ULTRALITE® AND

PERMALITE®

SERIES TOWERS

CERAMIC COOLING TOWER CORPORATION

MODULAR SOLUTION COOLING TOWERS:SUPERIOR DESIGN AND PERFORMANCE

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THE INNOVATIVE SOURCE

Ceramic Cooling TowerCorporation (CCTC) is anindustry leader with a globalreputation for high qualitycooling tower design and construction. CCTC is one ofthe world's premier manufac-turers of heat transfer andthermal energy equipment forair conditioning, refrigeration,and industrial process cool-ing. As an industry leader inresearch and development,CCTC offers an extensiveproduct line of cooling towers, several of which are CTI-Certified.

IDEAS CREATE SOLUTIONS

Founded in 1947, CCTC quickly estab-lished the concept of the "permanent" cool-ing tower structure, while pioneering theuse of non-clogging ceramic tile fill material.The successful marketing of this "perma-nence" concept evolved progressively to afamily of long-life fiberglass cooling towerstructures. This pioneering spirit, combinedwith years of research and development inmaterials and structures, led to today'sstate-of-the-art cooling tower structurescomposed of hi-tech pultruded structuralmembers. Offering many advanced featuresavailable only from CCTC, these towerssolve today's cooling tower requirements.

Quality of Fiberglass at aLower CostLong life and low maintenance advantagesof a quality fiberglass structure tower, butwith lighterweight, lower-cost PVC fill.

CCTC's tower designs enhance the surroundingarchitecture

Part of CCTC's manufacturing processincludes this robotic fabricating equipment

CERAMIC COOLING TOWER CORPORATION

DYNAMIC SYNERGY: A COLLABORATIVE APPROACH

Today’s global power engineering solutionsare found in progressive companies thatcooperatively share enormous complemen-tary strengths. Having recognized this needfor technological and business synergy,Balcke-Dürr continued its mission of techno-logical excellence by merging with ThermalEngineering International (TEI). Today's BDTengineering combines the excellence ofThermal Engineering International, Balcke-Dürr, and many other firms.

AN ENDURING EXCELLENCE

Balcke-Dürr’s heritage of excellence originat-ed in 1894, when Hans-Joachim Balcke builtthe first natural draft cooling tower, estab-lishing a legacy upon which BDT would builda world-class reputation for engineeringexcellence in the recooling sector.

ERMALITE 600 Towers

UNILITE Tower

PCS CounterflowTower

Concrete Tower

CCTC's R&D operationService and repair

The CCTC Corporate Headquarters andManufacturing Plant

®

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MAXIMUM BENEFITS WITH LOW MAINTENANCE

ULTRALITE® 100 AND

PERMALITE® 200 COOLING TOWERS:VERSATILE ECONOMY

Lower Installed Cost – The simple supportrequirements, generally consisting of onlytwo parallel I-beams, result from the heavy-duty construction and structural strength ofthe ULTRALITE® 100 and PERMALITE® 200 tow-ers. Rigging costs are minimized becausethe ULTRALITE 100 and PERMALITE 200 shipfully assembled.

Long Life – Both towers use high-performance fill materials: PERMAGRID® tile forPERMALITE towers; and economical, lighter-weight PVC fill for the ULTRALITES. The use ofsuperior mechanical components, high quality resin systems, ultraviolet inhibitors,and gel-coating results in factory-assembledcooling towers with impressive life-spanadvantages over conventional towers.

Low Maintenance – The FRP structure willnot rust, rot, corrode, or deteriorate, andthe mechanical equipment requires littlemaintenance. The easy-cleaning, one-pieceFRP basin is leak-resistant.

Compatible Design and Access – The eye-pleasing design of these towers canmaximize architectural compatibility. Visualinspections and maintenance are simplified,and the removable louvers provide conven-ient access to the interior of the unit. Because of size and weight advantages,these compact towers enable easy and flexible placement.

ULTRALITE® 600 AND

PERMALITE® 600 COOLING TOWERS: SLEEKLY POWERFUL

Tough and Refined – ULTRALITE 600 andPERMALITE 600 Modular Cooling Towers com-bine a high-quality, heavy-duty fiberglassreinforced plastic (FRP) structure anddurable mechanical components for enduring performance.

