ABSTRACT

PROBLEM SELECTION We have selected this project because the cooling tower is a main part of the condensing plant. The cooling tower performs the function of cooling the condenser cooling water and is now used in all the power plants and the A/C systems- The cooling tower is always selected on the basis of graphs and hence we showing the graphs. Which will enable the user to select the tower as per is requirement.

LITRATURE SURVEY: We collected the required date from the college library; we also collected information from the Mr. Shetty manufacturers of the cooling tower WORK: We selected certain parameters like flow rate, temperature drop, etc and depending on those parameters we fabricated a model- Compared it with the output of the theoretical solution.

FINDINGS: On taking trials on the model and comparing it with our theoretical solution. We found that our model was as functioning as per our design calculations. We have attached graphs, which indicate the relationship between various parameters.

ACKNOWLEDGEMENTS
We take this opportunity to express our sincere gratitude towards our guide, Prof. K.B. SALUNKE, LECTURER IN MECH.ENGG. GOVT. POLYTECHNIC, THANE. For his inspiration & encouragement. Without his invaluable help & guidance we could not have been able to complete this project to satisfaction. We would also like to take this opportunity to thank Prof K.B. SALUNKE Professor and head of Department of Chemical Engineering and the principal Mr. CHASKAR. We would like to thank EKTA COOLING SYSTEM manufacturers of: Cooling Tower. We would also like to thank Prof. KOKITKAR (workshop Department) and all other sirs of our college workshop & also we thankful MR. BHOR (Lab Assistant in Chemical Engineering). We enjoyed working on this project due to the keen interest, systematic and knowledgeable approach of our guide. Finally we thank everybody who have contributed towards this project in any respect.

CONTENTS
CHAPTER No. 01 02 03 04 05 06 07 NAME OF CHAPTER Introduction to cooling towers Selection of cooling tower Analysis of cooling tower Design and fabrication of model of a cooling tower Results and discussion Conclusion References PAGE No. 5 33 41 45 58 62 64

LIST OF FIGUER
FIGURE NO. 1.1 Diagram Showing The Various Ways In Which The Water Droplet Loses Heat 1.2 1.3 1.4 1.5 1.6 4.1 4.2 4.3 Cooling Tower Process Heat Transfer Direct Contact Evaporative Cooling Tower Indirect Contact Evaporative Cooling Tower Division of tower into increments of volume Performance Curves for 100 % design flow Sizing Chart Fan Horse Power Chart General Arrangement of a Cooling Tower 13 16 19 26 31 48 49 50 NAME OF FIGURE PAGE NO. 10

CHAPATER 1 INTRODUCTION TO COOLING TOWER

CHAPATER -1 INTRODUCTION TO COOLING TOWER

1.1 IN TRO DUC TIO N : Most air conditioning systems and industrial processes generate heat that must be remove dissipated. Power plant is very important to the society. All the heat generated by combustion can not be converted into work owing to the second low of thermodynamics. A large portion of head is to be rejected. Refrigeration and air conditioning plants are required for comfort as well as various processes and industries. Heat absorbs and works input; both have to be rejected. Chemical process plants produce unimaginable no. of products of daily use and for industries. The process heat has to be dissipated and temperature to be controlled. Absorb heat and/or work input. This heat has to be effectively rejected to some cooling medium. The temperature at which heat is rejected is of great importance with direct impact on the economy of system. The temperature requirement is decided as follows, Power plants: Turbine discharge pressure. Chemical plants: Operating pressure, distillation. Refrigeration air conditioning: Condensation temperature. Water is commonly used as a heat transfer medium to remove heat from refrigerant condensers or industrial heat process exchanger. In the past it was accomplished by drawing a continuous stream of water from utility water supply or a natural body of water, heating it as it passed through the process and then discharging the water directly to a sewer or returning it to the body of water. This was possible since there were very few plants and plenty of water available. According for topographical

consideration the plats were located near ponds, lakes, canal and rivers. In these sources hot water is cooled from evaporation from the limited surface area depending upon random winds. These limitations do not allow many plants to be near these sources since this will lead to ecological disaster. AIR COMPRESSORE Single stage Single stage with after cooler Two stage with an inter cooler REFRIGRATOR Mechanical vapor compression Absorption DISEL ENGINE Super charged Non supercharged Natural gas kw/bhp 0.11 0.74 0.45 Btu/hr/BHP 380 1530 2530 KW/TR

