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Cooling Towers: Overview: Spring 2008

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Cooling Towers: Overview

CM4120
Spring 2008

1
Topics

 Introduction
 Definitions
 Operating Conditions
 Basic Components
 Water Cooling Systems
 Types

2
Introduction
 Boxed shaped collection of multilayered wooden
slats

 Air flow breaks up water as it falls

 Design ensures good contact between water and


air

 Used to remove heat from water

3
Key Definitions
 Wet-bulb temperature = air temperature measured by a wet-
bulb thermometer
– simulates effect of evaporative cooling

 Dry-bulb temperature = air temperature measured by a dry-


bulb thermometer

 Approach = difference in wet-bulb temperatures between


inlet and outlet called “the approach to the tower”

 Latent heat = heat associated with change in state of matter


(e.g., liquid to gas phase)

4
Operating Conditions

 10-20% of heat (sensible heat) removed


from contact between water and air

 80-90% of heat removed following


evaporation

 Evaporation is most critical factor affecting


tower efficiency!
5
Operating Conditions

 Factors which affect cooling tower


performance:
– relative humidity
– temperature Let’s discuss these!
– wind velocity
– tower design
– water contamination
– equipment problems (pump failure)

6
Basic Components
 Water distribution system = includes header which
distributes (sprays) water from top of tower over splash bars

 Fan = induced and forced draft towers use fans to push or


pull air

 Air intake louvers = louvers on side of towers which direct


air into tower (fixed or movable)

 Water basin = collects water at bottom of tower prior to


discharge

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Basic Components
 fill = material inside a tower which redirects air flow and water

 column = wooden or metal post which supports tower

 stack = hyperbolic towers and chimney towers have huge


stacks located at top

 make-up water = water which is added due to evaporation and


blowdown

 splash bars = used to redirect the downward flow of water

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Parallel vs. Series Flow

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Classification of CTs

 By direction of air flow


– crossflow (airflow is horizontal )
– counterflow (airflow is vertical) designs

 By how the air flow is produced


– naturally (hyperbolic or chimney towers)
– mechanically (forced draft or induced draft)

10
Induced Draft, Cross Flow CT

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Atmospheric Cooling Tower (Natural Draft)

 Use natural forces (wind)


to move air through CT

 Air flows in through the


sides, and out the top

 Drift eliminators on the


top

12
Hyperbolic Cooling Tower

 Also called chimney CT

 Often seen at power plants

 Very high flowrates

 Air flows up, creating a


draft

13
Forced Draft Cooling Tower

 Fans used to create a draft

 Air forced in the bottom,


and flows out the top

 Typically solid sides

 Some recirculation of air


possible, harming
efficiency

14
Induced Draft Cooling Towers

 Fans located at the top of


the CT

 Lifts air out of the CT,


preventing recirculation

 Probably the most


common type used in
chemical plants and
refineries

15
Troubleshooting

 Water dissolves many things (especially hot


water!)

 Water is cooled and results in deposits in


tower

 Solids concentrate in cooling tower basin


Trivia Question: Are Cooling Towers equipped with automatic sprinklers?
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Problems Faced by Operators
 Scale formation - suspended
solids form deposits

 Corrosion - electrochemical
reactions with metal
surfaces

 Fouling - due to silt, debris,


algae

 Wood decay - fungi

17
Water Composition Control
 Suspended solids levels checked by operators (ppm)

 Measured values compared to make-up water


concentrations

 Problem controlled by “blowdown” (i.e., old water


replaced with new)

 Note: 100 ppm = 100 lbs. suspended solids/1,000,000 lb


water

18
Water Composition Control (Solutions)

 Scale formation
– remove scale forming solids with softening agents
– prevent scale forming materials by addition of
chemicals
– precipitate scale for removal

19
Water Composition Control (Solutions)

 Corrosion
– add chemical inhibitors (adds thin film to metal)

 Fouling
– use filtering devices
– use dispersants with filtering devices

 Wood decay
– use biocides (chlorine or bromine)
20
Water Testing (by Operators)

 pH of water
 total dissolved solids (TDS)
 inhibitor concentration
 chlorine or bromine concentration
 precipitant concentration
 filter and screen checks
 temperature and humidity
21
Humidity Measurements

22
Humidity -- Background
 Humidity is the amount of water vapor in the air

 Humidity is described in different ways


– "relative humidity," which is the term used most often in
weather information meant for the public
– Relative humidity is the amount of water vapor in the air
compared with the amount of vapor needed to make the air
saturated at the air's current temperature

 Dewpoint temperature gives a much better estimate of the amount


of moisture actually present in the air
– very important in determining precipitation amounts and even how
comfortable you feel

23
Definitions

 Absolute humidity: Mass of water vapor in a given


volume of air( i.e., density of water vapor in a
given parcel, usually expressed in grams per cubic
meter)

 Dewpoint: Temperature air would have to be


cooled to in order for saturation to occur
(Assumes there is no change in air pressure or
moisture content of the air).

24
Definitions
 Wet bulb temperature: Lowest temperature that can be
obtained by evaporating water into the air at constant
pressure.

 Name comes from the technique of putting a wet cloth over


the bulb of a mercury thermometer and then blowing air over
the cloth until the water evaporates. Since evaporation takes
up heat, the thermometer will cool to a lower temperature than
a thermometer with a dry bulb at the same time and place.
Wet bulb temperatures can be used along with the dry bulb
temperature to calculate dew point or relative humidity.

25
Definitions

 Relative humidity: The amount of water vapor


actually in the air divided by the amount of water
vapor the air can hold. Relative humidity is
expressed as a percentage and can be computed in
a variety of ways.

 One way is to divide the actual vapor pressure by


the saturation vapor pressure and then multiply by
100 to convert to a percent.
26
Sling Psychrometer

27
Humidity Determination

 From wet and dry bulb temperatures

 Use psychrometric charts


– find intersection of wet and dry bulb
temperature lines
– can read humidity from chart (y-axis)

28
END LECTURE!

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