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Applied Thermal Engineering 29 (2009) 33283333

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Applied Thermal Engineering


journal homepage: www.elsevier.com/locate/apthermeng

Enhancement of cooling capacity in a hybrid closed circuit cooling tower


M.M.A. Sarker a, G.J. Shim b, H.S. Lee b, C.G. Moon b, J.I. Yoon b,*
a
Department of Mathematics, Bangladesh University of Engineering and Technology, Dhaka-1000, Bangladesh
b
School of Mechanical Engineering, Pukyong National University, Namgu, Pusan 608-739, Republic of Korea

a r t i c l e i n f o a b s t r a c t

Article history: Performance characteristics of the Hybrid Closed Circuit Cooling Tower (HCCCT) have been tested exper-
Received 12 August 2008 imentally. Bare-type copper tubes and n tubes were used in staggered arrangement at the heat exchan-
Accepted 10 May 2009 ger of the HCCCT and the cooling capacity and pressure drop have been studied from various
Available online 21 May 2009
perspectives. The relevant temperatures and velocities were selected based on the typical East Asian
meteorological constraints for the year round operation of the HCCCT. Performance characteristics were
Keywords: compared and found that for the n tubes, cooling capacities were about 22% and 260% higher than those
Experimental testing
of the bare tubes in wet and dry modes, respectively. The pressure drop for the n tubes was nearly two
Fin tubes
Bare tubes
times higher than that of the bare tubes in both modes. The experimental results show considerable
Cooling capacity enhancement of cooling capacity.
Pressure drop 2009 Elsevier Ltd. All rights reserved.

1. Introduction can be packed in light and compact bundle with optimized cir-
cuitry [6]. In summer, water is sprayed using square form and wide
Cooling tower is a relatively inexpensive and dependable heat angle spray nozzles from the top of the tower along with a counter-
rejection device and used for dissipating heat from water-cooled type of air ow in both summer and winter from the bottom part.
refrigeration, air-conditioning, power plants and other industrial In wet mode operations, no plume formation is expected due to the
process systems [1,2]. Cooling tower can remove heat from a sys- higher ambient temperature and higher dew-point temperature in
tem or process without consuming excessive quantities of water. Southeast Asian region. Plume free state is predicted once again in
The water consumption rate of a cooling tower system is only dry mode due to the fact that typical Southeast Asian winter ambi-
about 5% of that of a once-through system, making it the least ent air contains very low moister.
expensive system to operate with purchased water supplies. The
amount of heated water discharged by cooling tower in the form
of blowdown is very small [3,4]. 2. Previous studies
A HCCCT is a closed type cooling tower which is capable of
working both in wet and dry modes. The cooling or condensing Gan et al. [79] reported numerical simulation results on wet-
system for uids operates as a dry cooler in winter and as an evap- closed cooling tower utilizing CFD (Computational Fluid Dynamics)
orative cooler in summer by spraying water on the heat transfer techniques. Khan et al. [10,11] presented mathematical models of
surface. A recirculating wet-cooling tower has energy penalty asso- cooling towers. Soylemez [12] produced numerical results regard-
ciated with additional pumps, fans, and auxiliary equipment and ing the sizing of cooling towers and registered the optimum heat
also requires more extensive water treatment [5]. During the and mass transfer area at which minimum cost exists throughout
mid-season and winter while ambient temperature remains less technical life of forced draft counter-current cooling towers, devel-
than 1214 C, HCCCT can produce cooling effect in plume-free, oping original formulae for the best thermoeconomical perfor-
ice-free state and lower noise level is expected in dry mode. In mance as a design point.
wet mode operation, while the ambient temperature crosses Experimental studies regarding the performance of a counter-
1214 C, HCCCT operates at its optimized level to supply cooling ow, packed-bed mechanical cooling tower can be found from
effect. Water consumption by HCCCT is lower than the conven- Bedekar et al. [13]. Milosavljevic and Heikkilia [14] reported an
tional Closed-Wet Cooling Tower (CWCT) and the process water experimental study on comprehensive approach to cooling tower
can be cooled down to 4 C above the wet bulb temperature and design. Sarker et al. [15] carried out experimental study on the
thermal performance of closed-wet cooling tower and hinted that
the heat and mass transfer process in a CWCT is dominated by
* Corresponding author. Tel./fax: +82 51 629 6180. mass transfer between the spray water and the air over the sensi-
E-mail address: yoonji@pknu.ac.kr (J.I. Yoon). ble heat transfer brought about by the evaporation of the spray