0.75

2545

4.4 8.8

0.76 0.88 1.32

2600 3000 4000

Table No. 1.1: heat rejection rate by some of the devices Water purchased from utility for this purpose has now become prohibitively expensive because of increased water supply and disposal costs. Similarly cooling water drawn from natural sources is relatively unavailable because the disturbance to the ecology of the water source caused by increase temperature of the discharged water has become unacceptable. Air-cooled heat exchangers are may be used to cool the water by ejecting directly to the atmosphere, but the first cost and fan energy consumption of these devices are high. These are capable of economically cooling the water to within approximately 11k of the ambient dry bulb
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temperature (WBT). Such temperature levels are too high for the cooling water requirements of most refrigerant system and many industrial processes. 1.2 NEED OF COOLING TOWER : Cooling towers overcome most of these problems and therefore are commonly used to dissipate heat from water in refrigeration, air conditioning and industrial process system. The water consumption rate of a cooling tower is only about 5% of that of a once through system making it the least expensive system to operate write purchase water supplies. Additionally the amount of heated water discharged (blow down) is very small, so the ecological effect is greatly reduced. Lastly, cooling towers can cool water to within 3 to 6 k of the ambient wet bulb temperature (WBT) or about 20 k lower than can air cooled systems of reasonable size. 1.3 RINCIPLE OF OPERATION OF A COOLING TOWER : A cooling tower cools water by a combination of heat and mass transfer. A process of cooling in cooling towers consists of 10 - 20 %sensible cooling and 80 - 90 %evaporative cooling Warm water from the condenser, usually at a temperature of37 - 40'C, enters the cooling tower from the top. Water is distributed and sprayed evenly over the PVC fills kept below the spraying mechanism, through the spraying nozzles. Thus water is broken down in small particles and at the same time air, which enters, from the bottom of the cooling tower flows opposite to the water and heat transfer from water to air takes place. The air is induced through the cooling tower by an induced draft fan located at top of a cooling tower. The water, which is cooled and collected in a basin
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at bottom, which is further, pumped through the condenser to pickup the heat load. Since the water is at the high temperature than air (usually), sensible heat transfer occurs. Once sensible heat transfer occurs, air get heated and at higher temperature it is not longer saturated since it can hold more water vapor at higher temperature, therefore evaporative cooling occurs. Fig. 1.1 illustrates various modes of heat transfer from a water droplet to the atmosphere. Now unlike natural cooling in ponds, lakes and rivers where cooling limited by top surface area exposed to air, in cooling towers water is broken down into no. of fine droplets and more surface area is exposed to air. The water to be cooled is distributed in the tower by spay nozzles, splash bar, or film-type fill, which exposes a very large surface area to atmospheric air. Atmospheric air is circulated by.

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(1) (2) (3) (4)

fans connective current natural wind current conduction effects by 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 transfer from the vapor remaining in the liquid state into the air stream. As figure shows the temperature relationship between water and air as they pass through the counter flow-cooling tower. The curve is indicate the drop in water temperature (point A to point B) and the rise in the air wet bulb temperature (point C to point D) in their respective passages through the tower. The important terms related to cooling towers are as follows: Range: The temperature difference between the water entering and leaving the cooling tower (A minus B) is the range. For system operating in a steady state, the range is same as the water rises through the load heat exchanger, provided the flow rate through the cooling tower and the heat exchanger is same. Accordingly the range is determined by heat load and water flow rate, not by the size or thermal capability of cooling tower. Approach: the difference between the leaving water temperature and the entering air wet bulb temperature (B minus C) in figure is the Approach to the wet bulb or simply the approach of the cooling tower. The approach is the function of cooling tower capability, and a large cooling tower produces a close approach (colder leaving water), for a given heat load, flow rate, and entering air condition. Thus the amount of heat transferred
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toto the atmosphere by the cooling tower is always equal to heat load imposed on the tower, while the temperature at which is the heat is transferred is determined by the thermal capability of the cooling tower and entering air wet bulb temperature. The thermal performance of a cooling tower depends on the entering air wet bulb temperature. The entering air dry bulb temperature and relative humidity, taken independently, have an insignificant effect on thermal performance of mechanical draught cooling tower, but they do affect the rate of water evaporation within the cooling tower. A psychometric analysis of the air passing through a cooling tower illustrates this effect. (Refer fig. 1.2). Air enters at ambient conditions at point A, absorbs heat mass (moisture) from the water, and exits at point B at saturated condition (at very light loads the discharged air may not be saturated). The amount of heat transferred from the water to the air is proportional to the difference in enthalpy of the air between the entering leaving conditions (hB hA). Because lines of constant enthalpy corresponds almost exactly to lines of constant wet bulb temperature, the change in enthalpy of the air may be determined by the change in wet bulb temperature of the air.

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FIG NO. 1.2 COOLING TOWER PROCESS HEAT TRANSFER

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1.4 DESIGN CONDITIONS Thermal capability of any cooling tower may be defined by the following parameters (1) Entering and leaving water temperature (2) Entering air bulb and bulb and dry bulb temperature (3) Water flow rate. The entering dry bulb temperature affects the amount of water evaporated from any evaporative type-cooling tower. It also affects airflow through hyperbolic towers and directly establishes thermal capability within any indirect - contact cooling tower component operating in a dry model. The thermal capability of a cooling tower use for air conditioning application may be expressed in nominal capacity, which is based on heat dissipation of 1.25kW of evaporator cooling. Nominal cooling capacity is defined as cooling 54mL /s of water from 35 'C to 29.4 'C at 25.6 'C entering wet bulb temperature. At these condition the cooling tower rejects 1.25kW per kilowatt of evaporator capacity. The historical derivation is based on the assumption that at typical air conditioning condition for every kilowatt of heat pick up in the evaporator, the cooling tower must dissipate an additional O.25kW of compressor heat. For specific application, however nominal capacity ratings are not used, and the thermal performance capability of the towers is usually expressed as a water flow rate at specific operating temperature conditions (entering water temperature, leaving water temperature, entering air wet bulb temperature).

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1.5 TYPES OF WATER COOLING TOWERS : Two basic types of evaporative cooling devices are used. The first type involves direct contact between heated water and atmosphere (see fig 1.3). The direct contact device exposes water directly to the cooling atmosphere thereby transferring heat load directly to the air. Second type involves indirect contact between heat fluid and the atmosphere. (see fig 1.4). To increase contact surface, as well as time of exposure a heat transfer medium, or fill, is installed below the water distribution system, in the path of the air. The two types of fills used are splash type and film types. Splash type fill maximizes contact area and time by forcing the water cascade through successive evaluation of splash bars arranged in staggered rows. Film type fill achieves the same effect by causing the water to flow in a thin layer over closely spaced sheets, principally polyvinyl chloride (PVC), that are arranged vertically.

