Performance Analysis of Natural Draft Cooling Tower in Chemical Plant

In Partial Fulfilment of the Requirements for the Course

Heat and Mass Transfer

Submitted By:

GUILLERMO, DENVER

LAPUEBLA, JEREMY

MANALIGOD, LAICA

RANTE, FERLYN JADE

SIA, JOHN PATRIC

Submitted to:

ENGR. CAESAR P. LLAPITAN

DECEMBER 30, 2017

 Table of Contents

I. INTRODUCTION..................................................................................1

A. OBJECTIVES:..................................................................................................1

II. PRINCIPLE.......................................................................................... 2

III.....................................................................................................OPERATION
............................................................................................................. 4

IV.DESIGN CONSIDERATIONS................................................................4

A. STRUCTURAL COMPONENTS.............................................................................4

1. Cold water basin.......................................................................................4

2. Tower framework......................................................................................4

3. Water distribution system.........................................................................4

4. Fan deck....................................................................................................5

5. Fan cylinder...............................................................................................5

6. Mechanical equipment supports...............................................................5

7. Fill (heat transfer surface)........................................................................5

8. Drift eliminator.........................................................................................5

9. Casing.......................................................................................................5

10.........................................................................................................Louvers
..................................................................................................................6

B. MECHANICAL COMPONENTS............................................................................6

2. Speed reducers.........................................................................................7

3. Drive shafts...............................................................................................7

4. Valves........................................................................................................7

C. ELECTRICAL COMPONENTS..............................................................................7

1. Motors.......................................................................................................7
 2. Motor controls...........................................................................................7

3. Wiring system...........................................................................................7

V. OPERATION CONDITIONS..................................................................8

VI.....................................................................................DESIGN ALGORITHM
............................................................................................................. 9

VII.DESIGN INPUT................................................................................ 10

VIII.DESIGN CALCULATION..................................................................11

IX............................................................................DESIGN SPECIFICATIONS
........................................................................................................... 20

X. DESIGN FIGURES..............................................................................21

XI..................................................................................................REFERENCES
........................................................................................................... 23

List of Figure

Figure 1: Cooling-tower process heat balance. (Markey Co.)............................2

Figure 2: Design Algorithm................................................................................9

Figure 3: Design Figure...................................................................................10

Figure 4: Tower Performance Curve................................................................20

Figure 5: Psychrometric Chart.........................................................................19

Figure 6: Parts of a Cooling Tower...................................................................21

Figure 7: Cooling Tower 3D View.....................................................................22

List of Tables

Table 1: Design Input........................................................................................11

Table 2: Tower Performance.............................................................................19

Table 3: Wet Bulb Temperature........................................................................20

Table 4: Design Specification...........................................................................20

I. Introduction

A cooling tower is a heat rejection device that rejects waste heat to

the atmosphere through the cooling of a water stream to a lower
temperature. Evaporative heat rejection devices such as cooling
towers are commonly used to provide significantly lower water
temperatures than achievable with "air cooled" or "dry" heat rejection
devices, like the radiator in a car, thereby achieving more cost-effective
and energy efficient operation of systems in need of cooling. Cooling
towers may either use the evaporation of water to remove process heat
and cool the working fluid to near the wet-bulb air temperature or, in the
case of closed circuit dry cooling towers, rely solely on air to cool the
working fluid to near the dry-bulb air temperature.

Common applications include cooling the circulating water used in oil

refineries, petrochemical and other chemical plants, thermal power
stations and HVAC systems for cooling buildings. The classification is
based on the type of air induction into the tower: the main types of
cooling towers are natural draft and induced draft cooling towers.

In some instances, the cooling towers have been added to the plant
design to help comply with environmental limits and the cooling tower
performance does riot directly impact the CCW temperature. However, in
the vast majority of the cases, the cooling tower is an integral part of a
closed cycle heat rejection system (HRS), and the cooling tower
performance directly impacts the plant performance.

