Overview
ARBOK-CoolTower is a closed-loop industrial cooling system designed to replace conventional open evaporative cooling towers. Unlike classic towers that continuously lose water through evaporation, aerosol drift and blowdown, CoolTower operates in a fully sealed recirculating circuit — water is filled once and never contacts open air. This eliminates evaporative water losses, aerosol emissions, and — critically — the biological habitat required for Legionella bacteria. The system delivers stable condenser temperatures independent of ambient water availability, making it viable for water-stressed regions, hot climates, and facilities facing environmental or sanitary restrictions on open cooling towers.
Applications
Primary use cases:
- Replacement or retrofit of open evaporative cooling towers at thermal and nuclear power plants
- Industrial cooling for petrochemical complexes, refineries, metallurgy, and chemical plants
- Data center cooling in water-scarce regions
- District cooling systems and desalination plant heat rejection
- Facilities with strict Legionella or aerosol regulations (hospitals, hotels, urban zones)
Target industries: Power generation / Petrochemicals / Refining / Metallurgy / Healthcare infrastructure / Data centers
Typical project scale: 50 MWth to 2,000+ MWth heat rejection; modular units of 20–200 MWth
Operating Principle
Heat from industrial processes or turbine condensers is transferred through closed heat exchangers into the CoolTower recirculating loop. The loop circulates continuously through thermal rejection modules — dissipating heat to the environment without open-air evaporation of cooling water. There is no spray, no aerosol, no open basin, and no contact between process water and atmosphere.
ARBOK-Sonar monitors water quality parameters 24/7. Any deviation triggers automatic protection or controlled shutdown. Water quality remains sterile by design — the closed environment eliminates conditions for biological growth (no standing warm water, no amoeba, no biofilm, no iron-rich open basin).
Key Parameters
| Parameter | Classic Wet Tower | ARBOK-CoolTower |
|———–|——————-|—————–|
| Makeup water (ΔT 16°C, 10,000 m³/h) | 380 m³/h = $4.56M/yr | Zero |
| Makeup water (ΔT 35–37°C) | 870 m³/h = $10.44M/yr | Zero |
| OPEX (ΔT 16°C) | $5.30–$5.71M/yr | $0.10–$0.20M/yr |
| OPEX (ΔT 35–37°C) | $11.18–$11.59M/yr | $0.10–$0.20M/yr |
| Aerosol drift / plume | Yes — up to 300m | Zero |
| Legionella risk | Structural | Architecturally eliminated |
| Biocide treatments | Required annually | Not required |
| Water loss reduction vs. classic | — | 70–95% |
Additional specs:
- Capacity: 50–2,000+ MWth (modular, 20–200 MWth/unit)
- Auxiliary load reduction: 15–30% vs. comparable open tower
- Scalability: Modular — phased retrofit from legacy open towers possible
Architecture and Components
Core modules:
- Closed heat exchange circuit — process heat transfer without atmospheric evaporation
- Thermal rejection modules — engineered surface heat dissipation
- Circulation pumps — closed-loop flow maintenance
- ARBOK-Sonar — 24/7 water quality monitoring, auto-protection
- Temperature control & automation — SCADA/PLC-based
- Structural weatherproof enclosure modules
Control & Monitoring: SCADA / PLC / Digital Twin compatible; remote monitoring; auto-halt on deviation
Modularity: Yes — 20–200 MWth per module; phased retrofit from legacy open towers possible
Advantages
Technical: Zero evaporative water loss; stable condenser temperature during heat waves; no aerosol drift or visible plume; Legionella habitat architecturally impossible; no scaling concentration cycles; reduced fouling risk.
Economic: OPEX $0.10–$0.20M/year vs. $5.30–$11.59M/year for classic towers. Annual savings: $5.1–$5.6M (ΔT 16°C) and $11.0–$11.5M (ΔT 35–37°C). CAPEX $4–6M vs. up to $10M for classic. Payback about 7 years — the standard horizon for industrial cooling assets. Leasing and BOOM (Build-Own-Operate-Maintain) models available.
Environmental: 70–95% reduction in freshwater consumption; zero aerosol emissions; no Legionella or biological contamination risk; reduced chemical discharge; compliance with tightening water abstraction regulations.
Strategic: Protects plant output during summer heat waves when river cooling is restricted; eliminates Legionella liability (EU, UK, USA legislation); applicable to nuclear, thermal, and urban industrial sites.
Integrations
Compatible systems: Steam turbine condensers, gas turbine combined-cycle plants, industrial heat exchangers, desalination heat rejection, district energy systems, ZLD water treatment
Monitoring / Automation: SCADA, PLC, Digital Twin, ARBOK-Sonar, predictive maintenance platforms
Deployment & Operation
Pre-installation: Thermal audit, heat balance analysis, condenser performance assessment, hydraulic integration engineering
Operating conditions: High-temperature climates, dust-exposed industrial sites, urban restricted zones, all-weather industrial duty
Operational workflow: Continuous closed-loop circulation → automated temperature regulation → 24/7 Sonar monitoring → periodic mechanical inspection
Personnel requirements: Plant operators + mechanical maintenance; reduced chemical treatment workload vs. open towers
TRL
Current TRL: 4–6
Evidence: Concept engineering complete; economic modelling vs. classic towers validated; integration scenarios with thermal condensers defined
Completed milestones:
- Closed-loop thermal architecture designed
- Economic modelling vs. classic towers completed
- Integration scenarios with thermal condensers defined
Next steps to TRL 9:
- Pilot installation at industrial heat load (20–50 MWth)
- Long-term seasonal operation and validation
- Third-party thermal performance and water reduction certification
- Commercial reference plant
Market Potential
Target markets: Water-stressed industrial regions — Middle East, North Africa, Central Asia, South Asia, Southern Europe, southwestern USA
Global market size: Industrial cooling market ~$15–20B globally; cooling tower replacement/retrofit growing due to water stress and Legionella regulation
Key drivers: Tightening water abstraction regulations, Legionella liability legislation, summer river temperature restrictions at nuclear/thermal plants, rising industrial water costs ($1–$4/m³)
Typical Project Economics
| Parameter | Range |
|———–|——-|
| Project size | 50–2,000+ MWth |
| CAPEX | $4–6M (vs. up to $10M classic) |
| OPEX | $0.10–$0.20M/year |
| Savings vs. classic (ΔT 16°C) | $5.1–$5.6M/year |
| Savings vs. classic (ΔT 35–37°C) | $11.0–$11.5M/year |
| Payback period | About 7 years — standard horizon for industrial cooling assets |
| Business models | Direct sale / Leasing / BOO |
Risk Factors
- Technical: Performance site-specific; large legacy plants require phased hydraulic integration
- Market: Conservative industrial procurement cycles; long decision timelines at power plants
- Regulatory: Site-specific permitting for cooling infrastructure retrofit
- TRL gap: Pilot-scale validation required before full commercial deployment
Related Technologies
ARBOK-EFFLUENT, ARBOK-JUMBO, Vacuum Osmosis, ARBOK Digital Twin, ARBOK-TURBIO (Closed-Loop Hydro Power Generator), SkyManager-SMOG (Fog & Smog Remover)