6 millimeters, or no more than 0.5 millimeters, or no more than 0.4 millimeters, or no more than 0.3 millimeters, or no more than 0.2 millimeters, or no more than 0.1 millimeters.

[0148] Block 1404 describes an aspect of the method 1400 involving providing a plurality of fill packs, where each fill pack comprises a plurality of fill sheets bonded together. Block 1406 describes an aspect of the method 1400 involving providing at least one support member having a first end and a second end. Block 1408 describes an aspect of the method 1400 involving constructing a fill module by arranging the plurality of fill sheets on the at least one support member, coupling a first fill pack to the first end of the at least one support member, and coupling a second fill pack to the second end of the at least one support member. Block 1410 describes an aspect of the method 1400 involving providing a heat exchange assembly comprising at least one heat exchange module. Block 1412 describes an aspect of the method 1400 involving installing the fill module in the at least one heat exchange module. In some aspects, method 1400 may comprise additional steps not depicted in FIG. 14. For example, the method 1400 may additionally describe that the fill module may be assembled and installed in the at least one heat exchange module at a first location and then shipped to a second location for assembly into the cooling tower. Furthermore, the method may additionally describe that the plurality of fill modules are installed side by side in the at least one heat exchange module, with the collective first ends of the plurality of fill modules defining a first side of the at least one heat exchange module and the collective second ends of the plurality of fill modules defining a second side of the at least one heat exchange module, where the first and second sides may define the length of the at least one heat exchange module.

[0149] The steps of the method 1400 may be initiated more than once, at predetermined time intervals, and implemented in any order. Further, any of the steps of the method 1400 may be omitted. It is to be understood that the method 1400 may be implemented with any of the cooling towers (e.g., the towers 100, 200, 300 of FIGS. 1, 2, and 3A) discussed herein.

[0150] It will be appreciated by those skilled in the art that while the above disclosure has been described above in connection with particular embodiments and examples, the above disclosure is not necessarily so limited, and that numerous other embodiments, examples, uses, modifications and departures from the embodiments, examples, and uses are intended to be encompassed by the claims attached hereto. The entire disclosure of each patent and publication cited herein is incorporated by reference, as if each such patent or publication were individually incorporated by reference herein. Various features and advantages of the above disclosure are set forth in the following claims.