A. Objectives:

The objectives of this paper are as follows:

1. Calculate for percent By-pass water

2. Determine the actual range of the tower

3. Determine the enthalpies

4. Calculate for air loading

5. Calculate for tower demand (NTU)

1
 6. Determine the characteristic curve

7. Compute for the area of obstruction in the air inlet

8. Calculate the pressure drop

9. Compute for height of inlet, straight, and velocity recovery zones

of fan stack

10. Determine motor power sizing

11. Calculate the evaporation loss and evaporation rate

12. Estimate the actual cold water temperature

13. Determine the tower performance

II. Principle

The most generally accepted theory of the cooling-tower heat-transfer

process is that developed by Merkel (op. cit.). This analysis is based upon
enthalpy potential difference as the driving force. Each particle of water
is assumed to be surrounded by a film of air, and the enthalpy difference
between the film and surrounding air provides the driving force for the
cooling process. In the integrated form the Merkel equation is

KaV T 1 dT
=∫T
L 2 h'−h

(1)

where K = mass-transfer coefficient, lb. water/ (h⋅ft2);

a = contact area, ft2 /ft3 tower volume;

V = active cooling volume, ft3 /ft2 of plan area;

L = water rate, lb./ (h⋅ft2);

h′ = enthalpy of saturated air at water temperature, Btu/lb.;

h = enthalpy of air stream, Btu/lb.;

T1 and T2 = entering and leaving water temperatures, °F.

The right-hand side of Eq. (1) is entirely in terms of air and water
properties and is independent of tower dimensions. Figure 1-2 illustrates

2
water and air relationships and the driving potential which exist in a
counter flow tower, where air flows parallel but opposite in direction to
water flow. An understanding of this diagram is important in visualizing
the cooling-tower process.

Figure 1: Cooling-tower process heat balance. (Markey Co.)

The water operating line is shown by line AB and is fixed by the inlet
and outlet tower water temperatures. The air operating line begins at C,
vertically below B and at a point having an enthalpy corresponding to
that of the entering wet-bulb temperature. Line BC represents the initial
driving force (h′ − h). In cooling water 1°F, the enthalpy per pound of air
is increased 1 Btu multiplied by the ratio of pounds of water per pound of
air. The liquid-gas ratio L/G is the slope of the operating line. The air
leaving the tower is represented by point D. The cooling range is the
projected length of line CD on the temperature scale. The cooling-tower
approach is shown on the diagram as the difference between the cold-
water temperature leaving the tower and the ambient wet-bulb
temperature.

The coordinates refer directly to the temperature and enthalpy of any

point on the water operating line but refer directly only to the enthalpy of

3
a point on the air operating line. The corresponding wet bulb
temperature of any point on CD is found by projecting the point
horizontally to the saturation curve, then vertically to the temperature
coordinate. The integral (Eq. 1) is represented by the area ABCD in the
diagram. This value is known as the tower characteristic, varying with
the L/G ratio.

For example, an increase in entering wet-bulb temperature moves the

origin C upward, and the line CD shifts to the right to maintain a
constant KaV/L. If the cooling range increases, line CD lengthens. At a
constant wet-bulb temperature, equilibrium is established by moving the
line to the right to maintain a constant KaV/L. On the other hand, a
change in L/G ratio changes the slope of CD, and the tower comes to
equilibrium with a new KaV/L. In order to predict tower performance, it
is necessary to know the required tower characteristics for fixed ambient
and water conditions. The tower characteristic KaV/L can be determined
by integration. Normally used is the Chebyshev method for numerically
evaluating the integral, whereby

KaV dT T −T 2 1 1 1 1
( )
T1
=∫T ≃¿ 1 + + +
L 2 h −h
w a 4 Δh1 Δh 2 Δh3 Δh 4
¿

Where hw = enthalpy of air-water vapor mixture at bulk water

temperature; Btu/lb. dry air

ha = enthalpy of air-water vapor mixture at wet-bulb

temperature; Btu/lb. dry air

∆h1 = value of (hw − ha) at T2 + 0.1(T1 − T2)

∆h2 = value of (hw − ha) at T2 + 0.4(T1 − T2)

∆h3 = value of (hw − ha) at T1 − 0.4(T1 − T2)

∆h4 = value of (hw − ha) at T1 − 0.1(T1 − T2

III. Operation

A cooling tower cools water by a combination of heat and mass

transfer. Water to be cooled is distributed in the tower by spray nozzles,
splash bars, or film-type fill, which exposes a very large water surface
4
area to atmospheric air. Atmospheric air is circulated by (1) fans, (2)
convective currents, (3) natural wind currents, or (4) induction effect
from sprays. A portion of the water absorbs heat to change from a liquid
to a vapor at constant pressure. This heat of vaporization at atmospheric
pressure is transferred from the water remaining in the liquid state into
the airstream. They are working on the principle of water evaporation.
Rate of evaporation is increased by increasing air velocity. In case of
cooling tower, we call this an air draft. This air draft is created by
mechanical system of power driven fan. We create the same air draft in
our cooling tower, by using specially designed spray nozzles.