1359-4311/$ - see front matter 2009 Elsevier Ltd. All rights reserved.
doi:10.1016/j.applthermaleng.2009.05.012
M.M.A. Sarker et al. / Applied Thermal Engineering 29 (2009) 33283333 3329

Nomenclature

A heat transfer surface area (m2) P pressure (Pa)


T temperature (C) Q cooling capacity (kW)
G ow rate of air (kg/h)
U overall heat transfer coefcient (kW/m2 C) Greek symbol
L ow rate of spray water (kg/h) D difference
M ow rate of cooling water (kg/h)

water. The effect of the wet-bulb temperature in effectively con- constant, waterair mass ow ratio is allowed to vary and the tem-
trolling the cooling water temperature has been reported by Sarker perature difference between the inlet and the outlet is measured.
et al. [16]. They have demonstrated that there is an appropriate air The uncertainties of the measured and calculated parameters are
ow rate for respective air constraints to preserve the cooling per- estimated following the procedures described in ASME PTC-23
formance in the cross ow cooling tower. Experimental studies and [20] (with a level of condence of 95%). The experimental uncer-
numerical simulation of evaporative cooling of air have been re- tainties associated with the measurement devices and sensors
ported by Kachhwaha et al. [17]. They developed a two-dimen- along with the specications of measuring devices are shown in
sional numerical model simulating the conservation of mass, Table 1. The method is based on a combination of all the uncertain-
momentum and energy of air, water, and obtained experimental ties pertinent to primary experimental measurements. It showed
data on a horizontal once through wind tunnel at different air an uncertainty of 1.14% and 2.45%, respectively, for the water ow
velocities in parallel ow conguration. Recently Sarker et al. rate and total systematic/random uncertainty.
[18,19] have reported both numerical and experimental studies The experiment is conducted under the experimental condi-
about the performance characteristics of the hybrid closed circuit tions mentioned in Table 2. The heat balance of the experimental
cooling tower. They claimed that the cooling capacity of the HCCCT apparatus and details of the experiment for the case of bare tube
was much closed to the rated one for the wet mode operation but can be found from Sarker et al. [19].
was rather poor in dry mode.
The objective of this investigation is to enhance the cooling 4. Results and discussion
capacity in a HCCCT. To accomplish this, the thermal performance
of the HCCCT will be experimentally tested using two different HCCCT can work in wet mode when spray water is uniformly
types of tubes namely; bare tube and n tube in the heat exchan- distributed from the top of the tower along with a counter-type
ger and the results will be compared to the rated ones for wet and of fan driven air ow from the bottom. In dry mode, only fan driven
dry operation modes. Performance enhancement of the HCCCT is cold air is utilized to get the cooling effect. Performance character-
expected out of this experimental study. istics differ greatly in these two modes and the results are dis-
cussed in the next two sections one by one starting with the dry
operation mode.
3. Experimental apparatus and method
4.1. Dry operation mode of HCCCT
The schematic of the experimental apparatus of the HCCCT is
shown in Fig. 1. The coil section is located at the upper part, and In the absence of spray water, the cooling capacity of HCCCT in
fans are installed at the lower part. The heat exchanger consists dry mode is much lower than that in the wet operation mode. The
of 16 rows and 22 columns in the 1.14 m  2.36 m  3.2 m dimen-
sional cooling tower. Bare-type copper coil having an outer diam-
eter of 15.88 mm is used in a staggered arrangement. The outer
diameter of n tube is 32.68 mm and the ns are 4.23 mm apart
from each other as shown in Fig. 2. The cooling water is supplied
by pipes having 65 mm inlet diameters and ows downward so
that low pressure drop may be expected across the coil bank. The
spray water is uniformly distributed at the upper part of the coils
with the help of header made of copper tube coils along with spray
nozzles having a big caliber. Recirculated cooling water collecting
tank section and the ambient air driving fans are installed at the
lower part of HCCCT.
15 HP type inverter is used to maintain air ow rate at a xed
level. Discharged air from the outlet of the cooling tower, which
is highly humid and has high temperature, passes through return
ducts and mixes with ambient air. The suitable air constraint is
maintained applying a 45 kW type heater and utilizing cooling
coils at the inlet of the HCCCT. Cooling water ows inside the coils
of the heat exchanger. 175 kW type boiler is applied to maintain a
ceaseless supply of cooling water having temperature at the de-
sired level. To control the temperature properly, a bypass system
is installed at the cooling water supplying pipe and at the hot
water supplying pipe, in addition to a plate heat exchanger as
shown in Fig. 1. Keeping the mass ow rate of cooling water Fig. 1. Schematic of the experimental apparatus.
3330 M.M.A. Sarker et al. / Applied Thermal Engineering 29 (2009) 33283333