No Deterioration – The tough FRP structureis fire-retardant and self-extinguishing, with aflame spread rating of less than 25 per ASTME-84. Its advanced fire-resistant designearns the PERMALITE tower both FM and IRIapproval for use without a fire sprinkler system.

Long Life – These pre-fabricated, field-assembled cooling towers have impressivelifespan advantages over conventional towers. Both utilize high-performance fillmaterials – PERMAGRID tile for the PERMALITE

tower, and light, economical PVC fill for theULTRALITE. Exterior and interior surfacesincorporate a high quality resin system,hand-applied uni-directional fiberglass, gel-coating for long life, and ultravioletinhibitors. All assembly connections utilizeunidirectional fiberglass-reinforced memberswith stainless steel attachment hardware.

Low Maintenance – These exceptional towers require little maintenance, demon-strate energy efficiency, and provide enduring performance far surpassing towers of similar size.

Flexible Placement – The towers are moldedin sections for rapid field assembly in mini-mum space, including installation at grade,on a roof top, or even in a mechanicalroom.

ULTRALITE 100 and PERMALITE 200 Towers ship readyto be installed, fully assembled

PERMALITE 600 fan being installed and tested atthe CCTC manufacturing facility

SIMPLE YET VERSATILE –

PERMALITE AND

ULTRALITE TOWERS ARE

YOUR BEST CHOICE FOR

COOLING.

Technician hand laying-up fiberglass at the CCTC manufacturing facility

PERMALITE 600 being transported tojob site by truck

Its light weight allows the Ultralite 100 Tower to beused virtually anywhere

THEULTRALITE 100®

SERIES COOLING TOWER

inspectionports

ULTRALITE 100 TowerULTRALITE 100 Towers

FACTORY-ASSEMBLED EXCELLENCE

The ULTRALITE® 100 Series Cooling Toweris the solution which promotes corrosionresistance, longevity, and minimal maintenance.

ADAPTABLE PERFORMANCE

The ULTRALITE 100 Series cooling towersare versatile performers whose lightweightdesign permits easy lifting to rooftop loca-tions, particularly for comfort coolingapplications. Architectural integrity is built-in, as the attractive design needs noscreening. Due to its heavy-duty construc-tion, support requirements are minimal,consisting of a hot-dipped galvanized steel base.

Rigging costs are minimized because theULTRALITE 100 ships fully assembled withall motors and drives factory installedand aligned. The modular design enablesunits to be multiplexed for larger installations, eliminating the time andexpense associated with field-erectedcooling towers.

FACTORY-ASSEMBLED READINESS

Each ULTRALITE 100 Cooling Tower leavesthe CCTC factory ready for immediateoperation. The tower structure consists ofa high-performance, fiberglass-reinforcedpolyester (FRP) composite laminate, engi-neered to ensure durability.

Tower fill consists of cross-corrugatedPVC film supported by stainless steel orFRP members. Drift eliminators are wave-formed PVC with ultraviolet (UV) inhibitors.Both have a flame spread of 15 or less.The UV-protected fiberglass structure andbasin are fabricated with fire-retardantresins, thus eliminating rust and corrosion.

ULTRALITE 100 SPECIFICATIONS

The ULTRALITE 100 Series isavailable in two basic cell sizes:

•The XL-36 measures 81" x 81".

•The larger XL-75 measures 98" x 128".

Capacities range from 47 to 232 nominaltons per cell, and multiple cells can beused for larger applications. Confirmingthat the performance of these towers iscommensurate with the quality of con-struction, the thermal performance ratingsare certified by the Cooling TechnologyInstitute (CTI) in accordance with their standard, STD-201 (96).

P V CI L L

FRP structure

outletinlet

make-up valve(optional)

overflow

PVC film fill

fill supports

galvanizedsteel support

one-pieceFRP basin

PVC film fill

fan screen

cast aluminum fan

direct drive motor

low-pressurewater distributionsystem

3-pass drifteliminators

COMPACT INSTALLATION

The counterflow design PERMALITE® 200 iscompact; its hexagonal shape occupiesless than 75 square feet when installed.