Hot water is pumped into the cooling tower which is splashed over to
the fills/packing by through the static perforated non clogging branch
pipes or self-rotating sprinkler. Dry air from the atmosphere is sucked by
the induced draft fan mounted on the top. The contact between upward
air and downward water leads to the evaporation, resulting in water
cooling. Cooled is collected in the sump of cooling tower, which is sent
back to the main application.

IV.Design Considerations

A. Structural Components

1. Cold water basin

The cold water basin has two fundamentally important functions:

collecting the cold water following its transit of the tower, and acting
as the tower’s primary foundation.

2. Tower framework

The most commonly used materials for the framework of field

erected towers are fiberglass, wood, and concrete, with steel utilized
infrequently to conform to a local building code, or to satisfy a specific
preference.

3. Water distribution system

Lines might be buried to minimize problem of thrust loading,

thermal expansion and freezing; or elevated to minimize cost of

5
installation and repair. In either case, the risers to the tower inlet
must be externally supported, independent of the tower structure and
piping.

4. Fan deck

The fan deck is considered a part of the tower structure, acting as a

diaphragm for transmitting dead and live loads to the tower framing.
It also provides a platform for the support of the fan cylinders, as well
as an access way to the mechanical equipment and water distribution
system. Fan deck materials are customarily compatible with the tower
framework.

5. Fan cylinder

Fan cylinder directly affects the proper flow of air through the
tower. Its efficiencies can be severely reduced by a poorly designed
fan cylinder, or significantly enhanced by a well-designed one.

6. Mechanical equipment supports

Customary material for the unitized supports is carbon steel, hot-

dip galvanized after fabrication, with stainless steel construction
available at significant additional cost.

7. Fill (heat transfer surface)

Fill (heat transfer surface) is able to promote both the maximum

contact surface and the maximum contact time between air and water
determines the efficiency of the tower. The two basic fill classifications
are splash type and film type. Splash type fill breaks up the water, and
interrupts its vertical progress, by causing it to cascade through
successive offset levels of parallel splash bars. It is characterized by
reduced air pressure losses, and is not conducive to logging. However,
it is very sensitive to inadequate support.

8. Drift eliminator

Drift eliminators remove entrained water from the discharge air by

causing it to make sudden changes in direction. The resulting
centrifugal force separates the drops of water from air, depositing

6
 them on the eliminator surface, from which they flow back into the
tower. Eliminator are normally classified by the number of directional
changes or “passes”, with an increase in the number of passes usually
accompanied by an increase in pressure drop.

9. Casing

A cooling tower casing acts to contain water within the tower,

provide an air plenum for the fan, and transmit wind loads to the
tower framework. It must have diaphragm strength, be watertight and
corrosion resistant, have fire retardant qualities, and also resist
weathering.

10. Louvers

Every well-designed crossflow tower is equipped with inlet louvers,

whereas counter flow towers are only occasionally required to have
louvers. Their purpose is to retain circulating water within the
confines of the tower, as well as to equalize air flow into the fill.

B. Mechanical Components

1. Fans

Cooling tower fans must move large volumes of air efficiently, and
with minimum vibration. The materials of manufacture must not only
be compatible with their design, but must also be capable of
withstanding the corrosive effects of the environment in which the
fans are required to operate.

7
 a) Propeller fans: They have ability to move vast quantities of air at
the relatively low static pressure encountered. They are
comparatively inexpensive, may be used on any size tower, and
can develop high overall efficiencies; but their application
naturally tends to be limited by the number of projects of
sufficient size to warrant their consideration.

b) Automatic variable-pitch fans: They are able to vary airflow

through the tower in response to a changing load or ambient
condition.

c) Centrifugal fans: They are usually used on cooling towers

designed for indoor installations; their capability to operate
against relatively high static pressures makes them particularly
suitable for that type of application. However, their inability to
handle large volumes of air, and their characteristically high
input horsepower requirement limits their use to relatively small
applications.

