ENEXIO Polypropylene film blocks for district cooling plant in Cairo

ENEXIO 4 Oct Cooling CarioENEXIO Water Technologies and long-term partner Kelvion collaborated in 2019, to build wet cooling towers to deliver the fill media as heat transfer surface for the HVAC system of a major district cooling plant in Cairo. ENEXIO Water Technologies? part in this project was the supply of fill media as heat transfer surface

Powerful counterflow cooling towers

The project comprised 16 cells of 150 sq m each, configured in two rows of eight, with a total cooling capacity of 66,000 TR ( tonne of refrigeration). These counterflow cooling towers were supplied with fibreglass reinforced pultruded structures, with stainless steel SS316 fixation in a concrete basin. Besides the fill media, the tower structures featured VFD-compatible motors, reduction gear and carbon fibre drive shaft for the low noise fans.

Huge heat transfer surface 

The huge surface of ENEXIO fills as heat exchange media amounted to 648,000 sq m which equals 95 football fields. Instead of shipping the completed fill blocks, which would have filled about 100 containers, nested foils were sent and thus the transport volume was reduced to five containers, saving considerably on transport costs. 

On-site assembly of fill media

Two foil-welding machines were used to assemble the foils to complete fill blocks. A three-shift process helped ENEXIO meet the tight time lines of the project. To be able to install the assembled blocks quickly and easily, the well-proven and robust welding process took place in a separate area next to the cooling tower.

Why Polypropylene fills?

Due to the hot climate, fire rated Polypropylene fills were chosen as these can handle maximum surface temperatures of 80? C while PVC is limited to 55? C. A second advantage of PP fills compared to PVC is the long life span as PP is less brittle especially after some time in operation. This means extra safety when storing, assembling and installing the fills in hot  temperatures.


With the help of a local agent, Kelvion and ENEXIO Water Technologies met the tight time schedule of this fast-track project and completed the installation in three months. The customer?s expectations on design, delivery time and installation were fulfilled to their satisfaction.


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