Fig. 2. Fin tube (left panel) along with its schematic and dimension (right panel).

Table 1 140 100


Measuring devices specication. Bare Tube
Fin Tube 90

Overall heat transfer coefficient(kW/m2 . C)


Parameter Sensor Range Accuracy 120
Water temperature T type 200400 C 0.1 C 80
Water ow rate Oval, vortex ow meter 148 m3/h 1%
100
Relative humidity Capacitive 0100% 1%
70

Cooling Capacity (kW)


Air temperature T type 200400 C 0.1 C
Air velocity Anemometer 020 m/s 0.03 m/s 80
Atmospheric pressure Manometer 1000 mm H2O 0.5 mm H2O 60

60 50

Table 2
40
Experimental condition.
40
Cooling water 30
Volume ow rate [m3/h] 24
Inlet temperature [C] 37 20
20
Spray water
Volume ow rate [m3/h] 33 0 10
0 5 10 15 20 25
Air
Air inlet temperature ( C)
Velocity [m/s] 3.1
Wet-bulb temperature [C] 27
Fig. 3. Cooling capacity (left axis), OHTC (right axis) by air temperature.
Dry-bulb temperature [C] 022 (dry mode)
[C] 3032 (wet mode)

Therefore, the cooling capacity decreases noticeably. Rather poor


thermal performances followed by pressure drop in dry operation cooling capacity is found in dry mode, which is a direct conse-
mode are discussed next. quence of sensible heat transfer, which is much lower than latent
heat transfer in the absence of spray water. For the n tube, the
4.1.1. Thermal performance of the HCCCT in dry operation mode cooling capacity is around 2.6 times higher than that of the bare
One of the objectives of this study is to enhance the cooling tube at 15 C of ambient air temperature. The reason for this
capacity of the HCCCT especially in dry operation mode. In this remarkable increase in cooling capacity for the n tube could be
mode, cooling capacity largely depends on the inlet air tempera- the increase of the heat transfer surface area, and it is perceptible
ture, cooling water inlet temperature and inlet air velocity of for this experiment that, the heat transfer area of n tube is much
HCCCT. The effects of air inlet temperature on the cooling capacity bigger than bare tube. The overall heat transfer coefcient also de-
and Overall Heat Transfer Coefcient (OHTC) were investigated creases with the increase of the air inlet temperature but the
experimentally. It may be note that OHTC takes into account the decreasing rate is slower than that of the cooling capacity as can
temperature differences and thermal resistance between the two be concluded from the left axis of Fig. 3. In calculating OHTC, the
uids and can be dened as: outer surface area for both bare and n tubes were used and it
can be claimed that OHTC for the bare tube is nearly 1.6 times
Q UADT LM 1
higher than that of the n tube at an air inlet temperature of
where DTLM is the log mean temperature difference. This equation 15 C. This is mainly due to the fact that the heat transfer area of
can be utilized to calculate OHTC in dry mode where the inside of n tube is much bigger than that of the bare one but the rate of
tube is lled with cooling water but only air ows over the outside heat transfer in case of n tube, Q in Eq. (1), does not increase in
of the tube. the similar rate of outer surface area increment of n tube. There-
In this part of the experiment, the cooling water inlet tempera- fore, U, the OHTC for bare tube is expected to be greater than that
ture (CWIT) and the velocity of air were kept constant at 37 C and for the n one.
3.1 m/s. Cooling capacity and OHTC for both n and bare tubes are, Left axis of Fig. 4 gives the cooling capacity whereas right axis
respectively, shown at the left and right axes in Fig. 3. Cooling shows the OHTC for both n and bare tubes with respect to
capacity decreases almost linearly with the increase of the air inlet (w.r.t.) a variable air inlet velocity. This time in the experiment,
temperature and vice versa for both n and bare tubes. This is sim- the temperature of air and cooling water at their respective inlets
ply because when air inlet temperature increases, then the differ- were held constant at 15 C and 37 C, respectively. At the designed
ence of the cooling water inlet temperature and the air inlet condition, the cooling capacity is about 37 kW and 98 kW for the
temperature decreases and thus the rate of heat transfer decreases. bare and n tube, respectively. Once again the cooling performance
M.M.A. Sarker et al. / Applied Thermal Engineering 29 (2009) 33283333 3331