All propeller type fans operate in accordance with common laws:

- The capacity varies directly as the speed ratio, and directly as the
pitch angle of the blades relative to the plane of rotation.

- The static pressure varies as the square of the capacity ratio.

- The fan horsepower varies as the cube of the capacity ratio.

- At constant capacity, the fan horsepower and static pressure vary

directly with air density.

2. Speed reducers

The optimum speed of a cooling tower fan seldom coincides with

the most efficient speed of the driver (motor); thus a speed reduction
or power transmission unit is needed between the motor and the fan.

3. Drive shafts

The drive shafts transmit power from the output shaft of the motor
to the input shaft of gear reduction units.

8
4. Valves

Valves are used to control and regulate flow through the water
lines serving the tower. Valves utilized for cooling tower application
include:

a. Stop valves: They are used on both counter flow and crossflow
towers to regulate flow in multiple-riser towers, and to stop flow
in a particular riser for cell maintenance.

b. Flow-control valves: They are considered to discharge to the

atmosphere, and essentially as the end-of-line valves.

c. Make-up valves: These are valves utilized to automatically

replenish the normal water losses from the system.

C. Electrical Components

1. Motors

Electric motors are used almost exclusively to drive the fans on

mechanical draft cooling towers, and they must be capable of reliable
operation under extremely adverse conditions.

2. Motor controls

Motor controls serve to start and stop the fan motor and to protect
it from overload or power supply failure, thereby helping assure
continuous reliable cooling tower operation. They are not routinely
supplied as a part of the cooling tower contract but, because of their
importance to the system, the need for adequate consideration in the
selection and wiring of these components cannot be overstressed.

3. Wiring system

The wiring system design must consider pertinent data on the

available voltage (its actual value, as well as its stability), length of
lines from the power supply to the motor, and the motor horsepower
requirements.

V. Operation Conditions
1. Water make-up

9
 Water losses include evaporation, drift (water entrained in
discharge vapor), and blowdown (water released to discard solids).
Drift losses are estimated to be between 0.1 and 0.2% of water supply.
2. Cold weather operation
Even during cold weather months, the plant engineer should
maintain the design water flow rate and heat load in each cell of the
cooling tower. If less water is needed due to temperature changes (i.e.
the water is colder), one or more cells should be turned off to maintain
the design flow in the other cells.
The water in the base of the tower should be maintained between
60 and 70 °F by adjusting air volume if necessary. Usual practice is to
run the fans at half speed or turn them off during colder months to
maintain this temperature range.

10
VI. Design Algorithm

START

Asses the given conditions

Calculate the water and air

loading

Determine the enthalpies and

humidity of air water mixture
using psychrometric chart

Calculate the number and

height of diffusion units

Determine the cooling tower

range

Calculate the mass and

volume of air required

Design the cooling tower

END

Figure 2: Design Algorithm

11
VII. Design Input

A process engineer is required to design a cooling tower that can be used in a

chemical plant that meets the following conditions:

Figure 3: Design Figure

Cell length 42.0 ft.

Cell width 42.0 ft.
Air inlet height 15.0 ft.
Number of spray nozzle 196 each
Center to center distance of nozzle 3.0 ft.
Water flow rate 12500 GPM
Exit (entering) water temperature 89 ºF
Inlet (Leaving) water temperature 104 ºF
Fill depth 4.0 ft.
Fill flute size 19 mm.
Entering wet bulb temperature 80 ºF
Relative Humidity 80.0%
Site elevation 0.0 ft.
Exit air temperature 97 ºF
Arrangement of air inlet Two sides open and ends
closed
Material of tower framework Wood
Type of air inlet louver Large widely spaced
Table 1: Design Input
VIII. Design Calculation

Step 1: % By-pass water calculation.

