PRESENTATION ON THE TYPES OF COOLING TOWERS

AND THEIR PARTS

• NAME: SATYAKAM SIKDAR

• 16UCH029/167609
• THIRD YEAR SIXTH SEMESTER
• DEPARTMENT OF CHEMICAL ENGINEERING
• SUBJECT- MASS TRANSFER OPERATIONS- II
COOLING TOWERS WERE ESSENTIALLY CREATED TO ELIMINATE EXCESS
WARMTH FROM WATER USED IN INDUSTRIAL OPERATIONS AND SEND IT
OUT INTO THE SURROUNDING BIOSPHERE. SURPRISINGLY, THERE ARE
MANY DIFFERENT TECHNIQUES FOR ACHIEVING THIS PROCESS. SINCE
THERE IS A HIGH DEGREE OF VARIATION BETWEEN HOW THESE DEVICES
OPERATE, THEY ARE CLASSIFIED WITHIN A NUMBER OF DISTINCT GROUPS.
THERE ARE THREE MAIN TYPES OF COOLING TOWERS THAT ARE DEFINED BY
HOW WATER OR AIR PASS THROUGH THEM. THESE TYPES INCLUDE:-
1) CROSSFLOW.
2) COUNTERFLOW.
3) HYPERBOLIC.
THERE ARE ALSO TWO VARIETIES CLASSIFIED SOLELY ON AIRFLOW:-
1) INDUCED DRAFT.
2) PASSIVE DRAFT.
• Crossflow cooling towers
Crossflow cooling towers use a splash fill that allows in-flowing
to air move in a horizontal path over the stream of water from the
upper reservoirs. Crossflow systems are some of the more expensive
equipment types, but they are also some of the easiest to maintain.
However, these cooling systems are more vulnerable to frost than
others.
• Counterflow cooling towers
In a counterflow system, the in-flowing air travels in a vertical
path over the splash fill as the water streams down from the
reservoir above. Counterflow systems are usually smaller than their
crossflow counterparts. These cooling towers are more expensive due
to the fact that more energy is needed to push the air upward
against the down-flowing water.
• Hyperbolic cooling towers
Hyperbolic systems are well-built and require a minimal amount of
resources. Though they require few resources, these cooling towers
are able to efficiently manage large-scale tasks within big
chemical or power plants.
Hyperbolic systems use a chimney stacking technique that allows the
cooler, outside air to push the damp, warmer air inside the tower.
Splash fill is placed around the bottom of the tower and the water
that sprays over it is cooled by the passage of upward-flowing air.
• Induced draft cooling towers
Induced draft or mechanical draft cooling towers use
some type of mechanical pressure, like a fan system, to
push air upward inside the tower. Induced draft systems
can also force air into the tower with a blow-through or
pull it out through a draw-through.

• Passive draft cooling towers

Passive or natural draft cooling towers combine the
upward motion of warmed air with a steep chimney
architecture to organically pull air throughout the
tower. Although passive draft systems may have either a
counter or crossflow transport design, hyperbolic towers
are always passive draft.
 HOW A COOLING TOWER WORKS
Warm water from industrial equipment, commercial ac system or any
other heat source enters the tower and spreads evenly at the top. As the
water flows down the tower, the equipment fill spreads it over a large area
to increase the water-air contact, thus enhancing heat transfer via
evaporation.
A large volume of air is constantly moving along the fill courtesy of large
fans in the tower. As evaporation takes place, the water loses heat. It
eventually enters the tower sump at the bottom. The cool water then goes
back to cool the initial heat source and the cycle repeats. For the sake of
system dilution, of portion of the system water goes to the drain through
a bleed-off valve. The makeup line feeds the cooling tower with fresh
water for replenishment.
These processes cannot be noted easily because their simultaneous
occurences creates a continuous loop
WORKING PRINCIPLE OF A COOLING TOWER
 THE INDUSTRIAL APPLICATION OF COOLING
TOWERS
The cooling tower system is common in many industries, chief among them being power,
commercial, HVAC and industrial. In the industrial setup, the system rejects heat from machinery,
heated process material among other sources. Specifically, industrial cooling towers are common in
food processing plants, petroleum refineries, natural gas plants and petrochemical plants.
OTHER INDUSTRIAL APPLICATIONS INCLUDE:-
• Water cooled air compressors
• Plastic Injection & Blow Moulding Machine
• Die casting machine
• Refrigeration and chilling plant
• Cold storage
• Anodizing processes plant
• Electrical power generation plant
• Water cooled air conditioning systems and VAM machines
9 ESSENTIAL PARTS AND COMPONENTS OF
COOLING TOWERS