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1.5.1 TYPES OF DIRECT CONNECT COOLING TOWERS: NATURAL DRAFTS TOWERS : Aspirated by sprays or density differential, these towers do not contain fill and do not use a mechanical air-moving device. The aspirating effect of the water spray, either vertical or horizontal induces airflow through the tower in a parallel flow pattern. Because air velocities, (both entering and the leaving) are relatively low, such towers are susceptible to adverse wind effects and therefore, are normally used to satisfy a low cost requirement when operating temperatures are not critical to the system. Mechanical draft towers : Mechanical draft towers use fans, either on the inlet airside (forceddraft) or the exit airside (induced - draft). The centrifugal or propeller fan is chosen depending on external pressure needs permissible sound levels, and the energy usage requirements. Water is down flow, while the air may be up flowing (counter flow heat transfer) or horizontal flow (cross flow heat transfer). Air may be single entry or double entry. All four combinations are possible. 1.5.2 INDIRECT CONTACT COOLING TOWERS : Indirect contact type cooling towers are similar to the evaporative condensers using indirect contact of water with atmospheric air tubes. The warm water from the condenser enters the coils of the cooling tower and gets cooled. The cooling water is sprayed on the coils from outside and a thin film / layer of water is formed on the surface of coil. As this water

17

film evaporates, the enthalpy of evaporation is taken from the water flowing through the tubes itself and the water gets cooled. There is also sensible heat transfer between the air and the water on the coil surface, which causes the heat transfer in turn between water film and the warm water through the coils. These types of cooling tower are not very popular. A typical indirect contact cooling tower is shown in fig 1.4

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1.6 PRINCIPAL COMPONENTS OF A MECHANICAL INDUCED DRAFT COOLING TOWER: Following are the principal components of a mechanical induced draftcooling tower: Fans Packing Water distribution system Drift eliminator Basin The relative disposition of these components distinguishes one cooling tower from another. Fans: Usually axial flow type induced draft fans are used. The capacity required for a fan is decided by the operating parameters of the cooling tower. Packing : Splash Type: Water is encouraged to form droplets. Water film Type: Water is encouraged to spread out on the surface and form a thin film. Fills: Fills are simple baffles in cellular shape provided in the path of water droplets falling from the spray nozzles. These fill spreads out the water in thin molecular layer, providing considerably large area. Pressure drop for air also reduces considerably. As a result higher air velocities can be used to achieve the better heat transfer between air and water. Plastic packing (PVC fills) are most widely used these days for following reasons. 1. Lightness and consequent ease and consequent ease of removal and replacement 2. Inert to acidic or alkaline water.
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3. Do not form sludge as timber and metal packing d 4. Lower scale formation 5. Do not provide nutrients to support algae and bacteria 6. Unaffected by electrolytic action 7. Easy to manufacture 8. Non flammable Significance of Packing It is found that if the water spray is exposed to for longer period of time more evaporation will occur. This is done by interrupting the free fall of water droplets by fills or packing. This increases the surface area for heat transfer. E.g. In a particular tower, the height of column is 9.8 m (dth = 0.5 g t). It will take 1.42 seconds approx. for a single droplet to pass. At feed rate of one drop / sec., there will be 1.41 drops present in column and the surface area will be area of 1.41 drops. Baffles might increase the droplet holdup time for 5 seconds. Then at a feed rate of 1 drop / sec., 5 drops will be present at any time and surface area will be 5 /1.41 = 3.5 times more effectively Water distribution system : It consists of a piping which distributes the water which enters into the cooling tower from top through a header pipe and a rotating spraying system consisting of no. of nozzles. The cooling of water is directly affected by the degree to which the water is atomized and maximum surface area of water droplets is made available for heat transfer. Drift eliminator : It consists of simple baffle arrangement that prevents the water from escaping out of the cooling tower with the air flowing out. The water

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particles, carried with air, fall down since they are unable to change the path through the baffle arrangement owing to their inertia. Thus, water loss by drift is prevented. Water basin : The water falling through the fills is collected in a water basin situated at bottom of a cooling tower. An arrangement for blow-down and overflow is made there. 1.7 COOLING TOWER THEORY : Merkel (1925) assumed the Lewis relationship to be equal to one combining the transfer of mass and sensible heat into an overall coefficient based on enthalpy difference as driving as the driving force. KG/(K Cpm) =1 Where, Cpm = humid heat of moist air, (kg K) dry air basis. Setting water heat loss equal to air heat gain yields. L cp. dt = G dh = k a (h ha) dv Where L = inlet water mass flow rate in lg/sec Cp. = specific heat of water in kJ/kgK Dt = difference in the temperature of water G = air mass flow rate in /sec Dh = change in enthalpy of air (kJ/kg) K= unit conductance, mass transfer, interface to main air stream (Kg/see.sq.m) h = intermediate enthalpy of saturated air in kJ/kg ha= enthalpy of air (kJ/kg) dV = elemental cooling volume in in cu m