12
 design water flow rate
Water Flow Rate per Nozzle =
total number of nozzles
12 , 500GPM
=
196
=63 . 776 GPM/nozzle

By Pass Wall Water =[2 ( cell length

center to center distance of nozzle
−2 )+

cell width GPM GPM

2( −2) ] x 100 (
nozzle ) ( nozzle )
+ 4 nozzlesx20%
center to center distance of nozzle

=2
[ ( ) ( )]
42
3
−2 +2
42
3
−3 x 10 ( 63 .776 )+ 4 ( 20 ) ( 63. 776 )

=357 . 1456 GPM

By pass column water due to spray nozzles near tower internal columns

By Pass Column Water =

[( cell lentgth
bay distance
−1
cell width
)(
bay distance )]
−1 x 4 nozzlesx5%x
GPM
nozzle

=
42
6 [( )( ) ]
−1
42
6
−1 ( 4 )( 5 )( 63 . 776 )

=459. 1872 GPM

by-pass wall water+by pass column water

GPM
% By-Pass Water=
2 x 100
357 . 1456+459 . 1872
12 , 500
=
2(100 )
=0 . 03265
=3 . 265
Step 2: Actual range through tower

Design Range
Net Tower Range =
by −pass wall water
1−
100
104−898
=
1−0 .03265
=15 . 5063
Step 3: Enthalpies

13
 L
Ha 1=Ha 2 + ( new tower range )
G

water loading L (Ha 2 −Ha1 )

= =
air loading G new tower range
Ha2 = air enthalpy at exit (97 ºF) = 66.5773 BTU/lb.

Ha1 = air enthalpy at inlet (80ºF) = 43.6907 BTU/lb.

L ( 66 . 5773−43. 6907 )
= =1 . 4760
G 15 . 5063

Step 4: Air loading

L
G=
L/G

L=Design Water Flow Rate (500

60 )( 1−
by Pass water
100 )
gal 500 3 . 265
=12 .500 (
min 60 )( 1−
100 )
=100765 . 625
100765 . 625
G= =68, 269 .39363 l b/ min
1. 4760
Step 5: Tower Demand (NTU) Calculation

L
=1 .4760 H ai =43 .6907 BTU /lb
R=104−89=15 ° F G
Water Side Air side Enthalpy Diff.
Descript 1
ion
tw ( ° F ) hw ( BTU /lb ) Description ha ( BTU /lb ) hw−ha
hw−ha
L 10.743
tw 1 +0.1 ( R ) 90.50 56.6478 ha1 +0 .1 (R ) 45.9047 0.0931
G 1
L 10.795
tw 1 +0.4 ( R ) 95 63.3426 ha1 +0 . 4 ( R ) 52.5467 0.0926
G 9
L 11.284
tw 1 +0.6 ( R ) 98 68.2591 ha1 +0 .6 ( R ) 56.9747 0.0886
G 4
102.5 L 12.784
tw 1 +0.9 ( R ) 76.4013 ha1 +0 .9 ( R ) 63.6167 0.0782
0 G 6
1
Sum of hw−ha =0.3525

14
 1
sum of
hw−ha
×R=1. 3219
Tower Demand (NTU)= 4

Step 6: Characteristic curve

Assume: m = -0.8

L1 = water flow rate

L2 = Alternative water flow rate, 16,000 GPM

Heat load:

D1 =L1 ( R1 )
( 500/60 ) lb/ min
D1 =12, 500 GPM ( 15 )
GPM
D1 =1,562 , 500 BTU /min

Air mass flow rate:

lb
68 ,269.59363
min
Liquid to Gas:

L L1 12,500 ( 500/60 )
= = =1. 5258
G1 G1 68 ,269 . 39363

Heat Load:

D2 =D1=1, 562 ,500 BTU /min

Air mass flow rate:

lb
G2 =G1=68 , 269 .59363
min
Liquid to Gas:

L L2 16,500 ( 500/60 )
= = =2 .0141
G2 G2 68,269.39363

Range:
15
 D2 1562 ,500
R2 = = =11.36 ° F≈12 ° F
L2 16 , 500

kaV
L
C= −m
=1. 3219 ( 1. 5258 )0 . 8=1 . 8535
( L/G1 )

New tower characteristics:

−m
L
C
( )
G2
=1.8535 ( 2.0141 )
−0 .8
=1.0586

Step 7: Area of obstruction in the air inlet

Area of obstruction due to columns= (no . of Bay )(width of column )(air inlet height)(no . of air inlet)
=7 ( 4/12 ) ( 15 ) (2 )
=70 ft 2
Area of obstruction due to transversal members=(no . of members)( ht . of members )
(cell length )(no . of air inlet)
4
=2 ( )
12
( 42 ) (2 )

=56 ft 2
2
Total area of obstructions =70+56=126 ft
Overall area of air inlet = Cell length (Air inlet height )(no . of air inlet)
=42(15 )(2)
2
=1260ft
Total area of construction
Percent obstruction at air inlet= ×100
Overall area of air inlet
126
= ×100=10
1260
2
Net area of air inlet = 1260−126=1134 ft

16
Step 8: Pressure drop

From: Psychrometric chart

at T wb> 80 ° F H=43.7 BTU/lb dry sir

Air specified volume at Tower Inlet = 14.2 ft3/lb dry air

Dry Bulb Temperature= 85.2° F

Airflow volume at Air Inlet= air mass flow (specific volume at air Inlet)

= 68269.39363 (14.20)

= 969425.3895 ft3/min

Air velocity at air Inlet

Airflow Volume at Air Inlet 969425 .3895

= = = 854 . 57 ft/min
Net Area of Air Inlet 1134
Air density at 85.24 OBT or 80% RH = 0.0718 lb/ft3

Pressure drop coefficient for this arrangement =2.5

Pressure drop=k( v/4008 . 7)2 (Density Ratio)

854 .87 2 .0718
= 2. 5 ( )(
4008 .7 0 .0710 )
= 0. 1088 in. aq.

Step 9: Height of inlet, straight, and velocity recovery zones of fan

stack

Use: 28 ft. of fan in the diameter and 16 ft. of fan stack in the
height

a. Fan Inlet Zone

R
=0.15
D
Inlet Zone Height = 0.15 (Fan Diameter)

17
 = 0.15(28 ft.)

=4
4.2 ft (121 ftin )
= 50.4 in

This inlet shape was proven to be the ideal inlet shape because the
air flows along the wall with a uniform velocity on as to the fan with
the slightest possible turbulence.

b. Straight Zone

 Vertical Dimension of Blade Tip at Mass pitch Angle: 5.73 in

 Maximum Deflection of Blade Tip: 14 in

 Extra Dimension from the Trailing edge of Blade: 6 in

Therefore, Height of straight Zone = 5.73 + 14 + 6= 25.73 in

c. Velocity Recovery Zone

Velocity Recovery Zone Height = Total Fan Stock Height – Fan

Inlet Zone Height

– Straight Zone Height

= 10 ( 12 )−50 . 4−25 .73

= 43.87 in

d. Velocity Recovery

Formulated by MRC Corp

Velocity Recovery = 0.8 – 0.2 (Venturi Height/ Fan Diameter)

(Velocity Pressure at

Fan – Velocity Pressure at Top of Fan Stock)

Angle of Taper= 7° is most efficient (Note)

18
Diameter of Fan Stock Top= Fan Diameter + 2 Ton 7° ( venture
height)

Area of Fan Stock Top= 0.7854 (Diameter of Fan Stack Top 2

–
Air Seal Depth2)

[( )) ( ) ]
2 2
43 . 87 88
= 0.7854
28+ 2 tan 7 ° ( 12
−
12

= 613.6 ft2

Air velocity at Fan Stack=

Air Volume at fan 1019716 .29

= = 1,661.86 ft/min
Area of Fan Stock Top 613 . 6
2
1661.86
Velocity Pressure at Fan Stack=
( 4008 . 7 ) ( 0.0696
0.0750 )
= 0.1594 in Aq

Venturi Height
Fan Stack Efficiency=
0 . 8−0 . 2 (Fan Diameter )
(100 )

( )
43.87
0.8−0.2
12 ( )
×(100)
=
28

= 77.4 %

2
Air Velocity at Fan
Velocity Pressure at fan=
( 4008 . 7 ) ( Air Density
0.075
at Fan
)
2
1778 .0
=
( 4008 . 7 ) ( 00.0686
.075 )
=0 .1825 in Aq