120 80 50

Bare Tube Bare Tube

Overall heat transfer coefficient(kW/m2 . oC)


100 Fin Tube 40
Fin Tube
60
Cooling capacity (kW)

80

Pressure drop (Pa)


30

60
40
20

40
10
20
20

0
1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0 3.2 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0 3.2
Air velocity (m/s) Air velocity (m/s)

Fig. 4. Cooling capacity (right axis), OHTC (left axis), w.r.t. air velocity. Fig. 5. Pressure drop in dry mode.

found for the case of n tube is about 2.6 times better than that of
10 180
the bare case and that the OHTC in case of bare tube is around 1.6
times higher than that of the n one. Bare Tube
160
Fin Tube
4.1.2. Pressure drop in dry mode 8 140
Pressure drop inside the HCCCT is a great concern for the
designers because the operational cost of HCCCT in the form of 120
Temperature Drop ( o C)

Cooling capacity (kW)


the power consumed by the pump or fan is directly proportional
6 100
to the pressure drop. Pressure drop can be reduced signicantly
through increasing the transverse pitch of the coils in the heat ex-
80
changer. Recently Sarker et al. [18,19] have demonstrated that
increasing the pitches at will is not a wise idea only for the sake 4 60
of reducing pressure drop. Minimizing the pressure drop in such
technique can minimize operating cost but it can increase the size 40
of the heat exchanger and thereby the initial cost. Pressure drop at
the internal part of the HCCCT can be assumed to be a function of 2 20
the inlet air velocity. The static pressures just below and right
above the cooling coils are measured and difference is recorded 0
22 24 26 28 30 32 34 36 38
with the help of manometer when the fan function gets stabilized.
Wet-bulb temperature ( o C )
Pressure drops for different air inlet velocity ranging from 1.5 to
3.2 m/s have been investigated experimentally and the compara- Fig. 6. Temperature drop (left axis), cooling capacity (right axis), w.r.t. WBT.
tive results are shown in Fig. 5. The pressure drop across the coil
bank is seen to increase nearly linearly for the increase of air veloc-
ity. Since no spray water is used in dry mode, so the pressure fall- increase of the inlet wet-bulb temperature. This is because when
ing rate is low especially with the bare tube. However, n tube the WBT at the inlet increases, the temperature difference between
produces higher pressure drop and at the design condition, pres- the cooling water and air at the inlet decreases. Therefore, the rate
sure drop for the n tube is around two times higher than that of of evaporation of spray water owing at the outer surface of the
the bare tube. It may be noted that the thermal performance of pipes decreases so that the falling of the temperature of the cooling
the HCCCT in dry operation mode is found to be low. The enhance- water owing inside the tubes deceases. For the bare tube, the
ment aspects of cooling capacity are discussed next in wet opera- temperature difference is about 6 C when the inlet WBT is 24 C.
tion mode. Drastic decline in the temperature drop could be noted while the
WBT is greater 26 C and 29 C for the bare and n tubes, respec-
4.2. Wet operation mode of HCCCT tively. It is evident that for the n tube, the capacity of heat trans-
fer of the cooling coils increases with the increase of the heat
The cooling capacity of the HCCCT can be increased signicantly transfer surface area and therefore, the temperature drop, that is,
if spray water is used which is possible only in wet operation the falling of temperature for n tube is higher than that of the
mode. The thermal performance and pressure drop in HCCCT are bare tube as expected. It may be noted that temperature drop of
discussed in two different sub-sections as given below. the n tube is almost same to that of the bare tube at low WBT,
but is considerably higher at high WBT. It could be due to the fact
4.2.1. Thermal performance of the HCCCT in wet mode that latent heat transfer dominates over the sensible heat transfer
Left axis of Fig. 6 shows the temperature difference between the in case of saturated air condition encountered at the outlet of the
inlet and the outlet of the cooling water with respect to variable in- HCCCT. Evaporation of spray water is smaller at high WBT
let wet-bulb temperature (WBT). From this gure it is clear that and therefore the cooling water temperature and outlet air
the temperature drop of the cooling water decreases with the temperature remain higher at their respective outlets. Outlet air
3332 M.M.A. Sarker et al. / Applied Thermal Engineering 29 (2009) 33283333