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The equation considers transfer from the interface to the air stream, but the interfacial conditions are intermediate. If the film resistance is neglected and an overall coefficient k' is postulated, based on the driving force of the enthalpy h' at the bulk temperature t, the equation becomes, L X Cp. X dt = G X dh = k X a X (h ha) X dV Or, K a V/L = ( DH / h) DT...(A) And K a V/G = ( DH / h- ha) In the cooling tower, practice the integrated value of the equation (A) is referred to as the Number of Transfer Units (NTU). This gives the number of times the average enthalpy potential (h' - ha) into the temperature change of water (t) and is the measure of difficulty of the task. Thus, one transfer unit has the definition of Cp X t / (h-ha) avg = 1. The equation is not self-sufficient and is not subject to direct mathematical solution. They reflect the mass and energy balance at any point in a tower and are independent of the two relative motions of the two streams. Mechanical integration is required to apply the equations and, procedure must account for the relative motion. The integration of equation (A) gives NTU for a given set of conditions. 1.7.1 COUNTER FLOW INTIGRATIO : The counter flow-cooling diagram is based on saturation curve for air - water vapor (fig. 1.2). As the water is cooled from inlet temperature (twin) to outlet temperature (t wout), the air film enthalpy follows the saturation curve from A to B. Air entering at wet bulb temperature (taw) has an enthalpy ha

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corresponding to C'. The initial driving force is the vertical distance BC. Heat removed from water is added to air, so the enthalpy increase is proportional to water temperature. The slope of the air operating line CD equals L/G ration. Counter flow calculation start at the bottom of the tower, the only point where air and water condition are known. The NTU is calculated for a series of incremental steps, and the summation is the integral of the process. Because of the slope and the position of CD related to saturation curve, the potential difference increases progressively from bottom to top of the tower in the given example. The degree of difficulty decreases as this driving force increase, which is reflected as a reduction in incremental NTU proportional to a variation in incremental height. This procedure determines the temperature gradient with respect to the tower height. Following example shows the calculation of NTU for a typical cooling tower application. The example is included here to make the reader understand the procedure of calculation of NTU, which is done in the software program automatically. 1.7.2 EXAMPLE : Air enters the base of the counter flow cooling tower at 24C wet bulb temperature, leaves at 30C and L/G ration is 1.2. So dh = 1.2X 4.18X dt, where 4.18 kJ/kg. K is the specific heat (Cp) of water. Calculate the NTU for cooling the water from 38C to 30C. Solution : Refer fig no. 1.5 showing division of tower into increments of volume.

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The calculation showed in (Table 1.2). Water temperatures are shown in column 1, for 0.5C increments from 30 to 33C and 1C increments from 33C to 38C. The corresponding film enthalpies, obtained from the psychometric table, are shown in the column 2. The upward air path is in column 3. The initial air enthalpy is 72.40 kJ/kg, corresponding to a 24C wet bulb temperature and increases by the relation, h = 1.2X 4.18X t. The driving force (h-ha) at each increment is listed in the columm 4.

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The reciprocal! 1/ (h' - ha) are calculated from the (column 5), t is noted (column 6), and the average for each of the increment is multiplied by Cpo t to obtain NTU for each of the increments (column7). The summation of the incremental values (column8) represents the NTU for the summation of the incremental temperature changes, which is the cooling range given in column9.
Water temp T0 c Enthalpy of the film, h kJ/kg Enthalpy of air ha, kJ/kg Enthalpy difference h-ha kJ/kg Reciproc al of (hha) t 0 c NTU =(cp x Vt/ (h-ha) avg. ntu Cum. Cooling range 0 c.

Table 1.2 Counter-flow integration calculation for the given example 1.7.3 SIGNIFICATION OF NTU : Value of NTU is a function of the dynamics of the air flow pattern and drop dynamics in the cooling tower, but the magnitude remains essentially constant for a given cooling tower provided that the air flow rate and water flow rate remains constant. The value of NTU thus characterizes the cooling tower and is the basis of predicting its performance at other inlet water temperatures and other inlet wet bulb temperatures.

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The equation mentioned above is based on the assumption that the temperature of the surface of the water droplets prevails through the droplets. Accordingly the interior of the droplets has a higher temperature than that of the surface, and heat flow by conduction to the surface where heat and mass transfer process occurs. The experimentally determined value of NTU includes the influence of this internal conduction. Cooling tower designers and manufacturers often use the number of transfer units (NTU) to refer to the term hc X A / Cpm. The higher the value of NTU, the closer the temperature of water leaving the cooling tower will come to the wet bulb temperature of the entering air. PREDICTING OUTLET CONDITIONS FROM A TOWER When the value of NTU for a particular cooling tower is known and the entering air and the water flow rates and conditions are known, it should be possible to predict the water outlet water temperature. The procedure for making the predict in a counter flow tower is not straightforward but requires iterative calculations since the temperature of the leaving water is initially unknown, a temperature can be assumed and trail value of NTU can be calculated. If the resulting NTU is too high or too low, the next leaving water temperature can be assumed and the iteration is carried our until a temperature is found where NTU calculated for that particular temperature is within close limits of that of the NTU for that cooling tower which is already calculated. 1.9 PERFORMANCE CURVES : The combination of flow rate and heat load dictates the range a cooling tower must accommodate. The entering air wet bulb temperature and required system temperature level combine with cooling tower size to