19
 Velocity Recovery = 0,774 (0.1825 – 0.1594) = 0.0178 in Aq

Step 10: Motor Power Sizing

a. Motor Power Input

Net fan BHP

Actual Fan BHP= System Environmental Correction factor

1019716 .28( 0. 6439 )

=128 . 98
Fan BHP = (0. 801)(6356 )

128 .98
=135 .77 BHP
Actual Fan BHP = 0. 95

Actual Fan BHP

Motor Shaft BHP = efficiency of Power Transmission of Gas Reducer

135 .77
=141. 43
= 0.96

Motor Shaft BHD

Motor Input Power = Motor efficiency

141.43
=158. 91 BHP
= 0.89

Step 11: Evaporation

a. Evaporation loss

Evaporation Dose Rate= (Absolute humidity at Tower Exit –

Absolute Humidity at

1
(
Tower inlet) 4 G
) (100)

Absolute Humidity at Tower Exit ( 97 ° F WBT ) = 0.039166

20
 Absolute Humidity at Tower Inlet ( 85 .24 °F DBT and 80% RIT ) =
0.021117

1
Evaporation Loss Rate=
(0 .039166−0 . 021117) ( 1 . 4760 )(100 )= 1. 22%
b. Evaporation Rate

( w2 −w 1 )( Latent Heat of Water) (0 .039166−0 . 021117)(1080 )BTU /lbwater

ER = = ×(100)
Enthalpy at Exit − Enthalpy at Inlet (66 .5773−43 . 0907 )

= 82.02%

Step 12: Estimation of Actual Cold Water temperature

a. Dry Bulb Temperature at Tower Inlet

Inlet Wet Bulb Temperature = 80° F

Relative Humidity= 80%

DBT= 85.2° F

H= 43 .2 BTU/lb

Actual Cold Water temperature= Wet Bulb Temperature + Approach

= 80 + 8.633

= 88.63° F

21
Step 13: Tower Performance

Method of Constant Fan BNB

Performance Details with 100% of water flow
Water WBT DBT(°F) Range(° L/G kaV /L Fan
flow (°F) F) Power
(GPM)
12500 60.00 68.97 12 1.3813 1.3935 138.37
12500 66.25 70.63 12 1.3949 1.3827 138.37
12500 72.50 77.28 12 1.4098 1.3709 138.37
12500 78.75 83.92 12 1.4264 1.3581 138.37
12500 80.00 85.24 12 1.4299 1.3555 138.37
12500 85.00 90.54 12 1.4450 1.3441 138.37
12500 60.00 63.97 15 1.3937 1.3836 138.37
12500 66.25 70.63 15 1.4069 1.3732 138.37
12500 72.50 77.28 15 1.4215 1.3619 138.37
12500 78.75 83.92 15 1.4378 1.3495 138.37
12500 80.00 85.29 15 1.4413 1.3469 138.37
12500 85.00 90.54 15 1.4561 1.3359 138.37
12500 60.00 63.92 18 1.4059 1.3740 138.37
12500 66.25 70.63 18 1.4187 1.3640 138.37
12500 72.00 77.28 18 1.4331 1.3531 138.37
12500 78.75 83.92 18 1.4491 1.3411 138.37
12500 80.00 85.24 18 1.4526 1.3385 138.37
12500 85.00 90.54 18 1.4673 1.3278 138.37
Table 2: Tower Performance

Wet bulb Temp (°F)

Range 60 66.25 72.50 78.75 80 85.00
12 73.93 77.61 81.95 86.47 87.39 91.17
15 75.72 79.58 83.62 87.85 88.72 92.29
18 77.72 81.31 85.09 89.08 89.91 93.30
Table 3: Wet Bulb Temperature

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 Tower Performance Curve @100% (12500 GPM)
95

90
Cold Water Temp. (°F)

85 12
15
80 18

75

70
55 60 65 70 75 80 85 90
Entering Wet Bulb (°F)

