Cooling Tower

Cooling Water System

How cooling tower works ?

Heat and Mass transfer
1 kg of water on evaporation removes approximately 530
kcals of heat
The heat given up by the water falling inside the
tower equals the heat gained by the air rising through
the tower
The hot water entering the tower is distributed within
the structure in a manner that exposes a very large
water surface to the air passing through.
Water distribution is accomplished by means of spray
nozzles or distribution pans and by means of various
types of fill.
This fill increases the exposed water surface to
maximize contact with the air, increasing the rate of
heat transfer.

Cooling Tower Types

Cooling towers fall into two main

categories: Natural draft and Mechanical
draft.
Mechanical draft towers are available in
the following airflow arrangements:
1. Counter flows induced draft.
2. Counter flow forced draft.
3. Cross flow induced draft.

Cooling Tower
Types

Cooling Tower Performance

Factors Affecting Cooling Tower Performance

Tower Size vs Approach

Thermal Performance
Thermal performance of an evaporative tower is
primarily dependent upon the entering air wet bulb
temperature (WBT) and relative humidity (RH).
The entering WBT is an independent variable that
dictates cooling tower selection.
It is both the theoretical limit to the leaving cold water
temperature and the only air parameter involved in
cooling tower selection.
The difference between the WBT and the tower
leaving or cold water temperature (CWT) is called the
approach temperature or the approach.
Approach temperatures generally fall between 5 and
20 F.
The difference between the tower leaving or hot
water temperature (HWT) and the CWT is called the
range

Water losses in cooling tower

Water losses include evaporation, drift (water entrained in discharge vapor),
and blow down (water released to discard solids).
Drift losses are estimated to be between 0.1 and 0.2% of water supply.
Evaporation Loss = 0.00085 x water flow rate x (T1-T2)
Blow down Loss = Evaporation Loss/(cycles-1)
where cycles is the ratio of solids in the circulating water to the
solids in the make-up water
Total Losses = Drift Losses + Evaporation Losses + Blow down Losses

Energy Saving Opportunities in Cooling Towers

Follow manufacturers recommended clearances around cooling towers and
relocate or modify structures that interfere with the air intake or exhaust.
Optimise cooling tower fan blade angle on a seasonal and/or load basis.
Correct excessive and/or uneven fan blade tip clearance and poor fan balance.
On old counter-flow cooling towers, replace old spray type nozzles with new
square spray ABS practically non-clogging nozzles.
Replace splash bars with self-extinguishing PVC cellular film fill.
Install new nozzles to obtain a more uniform water pattern
Periodically clean plugged cooling tower distribution nozzles.
Balance flow to cooling tower hot water basins.
Cover hot water basins to minimise algae growth that contributes to fouling.
Optimise blow down flow rate, as per COC limit.
Replace slat type drift eliminators with low pressure drop, self extinguishing,
PVC cellular units.
Restrict flows through large loads to design values.

End