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balance the heat rejected at a specified approach. The performance curves in this section are typical and may vary from project to project. Cooling towers can be accommodated a wide diversity of temperature levels, ranging as high as 65 to 70C hot water temperature in the hydrocarbon processing industry. In the Air Conditioning and refrigeration industry, towers are generally applying in the range of 32 to 46C hot water temperature. A typical standard design condition for such cooling towers is 35C hot water to 29.4C cold water temperature, 25. 6C wet bulb temperature. A means of evaluating the typical performance of a cooling tower used for a typical air conditioning system is shown in (fig 1.6). the example tower was selected for a flow rate of 54mL/s per kilowatt when cooling water from 35 to 29.4c at 25.6c entering wet bulb temperature. When operating at other wet bulb or ranges, the curves may be interpolated to find the resulting temperature level (hot and cold water) of the system. When operating at other flow rates (36,72, 90mL/s per kilowatt evaporator cooling capacity plus 0.25 kW for compressor cooling) this same tower performs at the levels described by the titles of the other figures. Intermediate flow rate may be interpolated between charts to find resulting operating temperature levels. The format of these curve is similar to the predicted performance curves supplied by the manufacturers of cooling towers, the difference is that only three specific ranges- 80%, 100%, and 120% of the design range and only three charts are provided, covering 90%, 1 0 0 0 ,!o and 110% of design flow. The curves bracket the acceptable tolerance range of test conditions and may be interpolated to any specific test conditions within the scope of the curve families and chart flow rates. The curves may also be used to identify the feasibility of varying the parameters to meet specific applications. For example, the subject tower
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can handle a greater heat load (flow rate) when operating in the lower ambient wet bulb temperature region. This may be seen by comparing the intersection of the 5k range curve with 21.8c wet bulb at 27. 5C cold water to show the tower is capable of rejecting 33% more heat load at this lower ambient temperature. Similar comparisons and cross plots identify relative tower capacity for a wide range of variables. The curves produce accurate comparisons within the scope of the information presented but should not be extrapolated outside the field of data given. Also the curves are based on atypical mechanical draft, film-filled, cross-flow, mediumsize, air-conditioning cooling tower. Other types and sizes of towers produce somewhat different balance points of temperature level. However the curves may be used to evaluate a tower for round or seasonal use if they are restricted to the general operating characteristics described.

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FIG NO. 1.6 PERFORMANCE CURVES FOR 100% DESIGN FLOW

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As stated, cooling tower, when selected for a specified design condition operates at other temperature levels when the ambient temperature is off design or when heat load or flow rate varies from the design conditions. When flow rate is held constant, range falls as heat load falls, causing temperature level to fall to a closer approach. Hot and cold water temperature levels fall when the ambient wet bulb falls at constant heat load, range and flow rate. As water loading to a particular tower falls at constant ambient wet bulb and range, the tower cools the water to a tower temperature level or closer approach a wet bulb.

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CHAPATER 2 SELECTION OF COOLING TOWER

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CHAPTER NO. 2 SELACTION OF A COOLING TOWER...

2.1 INTRODUCTION TO THE PROJECT: A cooling tower is not custom made equipment available in the market, except a few exceptions and towers are available from the various manufacturers, in a wide variety and ranges. 2.2.1 a. Range Range = win - wout b. Approach Approach = wout - wbt c. Cooling tower load in tons (tload) tload (tons) = igpm x 600 (constant) x range (in F) / 15000 (btu/hr/ton) or tload (tons) = (lpm/4.464) x 600 X range (in c) 1.8/15000 (btu/hr/ton) Hence, the final formula for calculating the cooling tower load would be tload (tons)= 1pm x 0.016129 x range This, cooling tower load (in tons) would be calculated, For example, if the values are as follows Win-38c Wout - 32 c WBT = 28.2 c
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 Flow rate = 6700 IPm Then, range = 6 c Approach =3.7 c The cooling tower load (tload) is calculated as: Toad (tons) = 1pm x 0.016129 x range Or tload (tons) = 6700 x 0.016129 x 6.0 tload (tons) = 648.38 Corrected cooling tower load in tons (ctload) Colt (tons) = tload x cmf x winef Where, Cmf = capacity multiplier factor, and Wincf = water inlet temperature correction factor. ( i ) capacity multiplier factor (cmf) cmf is determined by using a chart for cmf. Cmf is read for the given combination of approach, range and WBT. Up-to this stage the value of win, Wout, WBT. range, approach each is saved in c. Now the approach being a difference of two temperatures in c, is converted in F by multiplying by 9or 1.8. Now a new variable arw is created for the given combination which simply a combination of the digits of variables, approach (which is now approach x 1.8) and range and WBT rounded off to the nearest integer value.

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Now, for calculation of cmf, the approach will be now approach x 1.8, which is 6.66, Thus, finally the value of variable arw will be 7628 Where, A =7 is rounded value of approach 6.66 (rounded to nearest integer i.e.7) R=6 is the range, and W=28 is the rounded value of WBT (rounded to nearest integer i.e.28) Thus, arw =7628, will be the index which is searched in the arw column in the table cmf of MS Access database file and for that value corresponding value of cmf is read from cmf column in the same table. Value of cmf is stored. Here for arw =7628, the corresponding value of cmf would be read as 0.86 Water inlet temperature correction factor: (wincf). The win is converted in win in F by a simple formula, win = (win x 1.8)+32 Now, Wincf =1.00 for win < = 98F Wincf- 1.05 for win > 98F In the example given above the win - (38 x 1.8) +32 = 100.4 F Since, 100.4 > 98,the wincf- 1.05. The corrected cooling tower load (ctload) is calculated as: Ctload (tons) = tload x cmfx winf Ctload (tons) = 648.38 x 0.86 x 1.05 Ctload (tons) = 585.49

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Thus, the corrected cooling tower toad (ctload) is calculated and stored. 2.2.2 Once the ctload is calculated user can move on to the next form "results" to view the combination of capacity of tower and no. of towers required. No. Of cooling tower required for various capacities can be found as: No. of towers (ntower) = ctload/capacity of a cooling tower. The variable ntower is rounded off to next integer value. In the given example, the corrected cooling tower load=585.49 ton, then 585.49/100-5.85 i.e. rounded off to 6 585.49/150-3.90 i.e. rounded off to 4 585.49/200-2.93 i.e. rounded off to 3 585.49/300-1.95 i.e. rounded off to 2 585.49/400-1.46 i.e. rounded off to 2 Thus, it is quite clear that, towers of 100 tons capacity, (100 x 6) or towers of 150tons capacity, (150 x4 ) or towers of 200 tons capacity, (200 x3) or towers of300tons capacity, (300 x2) or towers of400tons capacity, (400 x2) or 2 towers of 500tons capacity, (500 x 2) are to be selected.