The full 360° air inlet allows flexible place-ment.

DESIGNED AND CONSTRUCTED FOR

LOW, EASY MAINTENANCE

The unique fiberglass structure PERMALITE 200is the first cooling tower designed to requirelow maintenance on key tower components.Gone are the maintenance expenses associated with fill replacement, structuredeterioration, and distribution system maintenance.

NON-CLOGGING, NON-DETERIORATING,LONG-LASTING TILE FILL

The PERMALITE 200 uses CCTC's PERMAGRID®

ceramic tile fill, guaranteed to provide serv-ice for 25 years, assuring a PERMALITE 200owner of thermal performance longevity.Tiles are stacked by hand in a predeter-mined pattern after tower assembly. Thecombination of a strong support system andthe strength of the tile assures the preven-tion of water and air flow distortion.

PERMAGRID's hardness, density, strength, andcomposition eliminate problems that arisefrom fill distortion, which disrupts thedesigned water and results in inefficientwater cooling and higher electricity con-sumption. PERMAGRID is unaffected by UVexposure, water treatment chemicals, fungal attack, and temperature extremes,including icing.

FIBERGLASS STRUCTURE

The tower walls are fabricated of pultrudedfiberglass members. The fan enclosure andbasin are made of molded FRP structuralfiberglass – a material of exceptionalstrength that will not rust, rot, deteriorate,or leak. The basin interior surfaces are tool-finished gel-coat (with UV inhibitors), have aflame spread rating of 25 or less per ASTM E-84, and are self-extinguishing. ThePERMALITE 200 is an extremely sturdy tower,capable of withstanding winds in excess of100 MPH, while complying with seismicZone 4 building codes. Because of its practical and attractive modular design, multiple towers can be installed in minimumspace for larger cooling requirements.

MECHANICAL HIGHLIGHTS

The direct drive PERMALITE 200 motor is anenclosed, corrosion-duty, variable-torque,sealed-bearing type motor that requires zeromaintenance. There are no gears to lubricateor belts to wear. The aluminum fan is a fixedblade design that requires no adjusting.

DISTRIBUTION SYSTEM

Another zero maintenance feature of thePERMALITE 200 is the totally enclosed, low-pressure distribution system. The large-diameter piping and CCTC-designed, large-orifice spray nozzles are self-cleaning.

PERMALITE 200 Towers

Distribution system arrangement and unitizedwaveform eliminators on a PERMALITE 200.

T I L EF I L LTHEPERMALITE 200®

SERIES COOLING TOWER

The PERMALITE 200 has a lightweightand compact design

direct drivemotor and fan

3-pass drifteliminators

FRP structure

PERMAGRIDceramic tilefill

air inlet louvers(optional)

one-piecebasin fill support

low pressurewater distributionsystem

A LEGACY OF PERMANENCE

The ULTRALITE® 600 incorporates all of thequality and permanent structure featuresof the famous PERMALITE® Cooling Tower.Like the PERMALITE tower, the ULTRALITE

tower’s fiberglass structure is a field-assembled, fire retardant, Class 1-ratedfiberglass structure, except that the ULTRALITE series utilizes economical, light-weight PVC film fill. ULTRALITE towers areavailable in the same plan sizes (12 x 12’and 12 x 18’) as the PERMALITE towers.

PRACTICALITY AND TECHNOLOGY

ULTRALITE 600 cooling towers are designedfor customers who want the long life andlow maintenance advantages of a quality

fiberglass structure tower, but with lighterweight, lower-cost PVC fill. These towersare well-suited for air conditioning orindustrial water cooling. Both ULTRALITE

and PERMALITE towers feature a shallow-sump FRP basin that is highly adaptableto rooftop installations.

DESIGNED FOR LOW, EASY

MAINTENANCE

ULTRALITE 600 towers require little main-tenance, while providing consistent ther-mal performance. The mechanical sec-tion is factory-assembled, including thefan, drive system, and water distributionsystem, all within a fiberglass enclosurewith integral fan stack. Quality construc-tion minimizes noise and vibration.

