Decsa was contacted by a company based in Marghera, specialised in the recovery and preparation of recyclable waste, for the revamping of four existing cooling towers.
Introduction
Ensuring the long-term reliability and efficiency of industrial cooling systems is essential for companies operating in demanding production environments. Through targeted revamping projects, existing cooling towers can be upgraded, extending their service life while improving performance, efficiency, and operational reliability.
This case study describes the revamping of four Decsa fibreglass evaporative cooling towers installed in 1991 at an industrial waste recovery facility in Marghera (VE), Italy. Thanks to a comprehensive modernisation project, the units were upgraded with new components and an improved water distribution system, allowing the Customer to continue using the existing cooling towers while enhancing their overall efficiency and reducing the risk of corrosion-related issues.
The Customer’s Problem
In July 2023, we were contacted by a long-standing customer specialised in solid waste recovery to carry out an inspection of four Decsa (Cofinair) fibreglass evaporative cooling towers installed in Marghera, Venice, Italy, in 1991.
Following a thorough analysis performed by Decsa’s Service technicians, it emerged that the units, although outdated, were still operational but required a major modernisation intervention (revamping).
The solution: cooling tower revamping
In agreement with the Customer — who did not want to replace the evaporative cooling towers but preferred to carry out maintenance work on the existing units — Decsa proposed an almost complete revamping of the cooling towers (with the exception of the motors, fans, and the upper fibreglass cover).
The revamping activity carried out on the four cooling towers involved, for each unit:
- Replacement of the heat exchange fills
- Replacement of the drift eliminators
- Replacement of the air inlet louvres
- Replacement of the nozzles with the new DecsaSpray nozzles
- Replacement of the main and secondary headers
- Replacement of the fibreglass panels and access doors
The project also required a significant effort from our Engineering Department, which had to redesign and develop the entire water distribution system.
In fact, in order to improve the efficiency of the evaporative cooling towers and prevent the severe corrosion found in the original metal distribution system, it was decided to replace it with the current PVC system and install the new DecsaSpray nozzles*.
*DecsaSpray is the new nozzle designed by Cofinair by Decsa that enables full-cone water spraying, ensuring total spraying of the fill pack.
Project timelines
The order was finalised in October 2023, while the revamping work — completed within the agreed timeframe — was scheduled for the weeks between the end of February and March 2024. During this period, the Customer had planned a complete plant shutdown to allow all maintenance activities to be carried out, including those involving the cooling towers.
The activity, supported by our local agency Tekimp Sas, was coordinated and completed by our Service technicians.
In the gallery, you can see the various removal and replacement operations carried out during the intervention.
| Company | Company specializing in recovery and preparation for recycling of solid waste |
|---|---|
| Year of Installation | 1991 |
| Year of Intervention | 2024 |
| Place of Installation | Marghera (VE), Italy |
| Type of interlocutor | End Client |
| Application | Industrial waste cooling |
| Fluid | Water |
| equipment provided | TVA 450 fiberglass cooling tower |
| Services Provided | Revamping work with replacement of: – Exchange fill packs – Drift eliminators – Air intakes – Nozzles – Main collectors – Secondary collectors – Panels and Portal |