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In this form, the user is also advised to select towers of equal capacity only to maintain equal water flow rate through each cooling tower. From this form the user can move on to the next form named as "models". After selecting the tower capacity and the make of a cooling tower in the form models, depending on the choice of the user for the make, the user will decide the next form "cooling tower specifications". 2.3.1 B) If F Fahrenheit is selected following will be the process sequence Water inlet temperature; (win in F) Water outlet temperature; (win in F) Wet bulb temperature of air, (WBT in F) Water flow rate, (flow rate in 1 pm) Now, calculates the various output valuesa. range range = win - wout b. approach approach = wout - WBT c. Cooling tower load in tons (tload) tload (tons) = igpm x 600(constant) x range (in F)/15000 (btu/hr/ton) or tload (tons) = {(lpm/4.464) x 600 x range (in F) x 1.8 /15000 (btu/hr/ton)}/1.8

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Where, range is calculated as shown above. Hence, the final formula for calculating the cooling tower load would be, Tload (tons) = (1pm x 0.016129 x range) / 1.8 Where, range is in F Thus, cooling tower load (in tons) would be calculatedFor example, if the values are as follows: Win Wout WBT Flow rate = = = = 100.4F 89.6 F 82.9 F 6700 1pm

Then, range = 10.8 F Approach = 6.7F The cooling tower load (tload) is calculated as: tload (tons) - {1pm x 0.016129 x range }/1.8 Or tload (tons) = {6700 x 0.016129 x 10.8 }/1.8 tload (tons)-648.38 d. Corrected cooling tower load in tons (ctload): Ctload (tons) - ttoad x cmfx wincf Where, Cmf= capacity multiplier factor, and Wincf - water inlet temperature correction factor. (iii) capacity multiplier factor (cmf): The procedure for determination of cmf is same as that explained in section A Up-to this stage the value of win, wout, WBT, range, approach each is saved in F. Now a new variable arw is created for the given

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combination which simply a combination of the digits of variables, approach and range (c) rounded off to the nearest integer value. Now, for calculation of cmf, the range in F is convened in c by simply dividing by 1.8 whereas wbt in F is converted in c with a simple formula, WBT 0c = (wbt 0F-32)1.8 In the given example, Range c = 10.8/1.8= 6 c and, WBTc = (82.9-32)/1.8=28.270c Thus, finally the value of variable arw will be 7628 Where, a=7 is rounded value of approach 6.7 (rounded to nearest integer i.e.7) R = 6 is the range, and W - 28 is the rounded value ofwbt (rounded to nearest integer i.e-28) Thus, arw = 7628, will be the index which is searched in the arw column in the table cmf of Ms Access database file and for that value corresponding value of cmf is read from cmf column in the same table. Value of cmf is stored. Here for arw = 7628, the corresponding value of cmf would be read as 0.86 (iv) Water inter temperature correction factor (wincf): win is already in F Wince - 1.00 for win, < = 98 F wincf- 1.05 for win > 98 F In the example given above, the win = 100.4 FS

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Since, 100.4 > 98, the wincf = 1.05. The corrected cooling tower load (ctload) is calculated as: Colt (tons) = tload x cmfx wincf Ctload (tons) - 648.38 x 0.86 x 1.05 Ctload (tons) = 585

41

CHAPTER 3 ANALYSIS OF COOLING TOWER

42

CHAPTER NO 3. ANALYSIS OF A COOLTNG TOWER

3.1 Calculation of NTU: The input required for the calculation of NTU for a cooling tower is as follows Water inlet temperature (win in c) Water outlet temperature (wout in c) Dry bulb temperature of air (DBT in c) Wet bulb temperature of air (WBT in c) Water flow rate (flow rate in 1pm) No- of towers (ntower) The procedure for calculating NTU is explained under section 1,7 3.1.1 The procedure for calculating the L / G ratio is as follows: The liquid i.e. water flowing through the each tower (1pm) = flow rate / ntower Air flowing through each tower (kg / mm) =101325 x Volume flow rate of air (cu. m) / (287 x (dbt + 273)) Where, 101325 are atmospheric pressure in Pa and the value of volume flow rate of air is read from the database for the cooling tower selected Thus finally the L / G ratio = water flow rate through each tower / air flow rate through each tower.

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3.1.2 Now once the L / G ratio is found, the logic for calculation of NTU for that particular tower is as follows: a) The complete tower volume is broken in no. of incremental volumes, No. of such incremental volumes (Nov) = range x 2, Where, range = win - wout. Thus, the drop in temperature of water would be 0.5 c in each Incremental volume as the water drops down in the tower. b) The value of NTU is set to zero. c) I = 1 to Nov d) The input for WBT is rounded off to nearest integer value and the value of enthalpy of air (hair) is read for that temperature from the database and stored. e) Now, value of film enthalpy (hwoutc) is read from the database for the temperature wout. A new variable haircm is calculated as, haircm = hwoutc - hair f) Then, NTU = NTU + (4.187 x 0.5) g) Again, hair - hair + (L /G ratio x 4.187 x 0.5) h) Wout = wout +0.5 i) I is incremented by 1 and go to step (d) Thus at the end of this loop we will get the value of NTU which is a measure of the difficulty of the cooling task for that particular cooling tower, higher the NTU, easier is the cooling task. 3.2 From, here we can move to the next form named as "analysis of a cooling tower" in which we can predict the water outlet temperature if the

