Cooling Tower Retrofit: 50%+ Energy Savings with EC Fan Wall

50%+ Cooling Tower Savings

Zhang Yu AUTHOR

Senior HVAC & EC Fan Applications Engineer· Published: AUGUST 01, 2026

When industrial cooling tower performance begins to decline, the first reaction is often to consider replacing the entire system.

But in many cases, the cooling tower itself isn't the real problem.

The airflow system is.

For facilities operating around the clock, aging belt-driven fan systems can quietly become one of the largest sources of unnecessary energy consumption, maintenance costs, and operational inefficiency.

A recent retrofit project completed by Beijinghengrui demonstrates how upgrading only the airflow system—with an ebm-papst EC Fan Wall—delivered more than 50% energy savings while extending the life of the existing cooling tower.

vThe Challenge

The original cooling tower used three 18.5 kW belt-driven fan systems (55.5 kW total). Over years of operation, several issues became increasingly apparent:

l High energy consumption

l Belt wear and mechanical transmission losses

l High maintenance requirements

l Uneven airflow distribution

l Fixed-speed operation regardless of actual cooling demand

For facilities running 24/7, these issues don't simply affect energy bills—they directly influence equipment reliability, production continuity, and long-term operating costs.

Actual exploration before renovation

Pic.1 Actual exploration before renovation

vThe Solution

Instead of simply replacing the motors, the retrofit upgraded the entire airflow system with:

· ebm-papst high-efficiency EC Fan Wall

· Intelligent variable-speed control

· Automatic water temperature regulation

· Modbus-TCP connectivity for BMS/DCS integration

Unlike traditional single large fans, the multi-fan architecture also provides built-in redundancy.

If one fan is offline, the remaining fans automatically compensate, ensuring stable cooling performance without interrupting operation.

Comparison before and after renovation

Pic.2 Comparison before and after renovation

vResult after renovation

Pic.3 Result based on the project's operating conditions.

Rather than simply reducing electricity consumption, the project improved the overall efficiency and stability of the cooling system.

vMore Than Energy Savings

The biggest improvement wasn't just lower electricity consumption.

The EC Fan Wall also delivered:

More uniform airflow

✔ Lower noise and vibration

✔ Direct-drive operation with reduced maintenance

✔ Intelligent demand-based control

✔ Higher system reliability for continuous industrial operation

vReady to Evaluate Your Cooling Tower?

If you're considering a cooling tower retrofit or exploring EC Fan solutions for industrial cooling applications, Beijing Hengrui is ready to share practical experience from real-world projects.

Whether you're looking to reduce energy consumption, improve airflow performance, or extend equipment life, we'd be happy to discuss the most suitable solution for your facility.

Contact us to evaluate your cooling tower retrofit potential.

Zhang Yu AUTHOR

Senior HVAC & EC Fan Applications Engineer

on EC and DC fan engineering, AC-to-EC energy retrofits, AHU modernization and data center cooling. Every article is grounded in real fan data, manufacturer documentation and completed retrofit projects.

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