| Parameter | Value |
|---|---|
| Model | ZL-10T |
| Cooling Capacity | 10 RT (35.2 kW heat rejection) |
| Water Flow Rate | 7.81 m3/h (130 L/min) |
| Cooling Range | 5C (37C inlet to 32C outlet at design WB 27C) |
| Approach to Wet-Bulb | 5C at design conditions |
| Fan Motor | 0.37 kW (0.5 HP) 380V 3-phase 50Hz |
| Fan Diameter | 635 mm axial |
| Air Flow Rate | 85 CMM (50,920 m3/h) |
| Head Loss at Design Flow | 13 kPa |
| Tower Dimensions (H x D) | 1820 x 940 mm |
| Dry Weight | 46 kg |
| Operating Weight (filled) | 190 kg |
| Noise Level | 60 dB(A) at 1 m |
| Tower Body Material | FRP (Fiberglass Reinforced Plastic) |
| Fan Blade Material | ABS plastic |
| Configuration | Counter Flow Square |
| Voltage | 380V 3-phase 50Hz (customizable 220V/415V) |
| Certifications | CE / ISO 9001:2015 |
| Warranty | 1 year (consumables excluded) |
The ZL-10T is rated at 10 refrigeration tons, equivalent to 35.2 kW of heat rejection at standard air conditioning conditions. Converting tons to water flow uses the fundamental formula:
Q = m × Cp × ΔT, where Q = 35.2 kW, Cp = 4.186 kJ/kg°C, ΔT = 5°C range.
Solving for mass flow: m = 35.2 / (4.186 × 5) = 1.682 kg/s, or 1.682 × 3600 / 1000 = 6.05 m³/h of pure evaporated mass transfer. However, the actual circulation flow must account for the full sensible cooling range. At 5°C range (37°C inlet → 32°C outlet), the rated circulation is 7.81 m³/h — a 22% margin above the minimum sensible flow to maintain adequate wetting of the fill media.
For a 30 kW process load (smaller than full 10 ton rating), the same tower can operate at 6.7 m³/h with the same approach. For a 50 kW overload condition, the tower delivers 32°C outlet at 27°C WB but approach degrades to 8°C — acceptable for non-precision cooling.
Approach temperature is the difference between the tower's leaving water temperature and the ambient wet-bulb temperature. The ZL-10T achieves a 5°C approach at design WB 27°C, meaning the tower leaves water at 32°C when ambient WB is 27°C.
This 5°C approach is the design point for all FRP counter flow cooling towers in this size class. As ambient conditions deviate — say, WB rises to 30°C on a humid summer day — the leaving water temperature climbs proportionally. At WB = 30°C, the ZL-10T delivers 35°C leaving water — still adequate for chiller condensers but tight for processes requiring sub-30°C supply.
For data center applications where leaving water temperature directly determines chiller efficiency, the 5°C approach specification is critical. Every 1°C reduction in approach saves approximately 2-3% chiller compressor power. A ZL-10T performing at 4°C approach (28°C leaving at WB 24°C) versus 6°C approach saves a data center operator approximately USD 800-1,200 annually per tower at typical commercial power rates.
The ZL-10T employs a counter flow fill configuration: water descends vertically through the fill while air is forced upward by the fan directly opposite to the water flow. This geometry provides three engineering advantages over cross flow designs:
1. Higher thermal effectiveness: Counter flow maintains a more uniform LMTD (log mean temperature difference) across the fill height. The ZL-10T achieves 65-70% approach reduction compared to 50-55% for equivalent cross flow towers in this capacity class.
2. Smaller footprint: Counter flow geometry packs the heat transfer area into a vertical column rather than spreading it horizontally. The ZL-10T's 940 mm diameter is 20-25% smaller than equivalent cross flow towers rated at the same 10 ton capacity.
3. Reduced air bypass: The enclosed counter flow design minimizes air recirculation at the tower's periphery, a common efficiency loss in cross flow configurations. Field tests show 2-4°C approach degradation in poorly sealed cross flow towers versus <1°C in counter flow.
The ZL-10T uses a 635 mm diameter axial fan driven by a 0.37 kW (0.5 HP) motor at 1,440 rpm. The fan delivers 85 CMM (cubic meters per minute) = 50,920 m³/h of induced airflow through the fill.