temperature in case of n tube is much higher than that of the bare and letting G, the mass ow rate of air, to vary. From this gure,
tube and if outlet air is saturated, air humidity in case of n tube is it is evident that temperature drop and the cooling capacity in-
much higher than that of the bare tube. crease with the increase of the mass ow rate of air. In other words,
Right axis of Fig. 6 shows the cooling capacity of the HCCCT. The cooling capacity and temperature drop of cooling water are
cooling performance of the HCCCT is dened as the product of the decreasing for the increasing L/G. This is mostly because when L/
temperature difference between the inlet and the outlet of the G increases over the standard designed value of L/G = 0.83, then
cooling water, multiplied by the mass ow rate of the cooling the mass ow rate of air decreases so that the air humidity at
water and the specic heat of the cooling water. That is, the outlet increases, therefore the falling of temperature slows
down.
Q m  cp  DT 2
The cooling capacity found at L/G = 0.83 is around 130 kW and
The cooling water ow rate is dened in the standard design 162 kW, respectively, for the bare and n tubes. The cooling capac-
condition given in Table 2 and the specic heat of cooling water ity of the HCCCT with n tube is enhanced largely by the latent
could be assumed to be constant, therefore the trend of the cooling heat transfer brought about by the increase of heat transfer area
capacity of the HCCCT looks identical to that of the temperature by n. Cooling capacity of the bare tube at L/G = 0.83 can be
drop plot given in the left axis of Fig. 6. The cooling capacity found achieved using only 80% of the mass ow rate of air while using
from right axis of Fig. 6 for the bare tube is 132 kW whereas for the n tube which could minimize the operating cost.
n tube, it is about 163 kW at the designed WBT of 27 C. The cool- In Fig. 9, temperature drop and cooling capacity with respect to
ing capacity of HCCCT with n tube is nearly 22% higher than that spray water volume ow rate are shown at the left and right axes,
of the bare tube, with respect to the rated capacity and this might respectively. Thermal performance of the HCCCT with n tube is
have happened due to the increase of the sensible heat transfer in considerably higher than that with bare tube as can be inferred
case of the n tube. from this gure as well. Since the designed spray water volume
The temperature drop and the cooling capacity of the HCCCT ow rate was 33 m3/h in this experiment, so, at the outlet of the
with respect to variable cooling water inlet temperature are, HCCCT, the air could be at an under-saturated state for lower spray
respectively, shown at the left and right axes of Fig. 7. As the inlet water mass ow rate than 33 m3/h. The cooling capacity of the bare
temperature of the cooling water increases, the temperature drop tube reduces almost linearly with the decreasing spray water vol-
and the cooling capacity increase almost linearly. When the tem- ume ow rate. However, for the case of n tube, rate of evaporation
perature of the cooling water is remaining less than or equal to is augmented by the exacerbated heat transfer area; therefore, the
35 C, Fig. 7 indicating that the temperature drop and the cooling cooling capacity is much higher than bare tube. It may be noted
capacity for bare and n tubes are not that different. This is mainly that air at the outlet of the HCCCT becomes under-saturated while
because the temperature difference between cooling water inlet the spray water volume ow rate remains approximately less than
temperature and wet-bulb temperature is very small at low cool- 25 m3/h and over there, thermal performance for both bare and n
ing water inlet temperature. However, as the cooling water inlet tubes decrease at a faster rate.
temperature increases, the temperature drop and the cooling If n tube is used at the heat exchanger of the HCCCT, a spray
capacity between n and bare cases differ signicantly. At the de- water volume ow rate of only 20 m3/h is required to attain the
signed temperature of 37 C, the cooling capacity of the HCCCT same cooling capacity with bare tube, which requires a spray water
with n tubes is about 15% higher than that with bare ones. There- volume ow rate of 33 m3/h.
fore it can be claimed that HCCCT having n tube at the heat ex-
changer has a clear advantage over one having bare tube if 4.2.2. Pressure drop in wet mode
HCCCT has to operate with relatively high cooling water inlet Fig. 10 shows the pressure drop of the HCCCT with respect to a
temperature. variable inlet air velocity in wet operation mode. It is evident that
The temperature drop and the cooling capacity with respect to pressure drop increases almost exponentially with the increase of
the ratio of mass ow rate of spray water and air are, respectively, the air velocity. The increasing rate has been augmented due to
shown in the left and right axes of Fig. 8. The experiment was the spray water in the wet mode operation. In case of bare tube,
conducted keeping L, the mass ow rate of spray water, constant

