CAPE PENISULA UNIVERSITY OF TECHNOLOGY

BELLVILLE CAMPUS
DEPARTMENT OF CHEMICAL ENGINEERING
ND : CHEMICAL ENGINEERING

SUBJECT

CHEMICAL PLANT III

LECTURER

Mr L. Kloppers, Mr. W Maree

STUDENT

Richardt Johan Loots

STUDENT NO.

214196585

Topic

Mark allocation

Title Page

Synopsis

Introduction

Experimental Set-up and

Procedure
Results and Discussion
Calculations

10
60

Conclusions

10

Bibliography

Total

Mark

100

I certify that this report is my own unaided work, except for the assistance
received from the teaching staff. I undertake not to pass this report onto
any other studen

Contents
List of Symbols....................................................................................................... ii
I.Synopsis.............................................................................................................. iii
1.Introduction........................................................................................................ 1
2.Experimental Set-up and Procedure...................................................................2
2.1 Experimental Setup...................................................................................... 2
2.2 Procedure..................................................................................................... 2
3. Results and Discussion...................................................................................... 3
3.1 Recorded Values........................................................................................... 3
3. 2 Mass Balance Results.................................................................................. 3
3.3 Energy Balance Results................................................................................ 4
3.4 Calculations.................................................................................................. 4
3.4.1 Mass Balance Calculations.........................................................................4
1.Mass flow rate of water................................................................................ 4
2.Density of Air................................................................................................ 5
3. Total Area calculation for orifice and column...............................................5
4. Volumetric flowrate of Air............................................................................ 5
5. Air mass flow rate........................................................................................ 6
6. Dry Air mass flow rate.................................................................................6
7. Mass of Vapour exiting column....................................................................6
8.Mass of Vapour entering column.................................................................6
9. Mass of evaporated water...................................... 10. Mass of water Cooled
6
3.4.2 Energy balance Calculations......................................................................7
1. Enthalpy of dry air leaving.......................... 3. Enthalpy of dry Air entering
7
2. Enthalpy of Vapour leaving......................... 4. Enthalpy of Vapour entering
7
5. Enthalpy of water leaving............................. 6. Enthalpy of water entering
7
7. Overall energy balance...............................................................................7
3.5 Discussion................................................................................................... 8
3.6 Conclusions...................................................................................................... 8
3.7 References....................................................................................................... 9

Symbol

Description

Unit

n
p
PT
Q
R

Enthalpy
Mass flow rate
moles
Pressure
Total Pressure
Flow rate
Ideal gas constant

kJ/kg
m3/hr
mol
Pa
Pa
m3/hr

T
VT
l
w

Temperature
Total Volume
Height
Specific Humidity

K
m3
m
Kgv/kg

Density

Kg/m3

Efflux coefficient (0.63)

J .K -1 .mol 1

Greek Symbols

Subscripts
1

Bottom boundary of Column

Top boundary of Column

a
atm
s

Air
Atmospheric
Property of the superheated vapour at the dry bulb
temperature

w
o

Water
Orifice

List of Symbols

I.Synopsis
The purpose of the experiment was to understand the workings of cooling towers and the
factors that affect the efficiency of a cooling tower. Factors such as the water flow rate and
air flow rate and how this variables affect the mass and energy contained in the system by
calculating the losses that occurred during the experiment.
During the experiment 2 runs were completed with a 15 minute duration for each and mass
and energy balances was carried out
For run 1 The amount of energy supplied by water was 2741.12 kJ/h and the amount of
energy gained by the air was 2223.6 kJ/h . A loss of 0.736 kg water and a energy loss of
517.52 kJ per hour was calculated
For run 2 now with the air flow rate doubled, The amount of energy supplied by water was
3461.5 kJ/h and the amount of energy gained by the air was 2621 kJ/h . A loss of 0.88kg
water and a energy loss of 517.52 kJ per hour was calculated
The above results was discussed and conclusions were drawn

1.Introduction
Cooling towers are used to remove excess heat that is generated in places such
as power stations, chemical plants and even domestically in air conditioning
units. In power stations, electricity is generated when steam drives a turbine.
This steam must be condensed before it can be returned to the boiler to continue
the cycle of steam and electricity generation. The condensation process happens
in a heat exchanger. Cooling water is needed in the heat exchanger and it is this
4

cooling water that is cycled through the cooling tower

Large cooling towers, like the ones seen in power stations, are called Natural
Draft towers. they create an updraft of air which cools the water as it falls down
the inside of the tower. Natural draft towers do not contain any fans to drive the
air flow.
Forced draft cooling towers contain large fans which force air through a smaller
tower.These are also the types of cooling towers that may be seen on buildings
which is used for air conditioning
A basic diagram to show the principles of a cooling tower

Figure 1: Basic cooling tower

2.Experimental Set-up and Procedure

2.1 Experimental Setup
The Cooling tower in figure 1 was used during the experiment aided by a
computer which displays all the temperature readings and flow rates.