Calculating the air-to-water ratio: 50,920 m³/h air versus 7.81 m³/h water = 6,520:1 mass ratio. This high air ratio is necessary because the heat transfer is dominated by evaporation — each kg of evaporated water carries 2,260 kJ of latent heat, while each °C of sensible cooling carries only 4.186 kJ per kg.
The 635 mm fan diameter is chosen to deliver 85 CMM at a static pressure of approximately 50-80 Pa (typical for 10 ton counter flow fill). Increasing the fan diameter would reduce motor power consumption but increase tower height. The current 635 mm / 0.37 kW combination achieves an airflow efficiency of 230 CMM per kW — industry-typical for this capacity class.
The ZL-10T's rated head loss is 13 kPa at the design water flow of 7.81 m³/h. This is the pressure the condenser water pump must overcome to push water through the tower's spray nozzles, fill media, and eliminators.
At 50% flow (3.9 m³/h), head loss drops to approximately 4 kPa — proportional to flow squared (h = k × Q²). At 120% flow (9.4 m³/h), head loss rises to approximately 19 kPa. The condenser water pump should be sized to deliver at least 15 m head (150 kPa) at design flow to accommodate the 13 kPa tower loss plus piping losses.
Higher head loss than rated indicates fill media fouling, biological growth, or air entrainment. Quarterly inspection of the fill media surface and water chemistry analysis is recommended for towers operating above 10 kPa head loss.
The ZL-10T's tower body, fan stack, and water basin are constructed from FRP (Fiberglass Reinforced Plastic) with isophthalic polyester resin and a UV-stabilized gel coat surface. This material selection is driven by three engineering requirements:
1. Corrosion resistance: FRP tolerates pH 6.5-9.0 circulating water without degradation. In comparison, galvanized steel shells typically fail in 5-8 years in similar water chemistry, while FRP shells show <0.1 mm surface erosion over 15 years.
2. Thermal stability: FRP maintains structural integrity from -30°C to +80°C, covering all operating conditions including winter freeze protection and summer peak ambient.
3. Weight reduction: The ZL-10T's 46 kg dry weight (FRP) compares to 80-100 kg for equivalent galvanized steel construction, simplifying rooftop installation and foundation requirements.
The fan blades use ABS plastic for similar corrosion resistance at the rotating interface, where water spray continuously contacts the air-side surfaces.
The ZL-10T rejects 35.2 kW (10 RT) at design conditions (37°C inlet, 32°C outlet, 27°C WB). At 5°C approach, the leaving water temperature is 5°C above the ambient wet-bulb temperature.
Water flow m = Q / (Cp × ΔT). For 10 RT (35.2 kW) at 5°C range: m = 35.2 / (4.186 × 5) = 1.68 kg/s = 6.05 m³/h minimum. The ZL-10T's 7.81 m³/h provides 22% margin for proper fill wetting.
Range = inlet water temperature − outlet water temperature (5°C for ZL-10T). Approach = outlet water temperature − ambient wet-bulb temperature (5°C for ZL-10T at design WB 27°C).
Counter flow maintains a more uniform LMTD across the fill height. The ZL-10T achieves 65-70% approach reduction compared to 50-55% for equivalent cross flow towers, plus a 20-25% smaller footprint.
Air flow = water flow × heat duty / (humidity ratio change × air density). The ZL-10T's 85 CMM (50,920 m³/h) air flow versus 7.81 m³/h water flow gives a 6,520:1 air-to-water mass ratio, optimized for evaporative heat transfer.
Authoritative References: ASHRAE Handbook — HVAC Applications (Chapter 36: Cooling Towers) | CTI Certification Standards (STD-201)
Explore other ZL-10T 10 Ton FRP Counter Flow Cooling Tower variants engineered for different applications:
Zillion has supplied industrial cooling towers since 2009, with FRP counter flow construction as our standard since 2014. The ZL-10T's 7.81 m3/h flow at 5C range and 35.2 kW heat rejection cover the 10-ton process cooling capacity class at 0.37 kW fan power — the lowest power consumption per ton in our ZL series.
Contact: Leika Li, +86 185 2053 2504, Leika@gdzillion.cn. Factory: Building 103-B, Yi'an Industrial Park, Fenggang Town, Dongguan, Guangdong, China.
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