44

inlet parameters like the water inlet temperature and /or wet bulb temperature of air is changed. Here the manufacturer is required to know the following parameters: New water inlet temperature (win in c) New inlet air wet bulb temperature (wbtn in c) When the value of Ntu for a particular cooling tower is known and the entering air and the water flow rates and conditions are known, it is possible to predict the water outlet temperature. The procedure for making the prediction in a counter flow tower is not straight forward but requires iterative calculations, since the temperature of the leaving water is initially unknown. A temperature is assumed and trail value of NTU can be calculated. If the resulting NTU is within close limits of earlier calculated NTU, the assumed temperature can be approximated as new water outlet temperature. If not, another temperature can be assumed and the process is repeated until a fairly close approximation for new water outlet temperature is done. Initially assumes a water outlet temperature of 24 c and calculates the value of NTU. If it's very close to one calculated earlier the 24 c is the expected water outlet temperature. If not, next temperature assumed would be 24,5 c and the process is repeated until an appropriate prediction can be done.

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CHAPTER 4 DESIGN AND FABRICATION OF MODEL OF A COOLING TOWER

46

CAPTERNO. 4 DESIGN AND FABRICATION OF A COOLING TOWER:

4.1 INTRODUCTION: The group members and the guidance of the project guide did design and manufacture of cooling tower in the college workshop. 4.2 DESIGN OF A COOLING TOWER MODEL: The design has been taken from the Terry's Chemical Engineer's Handbook', sixth edition, S Domkundwar. The design parameters were selected by us are the same as that selected by most of the professional cooling tower manufacturers. The parameters are as follows, Water inlet temperature = 38C (100.4F) Water outlet temperature = 33C (91.4F) Air inlet temperature = 288C (82.4F) Water flow rate 181pm =3.85gpm Calculation of cooling tower cross - section area: Now as per the handbook mentioned above from the fig-4.1 for the corresponding inlet and outlet temperatures, WBT of air selection and the water flow rate the water concentration is found to be 5.0gal/mm/sq. ft. Thus empirically, The floor area required for the tower (sq. ft.) = 1pm / water concentration = 18/5.0 Thus the cooling tower basin area = 3.60 (sq. ft.)
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= 3.60 X 0.0929 sq.m = 0.3344sq.m = 334440sq.m Finally, we selected the c/s area of cooling tower as 600mm X 600mm. Calculation of horse power of fan motor: From the monograph in the handbook, as in fig. 4.2, Selecting the percentage of tower standard performance as 90, the hp/sq. ft. of tower are == 0.02 Thus, total fan hp required = 0.02 X 3.60 = 0.072 hp = 0.53kW = 53 Warts Finally, we selected 45 warts fan motor and exhaust fan with 6 blades. We selected 50 watts centrifugal pump for pumping the water from the tank of heated water to the cooling tower with rated discharge of 2401ph (41pm) and 15m head. Though the rated discharge in the less than required, the head is very less for pumping the water and thus the above pump was selected, A 2kW-resi stance heater was selected to heat the water for the test. Thus design procedure is completed for the cooling tower model. 4.3 FABRICATION OF THJE COOLING TOWER MODEL: A general arrangement of the cooling tower set-up is shown in fig.4.3 The procedure for the fabrication is as follows, Selection of the material required for the fabrication. Making a skeleton structure.
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49

50

51

 Making basin required storing water. Fixing of side plates For the air inlet, net is provided for the better flow. Arrangement for the water distribution system. Arrangement is made for fixing the fan on the top of the cooling tower. 4.3.1 SELECTION OF MATERIAL: SR.NO. MATERIAL 1 MS-ANGLE ISA 3535 2 3 4 5 6 7 8 MS-ANGLE ISA 2525 MS-ANGLE ISA 5050 MS-SHEET (BASIN) MS-SHEET (SIDE PLATE) MS-PLATE MS-PLATE MS-PLATE SIZE (MM) 35 X 35 X 1200 25 X 25 X 600 50 X 50 X 600 800 X 800 600 X 890 20 X 580 X 6 20 X 600 X 6 600 X 160 QUANTITY 4 8 2 1 4 8 2 4

Table No. 4.1: Bill Of Material For the given Model 4.3.2. MAKING SKELETAN STRUCTURE: The first phase of the fabrication is to make a skeleton structure. The skeleton structure was made by taking four ms-angles ISA3535. These angles were welded together by using MS-angle 1SA2525 and MS-angle ISA5050.To check for any distortion while fabrication dimensions are checked diagonally.

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4.3.3 MAKING BASIN REQUIRED BE TO STORE WATER: Ms sheet of size 800 x 800 x 14 gauge thickness was taken; layout was drawn on the sheet for the bending purpose. After this notches were cut from the sheet as per the requirement. Holes were drilled before bending for water outlet. Bending of the sheet was done by hammering along the edges of the sheet with the help of the mallet. The sheets were properly bent from all the sides to get the shape of the basin 4.3.4 Fixing of side plats on the sides of cooling tower: After the skeleton was made and after fixing the basin at the bottom part of the tower the next step was to fix the side plates. Three side plates of MS sheet of size 560 X 775 X 14 gauge each were cut. These sheets were then fixed on the three sides of the cooling tower. Hole for the inlet of water was drilled of size 20mm on one sheet at a suitable height from bottom. Arrangements were made on side to fix the acrylic sheet of size 560 x 775 x 3mm. 4.3.5 Net for the inlet of the air. For the better heat transfer there should be better heat transfer between the air and the water, for this reason the net is provided at the bottom of the tower. The net is cut in proper dimension and fixed to the plate and the plate is welded to the structure. 4.3.6 Arrangements for water distribution system This is the main portion of the cooling tower whereby it provides a heat transfer between water and air. This system consists of inlet water system and outlet water system. The inlet water system consists of piping arrangement with spraying system water, which is collected in the basin is