Figure 2 : Cooling tower schematic

2.2 Procedure
1.
2.
3.
4.
5.
6.
7.

It was ensured that the level of water in the tank was above the level sensor.
The Wet and Dry bulb Temperatures of water levels was checked.
A set point temperature was selected for water.
The water allowed to reach the set point temperature.
The level in the tank was recorded.
air flow and water flow rates was selected .
Once steady state was reached the water level was recorded and the timer

started.
8. Ater 15 minutes the values was recorded
9. Steps 3 to 8 was repeated with a different flow rate.

3. Results and Discussion

Top of column

Run 2

Run 1

3.1 Recorded Values

Top of column

Inlet temperature (C)

39.5

Inlet temperature (C)

37.7

WB (C)

29.3

WB (C)

26.9

DB (C)

32.1

DB (C)

29

Specific Humidity
(kgv/kg)

0.035
91

Bottom of column
Outlet temperature
(C)

Specific Humidity
(kgv/kg)

0.031
27

Bottom of column

31

Outlet temperature
(C)

28.4

WB (C)

20.9

WB (C)

21.7

DB (C)

21.9

DB (C)

23

Specific Humidity
(kgv/kg)

0.015
04

Tank Level
Tank height (mm)

0.022
87

Tank Level
3

Tank height (mm)

Flowrates
Air flow Rate (kg/s)

Specific Humidity
(kgv/kg)

Flowrates
0.015
7

Air flow Rate (kg/s)

0.031

6
Water flow Rate
(m/min)

0.001
25

Water flow Rate

(m/min)

0.001
45

Table 1 :Values For Run 1&2

3. 2 Mass Balance Results

Table 2: : Mass Balance of Run 1&2

water @ 37.7C
(kg/m3)

992.4

Water

Rate
(kg/h)

in

74.43

cooled

evaporated

993.
1

Water

Rate
(kg/h)

in

86.4

73.694

cooled

85.52

0.736

evaporated

0.88

Run 2

Run 1

water @ 39.5C
(kg/m3)

3.3 Energy Balance Results

Table 3: Enthalpy Results of Run 1&2

Top of column

ma2

ms2

ha2 (

kg
h )

46.8

hs2 (

kJ
kg )

ms2

1.44

kJ
kg )

kJ
kg )

Run 1

ma2

kg
h )

hw2 (

mw2

74.43

mw1

ma1

ms1

ha1 (

kg
h )

kg
h )

kJ
kg )

kJ
hw1 ( kg )

kg
h )

kJ
kg )

165.07

hw2 (

kJ
kg )

2319.71

hs2 (

kJ
kg )

73.694

mw1

46.8

ms1

ha1 (

21.22
10

129.52

92.66

2.95

29.17

157.5
8

2313.
9

Bottom of column

ma1

0.704

86.4

kg
h )

ha2 (

Bottom of column

kg
h )

kg
h )

32.3

Run 2

mw2

kg
h )

Top of column

hw1 (

kg
h )

kg
h )

kg
h )

kJ
kg )

kJ
kg )

85.52

92.66

2.07

23.14

118.7
1

3.4 Calculations
Calculations will be based on Run 1

3.4.1 Mass Balance Calculations

1.Mass flow rate of water

mw 2=water x Qwater

*Values from

psychrometric chart

m w 2=992.4

kg
m3
X
0.00125
3
min
m

mw 2=74.43

kg
hr

2.Density of Air

air =

air =

( 1+w )

( M1

air

w
R ( T WB 1 )
M water

( Patm+ P o )

Mmair =0.02897

( 1+0.03591 )

1
0.03591
+
8.3145 ( 302.45 )
( 0.02897
0.01802 )

air =1.15

( 101325+160 )

kg
mol

Mm water=0.01802

kg
m3

3. Total Area calculation for orifice and column

11

kg
mol

A o total=[ ( A 0 n1 ) + ( A 0 n2 ) ] ( A p n p )

* Values used from Table

A o total=

[(

)] (

)(

d
d
d
16 +
3
3
4
4
4

[(

)] (

(0.0078)2
(0.0118 )2
(0.0061)2
A o total=
16 +
3
3
4
4
4

)(

A o total= [( 0.007645 )+ ( 0.0032807 ) ]( 0.00008767 )

A o total=0.001005m

A column =Width2

*Width Measured from unit

A column =162.5 mm2

3

A column =4.3 x 10 m

4. Volumetric flowrate of Air

Q= A0

A0
A

)
2

2 ( pp 0 )

Q=(0.63)(0.001005)