10 200 10 200

180 Bare Tube 180

160
Fin Tube
8 160
8
140 140
Cooling Capacity (kW)
Temperature Drop ( O C)

Cooling capacity (kW)

Temperature Drop ( OC)

120 120
6
100 6 100

80 80
4
60 60
Bare Tube 4
Fin Tube 40 40

2 20 20

0 2 0
32 34 36 38 40 42 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4
O
Cooling water inlet temperature ( C) L/G

Fig. 7. Temperature drop (left axis), cooling capacity (right axis), w.r.t. CWIT. Fig. 8. Temperature drop (left axis), cooling capacity (right axis) versus L/G.
M.M.A. Sarker et al. / Applied Thermal Engineering 29 (2009) 33283333 3333

8 160 n tube. In case of n tube, a spray water volume ow rate of only


Bare Tube 140 20 m3/h is required to achieve the same cooling capacity with bare
Fin Tube tube which requires a spray water volume ow rate of 33 m3/h.

Cooling capacity (kW)


6 120 The pressure drop for the n tube was nearly double of that of
Temperature Drop ( C)
O

100 the bare one in both modes which should get proper attention
from the designers of HCCCT. The results of this experimental
4 80
study indicate that if higher cooling capacity is preferred over
60 the energy consumption, then n tube should be used in the heat
exchanger instead of bare tube. If the operation mode of the HCCCT
2 40
is selected judiciously and the designed conditions are set sensibly,
20 then the initial as well as operational cost can be greatly reduced
0 for the year round operation of the HCCCT.
0
0 5 10 15 20 25 30 35

Spray water volume flow rate (m /h)


3 Acknowledgement

Fig. 9. Temperature drop (left axis), cooling capacity (right axis) versus spray water This study was supported nancially by the Grant No.
ow rate.
70000279 from the Regional Industry Program of Gyongnam,
South Korea. Their cooperation is greatly acknowledged.
90
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80
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