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taken our from the outlet piping arrangement provided at the bottom of the basin. The inlet water is pumped in to the cooling tower with the help of pump. PVC and flexible pipes of suitable size are used. 4.3.7 Arrangement for fixing the fan on the top of the cooling towers. Induced draft fan is mounted on the top of the cooling tower, which is bolted on plywood, and remaining area is covered with plywood. This is done by drilling hole of the same diameter as that of the fans outer body.

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TIME CALCULATIONS:
OPERATION MACHINE Angle cutting Drilling on angle Welding Cutting G.I. Sheet Making the Bending m/c basin Nut bolting on sheet & angle Air net cutting & welding Cutting Cutting m/c plywood Pipe threading on nozzle arrangement Arranging bottle plates & nozzles Fixing fan & connecting circuit Fixing of pipe Time for sets Arasel Painting Assembly of pump with cooling tower Saw m/c TOOLS Hacksaw blade SHOP Fabrication .. .. .. .. Spanner Electrode Blade .. .. Wood Working .. OPERATION TIME 2 hrs 1 hr 1 hr 2 hrs hr 1 hr hr hr 2 hrs

Drilling m/c Drill (M10) Electrode Scissors

..

hr

.. .. .. .. ..

hr hr 4 hrs 4 hrs 2 hrs

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MATERIAL COST:
Material Size : Quantity Rate Weight Cost : M.S. angle 1) 50 x 50 x 60 : 2 : Rs. 36 / kg : 2 kg : Rs. 72 ...............(i)

2) 35 x 35 x 1200 Quantity Rate Weight Cost : 4 : Rs. 36 / kg : 16 kg : Rs.576...........(ii)

3) 20 x 20 x 60 Quantity Rate Weight Cost : 8 : Rs. 36/kg : 6 kg : Rs.216 (iii)

Material Size Quantity Rate

: M.S. plate : 20 x 60 : 2 : Rs. 20 / kg

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Weight Cost

: 1 kg : Rs.20 .......... (iv)

Material Size Quantity Rate Cost

: Air Net : 600 x 160 (1.07 sq. ft.) : 4 : Rs. 25 / sq. ft. : Rs.100 . (v)

Material Size Rate Cost

: G. I. Sheet : l) 800 x 800 (7.11sq.ft.) : Rs.10 / sq.Pt : Rs 72 .. (vi)

2) 600 x 890 (7.71sq.ft) Quantity Cost : : 1 RS. 78 .......................(vii)

PART NAME PVC fills PVC pipe Flexible pipe Nozzle Pipe joints Pump

QTY. 6 10 feet 3 meter 6 1

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COST (Rs.) 1500 70 30 50 220 1000

Exhaust fan Heater Water tank

1 1 1

550 250 200 3870....... (viii)

Total cost = (i) + (ii) + (iii) + (iv) + (v) + (vi) + (vii) + (viii) = 72 + 576 + 216 + 20 + 100 + 72 + 78 + 3870 Total cost = Rs 5004 Total material cost is Rs. 5004

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CHAPTER 5 RESULTS AND DISCUSSION

59

CHAPTER NO. 5 RESULTS AND DISCUSSION:

INTRODUCTION: The cooling tower model thus fabricated was tested for the design conditions, and then for the condition off-design to check the performance at varied conditions.

OBSERVATIONS: Five trials were conducted on the cooling tower at following parameters and the observations are tabulated as follows: SR. NO Water inlet temp. Win c Water Outlet temp. Wout c DBT of air c WBT of air c Flow rate of water Lpm

Table No. 5.1 Observation Table For The Trials Conducted On Model

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RESULTS: The Results are as follows: SR. NO Water inlet temp. Win c Water Outlet temp. Wout c WBT of air c Range 0 c Approach Efficiency 0 c %

Table No. 5.2 Table showing the Results of the Trials Conducted On Model

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DISCUSSION OF RESULTS: The results found by the trial are tabulated as above. During the trial the DBT and WBT of the atmospheric air was found to be constant The flow-rate of water was also found to be constant. The From the results it is clear that The tower works satisfactorily at the design conditions As the inlet water temperature increases, the range increases, and so does the efficiency. This is because efficiency - range / (range + approach). Since the WBT of air and outlet temp is almost constant the approach also remains more or less constant. But the range goes on increasing, and thus the efficiency also increases. If the same water is circulated through the cooling tower without supplying any external heat i.e. using heater, then the temperature of the water drops down continuously and approaches WBT of atmospheric air.

62

CHAPTER 6 CONCULSION

63

CHAPTER 6 CONCLUSION
The results of the trial conducted on the fabrication model (Table 5.1 & 5.2) are found as per the design calculation approximately. As the inlet temperature increases the range increases and so does the efficiency.

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CHAPTER 7 REFERENCES

65

CHAPTER 7 REFERENCE
1. 2. Robert Perry, Perrys Chemical Engineers Handbook. S. Domkundwar and C.P. Kothandraman, Thermal Engineering, Dhanpatrai Publications. 3. 4. W.F. Stoeker, Refrigeration and Air Conditioning. Cooling towers manual, United Cooling Towers (Mr. Shetty).

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