Gearboxes
Fill media
Drift reducers
Nozzles
Fans
Driveshafts
Air intake louvers
Electric float valves
Reservoir heaters
GEARBOXES
Gearboxes are available in a number of
different reduction rates and styles to
support the variable strengths and fan
speeds of cooling towers. Cooling tower
producers typically allow clients to purchase
new gearboxes or employ skilled experts
who can restore or renew a gearbox with
original equipment manufactured (OEM)
parts. Amarillo Gear Service uses OEM and
all american manufactured parts when
restoring gearboxes.
They are of four types:-
1) A Series Single Reduction
2) A Series Double reduction
3) Single Reduction
4) Double Reduction
 FILL MEDIA
• Fill media is an essential cooling tower element. Most modern cooling towers effectively use
plastic fill media for maximum water evaporation. Water is dispersed through the fill, which
flattens out into a thin film with a large surface area. This procedure makes it possible for
excess moisture and heat to rapidly evaporate.
• The key components of selecting fill media include TSS (Total Suspended Solids) levels,
intended use, water composition, and vulnerability to contamination. The two primary kinds
of fill media are film-style, which distributes water across a flat layer, and splash-style, which
breaks up moisture. Crossflow and counterflow fill media are other types of materials
available for specialized cooling towers.
 DRIFT REDUCERS
Drift reducers are important cooling tower parts that work to eliminate water droplets
in the air and recycle the moisture for operational processes. They do this by abruptly
forcing the moist air in another direction, separating the moisture from the air and
redirecting it to another part of the cooling tower.
 NOZZLES
• Nozzles are most commonly found in crossflow cooling towers, which harness the power
of gravity to distribute water. In these kinds of systems, water is lifted up to dispersal
reservoirs above the fill media. Gravity then pulls the water through the fill media
through nozzles in the bottom of the reservoirs.
 FANS

• Fans serve the purpose of forcing or pushing air throughout a cooling tower. The
fans must be durable enough to stand up to the caustic atmosphere in which
they work. They are often pretty noisy, but there are quieter cooling tower fans
available. This equipment can be found in counterflow, crossflow, and other
mechanical draft cooling towers. Natural air flow cooling towers have no use for
fans, as they use natural drafts and water cooling techniques.
 DRIVESHAFTS

• Driveshafts are tailor-made to transfer energy from a cooling tower engine’s outflow
shaft into the intake shaft of the gear reducer. This process generates a rotating force
that turns the fan blades. Driveshafts are available in lengths spanning from two feet
in compact AC towers to more than 20 feet in heavy-duty industrial towers.
Driveshafts need to be rust-proof because of the corrosive atmospheres they
function in.
 AIR INTAKE LOUVERS
• Air intake or inlet louvers prevent the sun’s rays from penetrating the water reservoir,
which stops mold and algae from forming and reduces chemical expenses. Air intake
louvers also prevent water from splashing out of the reservoir. This benefit reduces
the amount of water and chemicals needed, while making the reservoir itself easier
to access and remove. Counterflow air intake louvers are known to develop scales if
they are not properly cleaned and taken care of. This issue restricts air circulation and
decreases the effectiveness of the entire system.
 ELECTRIC FLOAT VALVES
• Electric float valves are low-maintenance components that maintain the
functionality of your cooling tower for an extended period of time. In most cases,
you can find electric float valve kits that come with floats, arms, and valves to
accommodate a variety of different tasks.
 RESERVOIR HEATERS

• Reservoir heaters prohibit the water from freezing in a cooling

tower reservoir during winter. These components are suitable for
use with a variety of commercial cooling tower brands, including
BAC and Evapco. Carrying both CSA and UL ratings, BAC reservoir
heaters are made with tough copper heating elements that last.