PERMALITE 600s

V CI L L

THEULTRALITE 600®

SERIES COOLING TOWER

THEPERMALITE 600®

SERIES COOLING TOWER

LOW MAINTENANCE AND THERMAL

PERFORMANCE

PERMALITE 600 towers offer the perform-ance-proven advantages of a concretestructure tower in a lighter-weight, long-lifefiberglass tower. PERMALITE towers require little maintenance and provide enduring, con-sistent thermal performance. The hardy FRPstructure will not rot or rust. The minimal-maintenance mechanical section is factory-assembled, including the fan, drive system,and water distribution system, all within afiberglass enclosure with integral fan stack.

ADVANCED TECHNOLOGY

PERMALITE 600 modular cooling towerscombine structural fiberglass construction,CCTC's "permanent" PERMAGRID® CeramicTile Fill, and advanced technology to produce significant performance advan-tages over conventional cooling towers.

The PERMAGRID tile fill is the most durablefill in the industry, with a guaranteed mini-mum 25 years of service. Made fromdomestic clay to strict specifications, theclay is heat fired to create a fill that isimmune to traditional fill deteriorationproblems. Because tile fill is unaffected byultraviolet exposure and fungal attack,PERMALITE towers are unusually well-suitedfor harsh operating environments involvingtemperature extremes. Characterized bylarge openings, PERMAGRID tile is an excel-lent performer in the high-solid contents environment of dirty water applications.

ADAPTABILITY

PERMALITE towers are available in plan sizes12 x 12’ and 12 x 18’. Multiple-unit installa-tions can meet larger cooling requirements.The PERMALITE tower’s pleasing appearancemakes it architecturally compatible.

T I L EF I L L

ULTRALITE 600s are attractive enough to be used inprominent locations

screen

adjustable pitchFRP fan

gear drive (beltdrive optional)

3-pass drifteliminators

low-pressure waterdistribution system

PVC fill

FRP fill supportlintels

FRP structure1-piece FRP basin

ladder and access door

air inlet louvers(optional)

screen

motor and beltdrive

access door

FRP structure

fill support lintels

one-piece FRPbasin

FRP ladder(optional)

air inlet louvers(optional)

PERMAGRID tile fill

Structural upgrade of a wood tower

Field testing being performed

CCTC possesses a well-earned reputationas a leading provider of comprehensiveengineering services to many industries,including power generation, chemical andpetrochemical, and the comfort coolingsectors. Our service operations benefitfrom CCTC's combined internationalresources and expertise, providing ourcustomers with rapid, flexible, and efficient service.

Our service expertise encompasses:

• Expert inspections• Performance testing & evaluations• Structural repairs• Thermal upgrades• High-performance, non-fouling film

and splash fill replacements• Drift eliminator replacements• Water distribution system upgrades• Mechanical component replacements• Full range of spare parts available for

all OEM equipment

SERVICE

Most cooling towers lose efficiency everyyear through normal wear. Eventually, thetower requires repair, upgrade, or replace-ment to meet modern standards. CCTC’smission is to provide the most advanced,cost-effective solutions for all coolingtower service requirements. Regardless ofmanufacturer, builder, or date of construc-tion, CCTC possesses the materialresources to restore and enhance yourcooling operations.

CCTC's experienced, capable staff pro-vides clients great benefit, derived from a100-plus year legacy of service and con-struction. Manufacturing resources locat-ed around the world assure customers ofprompt technical assistance and equip-ment availability.

REPAIR

CCTC has provided repair services for allsituations for over 75 years. Experiencedreconstruction specialists are strategicallystationed for superior response to yourcooling tower needs. After inspecting andassessing your tower’s condition, thesespecialists identify the required repair andprovide a time and cost estimate forreturning the tower to appropriate opera-tion. Regardless of the manufacturer ofyour tower, natural or mechanical draft, counterflow or crossflow, CCTC canensure that you meet the demands ofreduced water temperature or lowerpower consumption requirements.