0.001005
0.0043

)
2

2 (160 )
1.15

12

Qair =0.0109 m /s

5. Air mass flow rate

ma 1=1.15

ma 1=a x Qa

kg
x 0.0109 m3 / s
3
m

ma 1=46.8

6. Dry Air mass flow rate

m a 1 ma 2

*For dry air :

ma 1,2 x

1
1+ w

1
kg
0.013
1+0.03591
s

0.0126

45.36

kg
s

kg
h

7. Mass of Vapour exiting column

ms 2=ms 1ma 1

46.8

kg
kg
45.36
h
h

1.44

kg
h

13

kg
h

8.Mass of Vapour entering column

ms 1=w 1 ma 1

0.01504

kg
kg
0.013
s
s

0.704

kg
h

9. Mass of evaporated water

10. Mass of water Cooled

mw lost =ms 2ms 1

mw lost =1.44

mw 1=ms 2m s 1

kg
kg
0.704
h
h

mw lost =0.736

mw 1=74.43

kg
h

kg
kg
0.736
hr
h

mw 1=73.694

kg
h

3.4.2 Energy balance Calculations

1. Enthalpy of dry air leaving
entering

3. Enthalpy of dry Air

ha 2=C p dry air T DB 2

ha 1=C p dry air T DB 1

ha 2=1006 32.

ha 1=1006 21.1

ha 2=32.3

kJ
kg

ha 1=21.22

2. Enthalpy of Vapour leaving

entering

kJ
kg

4. Enthalpy of Vapour

h s2 =C p vapour T DB 2 + Lv

h s1 =C p vapour T DB 1 + Lv

14

h s2 =1.860 32.1+2260
h s2 =2319.71

h s1 =1.860 21.9+2257

kJ
kg

h s1 =2297.7

5. Enthalpy of water leaving

entering

6. Enthalpy of water

hw 1=C p water T w 1

hw 2=C p water T w 2

hw 1=4.178 31

hw 2=4.179 39.5

hw 1=129.52

kJ
kg

kJ
kg

hw 2=165.07

kJ
kg

7. Overall energy balance

w1
l 2 mw 2l 1 m
( ma 2 ha 2ma 1 ha 1 ) + ( ms 2 hs 2ms 1 hs 1 ) + g ( l2 ( ma 2 ha 2 )l 1 ( ma 1 ha 1 ) )=( mw 2 hw 2mw 1 hw 1 ) + g
Run 1

Run 2

RHS(water)= 2741.12 kj/h

RHS(water)= 3461.5 kj/h

15

3.5 Discussion
During the experiment it can clearly be seen that a there is a drop in water
level, in this case both water levels dropped by the same amount. This is in
conclusive as the water level meter measures in millimetres which leaves a lot of
room for error. If the water were to be weighed it would have served for much
more accurate results.
Concerning the mass balance it was seen that with an increase in air flow rate a
increase in evaporation can be seen where in run 1 the flowrate of air was 13l/s
with a total of 0.736 kg water evaporated per hour . In run 2 the the air flow rate
was set to 26l/s and the total amount of water evaporated was 0.88 kg per hour.
With this facts it can be seen with double the air flow rate there is a increase in
water evaporated per hour but a lower outlet temperature of the water, so by
increasing air flow rate, rate of evaporation and rate of cooling increases.
Decreasing air flow rate, decreases evaporation and rate of cooling.
In the energy balance it can be seen that the energy supplied by the hot
water,2741.12 kj/h, in run 1 is not equal to the energy removed by the air ,
2223.6 kj/h. It can also be seen that the difference in energy is more in run2 than
run 1 which is possible due to the increase in air flow rate. The missing energy
can be contributed to many various aspects such as heat losses through the
chamber, pipes or tank. To reduce the energy losses one can insulate the column
and pipes entering, but that would defeat the purpose of a cooling tower which is
to lose energy and heat

3.6 Conclusions
The experiment was successfully carried out and the calculations were made for
Mass and energy
It was seen that mass and energy is lost when using a cooling tower.
Given al the results collectively it can be seen that many variables play a role
when using a cooling tower in the industry.
The value of cooling towers within the industry is understood and the efficiency
is good that is why they are so widely used in the industry

16

3.7 References
Coulson , J.M and Richardson , F.1999. Chemical Engineering vol 1 , 3rd edition:
BUTTERWORTH HEINEMANN .
Gerald Bowen Hill, E. J. Pring, Peter David Osborn, William Stanford. (1990).
Cooling towers: principles and practice. Technology & Engineering: ButterworthHeinemann.
Perry, R. 1997.Perrys Chemical Engineers Handbook, 6th ed. Mc Graw Hill.
"Chemical Engineering Practical manual",Dep. of Chemical engineering.

17