Figure 4: Tower Performance Curve

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Psychrometric Chart Use

Figure 5: Psychrometric Chart

19
 IX. Design Specifications
% by pass water 3.265%
Net tower range 15.5063
Air enthalpy at exit 66.577343.6907BTU/lb.
Air enthalpy at inlet 43.6907BTU/lb.
Air loading rate 68,269.39363lb/min
NTU 1.3219
Heat load 1,562,500BTU/min
Total area of obstructions 126ft2
Overall area of the air inlet 1260ft2
Net area of air inlet 1134 ft2
Pressure drop 0.1088in. aq.
Fan inlet zone height 50.4 in
Straight zone height 25.73 in
Velocity recovery zone height 43.87 in
Velocity recovery 0.0178 in aq.
Motor input power 158.91 BHP
Evaporation loss rate 1.22 %
Evaporation rate 82.02%
Dry bulb temperature 85.2°F
Humidity 43.2BTU/lb.
Actual cold water temperature 88.63°F
Table 4: Design Specification

Cooling tower fan

Sprinkler
Water column

X. Design Figures

Hot water inlet

20

Cool water outlet

Drain port
Figure 6: Parts of a Cooling Tower

21
Figure 7: Cooling Tower 3D View

22
XI. References

Cheremisinoff, N. P. (1981). Cooling Towers Selection, Design and

Practice. Ann Arbor Science Publisher, Inc.

Dileep KJ, D. K. (2017). Design and Fabrication of Cooling Tower. 34-

37.

Sai, B. B. (2013). Design of Cooling Tower. International Journal of

Scientifc and Engineering Research, 1561-1562.

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24
 RUBRIC FOR HEAT AND MASS TRANSFER DESIGN PROJECT EVALUATION

Name: Guillermo, Denver, Lapuebla, Jeremy, Manaligod, Laica, Rante, Ferlyn Jade, Sia, John Patric

Title of Design Project: Performance Analysis of Natural Draft Cooling Tower in Chemical Power Plant

EVALUATION CRITERIA
Identification of Problem or
Definition of Project
(3 points)
Application of Engineering
Principles
(5)
Use of Computer–Aided Tools
(2)
Meeting Design Requirements
(5)
1 2 3 4
SCORE
Beginning Developing Proficient Exemplary
Insufficient Partial identification of Adequate identification Clear and complete
identification of problem; lack of of problem; any lack of identification of design
problem; inadequately specifics does impair specifics does not goals and objectives.
objectives. solution of design. impair solution or
design.
No or erroneous Serious deficiencies in Effective application of Critical selection and
application of proper selection and engineering principles application of
engineering principles use of engineering resulting in reasonable engineering principles
yielding unreasonable principles. solution. ensuring reasonable
solution. results.
Serious deficiencies in Minimal application Computer–aided tools Computer–aided tools
understanding the and use of appropriate used with moderate are used effectively to
correct selection and/or tools. effectiveness to develop and analyze
use of tools. develop designs. designs.
Few design Only basic Design requirements All design
requirements are met. requirements are met. are met. requirements are met
and exceeded

25
 Design Documentation Reports may have poor Reports attempts Reports use mostly Reports use appropriate
and Presentation quality writing and mix appropriate appropriate language/format for the
jargon with engineering language/format for the language/format for the engineering field.
language. engineering field. engineering field.
Reports are informative
(5 points) Reports miss many Reports are fairly Reports are mostly and easy to read.
important topics and are informative and informative and easy to
not easy to read. generally easy to read. read. Information in reports is
well organized so that
Information in report is Information in reports Information in reports is data or design feature
not organized. Data or organized into sections well organized. All data explanations are easy to
design features with data or design and design features can found.
explanations very features explanation be found without
difficult to locate. present. difficulty. Avoid plagiarism, does
not use information
Evidence of plagiarism. Evidence of plagiarism. Both positive and without giving credit to
negative results the appropriate source.
presented.

Punctuation, Capitalization & There are a number of There are 3 or 4 minor There are 1 or 2 minor There are no
Spelling major errors in errors in punctuation, grammatical, spelling or grammatical, spelling or
(3) punctuation, grammar grammar and/or spelling punctuation errors punctuation errors
and/or spelling which which do not break the
make it difficult to read flow for the reader
Sources Attempt to document All sources are All sources are All sources are
(2) source used is not accurately documented accurately documented accurately documented
completely accurate Only 1 or 2 sources and in the desired and in the desired
Only 1 source was used were used format format
26
 2 or 3 sources were
used
TOTAL SCORE

Rater: Engr. CAESAR P. LLAPITAN

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