PARTS

CCTC maintains an extensive inventory ofparts to meet your requirements quicklyand efficiently. We will supply any partrequired. For any part not in stock, ourrelationship with major suppliers in theindustry enables us to obtain other parts.Whether you are restocking parts beforethe next scheduled outage or have anurgent need, contact CCTC for expertassistance. By maintaining a vast supplyof cooling tower replacement parts, CCTCputs the "immediate" in delivery.

SERVICE, REPAIR AND PARTS

CCTC’S MISSION IS

TO PROVIDE THE MOST

ADVANCED, COST-

EFFECTIVE SOLUTIONS

FOR ALL COOLING TOWER

SERVICE REQUIREMENTS.

CCTC builds quality into its components,which helps minimize service calls later

Replacing louvers

Installing fan stacks

THE WORLD OF

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M

Office locations

Office locations withmanufacturing plants

w w w. b d t e n g i n e e r i n g . c o m

Ceramic Cooling TowerCorporationFort Worth, TexasPhone: (817) 232-4661

(800) 779-4661Fax: (817) 232-4703Email: unilite@ceramic-ct.comWet Cooling Towers, Spare Parts,Service and Repair for all CoolingTower Brands

Santa Rosa, CaliforniaPhone: (707) 544-5833Fax: (707) 545-9118E-mail: unilite@ceramic-ct.comAftermarket Services for All CoolingTowers

Balcke-Dürr, Inc.Tampa, FloridaPhone: (813) 289-1516

(800) 233-2045Fax: (813) 289-9385E-Mail: info@balckedurr.comWet & Dry Cooling Towers,Air Cooled Condensers andAftermarket Services for All CoolingTowers

ZBD Constructors, Inc.Tampa, FloridaPhone: (813) 289-1520Fax: (813) 282-8514E-Mail: info@zbdconstructors.comChimneys, Stacks and AftermarketServices for All Chimneys/Stacks

Regional OfficeFlorence, KentuckyPhone: (606) 342-5200Fax: (606) 342-5201

BD AirFinDivision of Balcke-Dürr, Inc.Tulsa, OklahomaPhone: (918) 627-9636Fax: (918) 627-9630E-Mail: balckedurr@webcombo.netHeat Exchanger Products

Boiler Tube Company of AmericaLyman, South CarolinaPhone: (864) 439-4489

(800) 845-3052Fax: (864) 439-8292Email: sales@boilertubes.comwww.boilertubes.comBoiler Tube Products andEconomizers

Industrial Products DivisionMilwaukee, WisconsinPhone: (414) 353-3112Fax: (414) 353-3304E-Mail: sales.teiipd@thermalengint.comIndustrial Heat Exchangers

MSR Technology and Advanced Programs DivisionLos Angeles, CaliforniaPhone: (323) 726-0641Fax: (323) 838-6454MSR E-Mail:msr@thermalengint.comMoisture Separator Reheaters

TEi Construction Services, Inc.Greer, SouthCarolinaPhone: (864) 879-4800Fax: (864) 879-3530Boiler Construction Services

Thermal Energy ServicesRoyersford, PennsylvaniaPhone: (610) 948-5400Fax: (610) 948-5779E-Mail: service@thermalengint.comFeedwater Heater, Condenser andHeat Exchanger Repair, Retubing,and Refurbishment

Thermal EngineeringInternationalLos Angeles, CaliforniaPhone: (323) 726-0641Fax: (323) 726-9592E-Mail: sales@thermalengint.comFeedwater Heaters, Condensers,Power Plant Heat Exchangers, andSpare Parts

Demex DivisionPicayune, MississippiPhone: (228) 255-7584Fax: (228) 255-7588E-Mail: demex1@msn.comExplosive Products and Offshore Services

BTA Drayton CorporationJacksonville, AlabamaPhone (256) 435-3576Fax (256) 435-3771Portrodders, Sootblowers,Dampers, Sonic Horns, Tube Shields

FULL RANGE OF RE-COOLING AND HEAT TRANSFER COMPONENT SYSTEMS AND SERVICES