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Cooling towers are a very important part of many chemical plants. The primary task of a
cooling tower is to reject heat into the atmosphere. They represent a relatively inexpensive
and dependable means of removing low-grade heat from cooling water. The make-up water
source is used to replenish water lost to evaporation. Hot water from heat exchangers is sent
to the cooling tower. The water exits the cooling tower and is sent back to the exchangers or
to other units for further cooling. Cooling towers are able to lower the water temperatures
more than devices that use only air to reject heat, like the radiator in a car, and are therefore
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2. TYPES OF COOLING TOWER:
rises), fresh cool air is drawn into the tower 2.1 Natural draft cooling tower
through an air inlet at the bottom. Due to the layout of the tower, no fan is required and there
is almost no circulation of hot air that could affect the performance. Concrete is used for the
tower shell with a height of up to 200 m. These cooling towers are mostly only for large heat
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2.2 Mechanical Draft Cooling Tower
Mechanical draft towers have large fans to force or draw air through circulated water. The
water falls downwards over fill surfaces, which help increase the contact time between the
water and the air - this helps maximize heat transfer between the two. Cooling rates of
mechanical draft towers depend upon various parameters such as fan diameter and speed of
operation, fills for system resistance etc. Mechanical draft uses power-driven fan motors to
force or draw air through the tower. Mechanical draught cooling tower are divided into two
A mechanical draft tower with a fan at the discharge (at the top) which pulls air up through
the tower. The fan induces hot moist air out the discharge. This produces low entering and
high exiting air velocities, reducing the possibility of recirculation in which discharged air
flows back into the air intake. This fan/fin arrangement is also known as draw-through.
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2.2.1.1. Cross Flow Tower: Cross flow is a design in which the air flow is directed
perpendicular to the water flow (see diagram at left). Air flow enters one or more vertical
faces of the cooling tower to meet the fill material. Water flows (perpendicular to the air)
through the fill by gravity. The air continues through the fill and thus past the water flow into
an open plenum volume. Lastly, a fan forces the air out into the atmosphere.
Advantages:
Gravity water distribution allows smaller pumps and maintenance while in use.
Non-pressurized spray simplifies variable flow.
Disadvantages :
sandy areas.
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2.2.1.2. Counter Flow Tower: In a counter flow design, the air flow is directly opposite to
the water flow (see diagram at left). Air flow first enters an open area beneath the fill media,
and is then drawn up vertically. The water is sprayed through pressurized nozzles near the top
of the tower, and then flows downward through the fill, opposite to the air flow.
Advantages:
Disadvantages:
Typically higher initial and long-term cost, primarily due to pump requirements.
Difficult to use variable water flow, as spray characteristics may be negatively
affected.
Typically noisier, due to the greater water fall height from the bottom of the fill into
the cold water basin
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2.2.2. FORCED DRAFT COOLING TOWER:
A mechanical draft cooling tower especially consists of a blower type fan at the intake end.
The fan forces air into the tower, creating high entering and low exiting air velocities. The
low exiting velocity is much more susceptible to recirculation. With the fan on the air intake,
the fan is more susceptible to complications due to freezing conditions. Another disadvantage
is that a forced draft design typically requires more motor horsepower than an equivalent
induced draft design. The benefit of the forced draft design is its ability to work with high
static pressure. Such setups can be installed in more-confined spaces and even in some indoor
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3. COMPONENTS OF COOLING TOWER:
The basic components of a cooling tower include the frame and casing, heater, cold-water
basin, submersible pump, drift eliminators, digital temperature detector, air inlet, nozzles and
a) Frame : Frame structure of the cooling tower was made by the thin sheet metal. C shaped
b) Nozzles : To spray the water on the frame, copper pipes with nozzle are used. Nozzles are
placed in such a location that water can flow in all the direction.
d) Fans : A induced draught fan was used on the top of the tower to create draught inside the
cooling tower.
e) Digital Temperature Detector: Two digital temperature detector were used to measure the
hot water temperature and the temperature of the cooling pond water.
f) Heater: A heater coil was used to supply the hot water to the nozzle.
g) Submersible Pump: Submersible pump was placed inside the cooling pond to supply
water to the heater. It can also be use to drain water from the cooling pond.
h) Float Valve : Float valve was placed at the water inlet point. Its function is to check the
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4. TECHNICAL SPECIFICATION OFABRICATED SETUP:
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5. PERFORMANCE ANALYSIS PARAMETERS:
To determine the cooling tower performance, there are several number of parameters are
used.
a) Range : This is the difference between the cooling tower water inlet and outlet
temperature. A high CT Range means that the cooling tower has been able to reduce the water
b) Approach : This is the difference between the cooling tower outlet coldwater
temperature and ambient wet bulb temperature. The lower the approach the better the cooling
tower performance; although, both range and approach should be monitored, the `Approach
c) Effectiveness : This is the ratio between the range and the ideal range (in percentage), i.e.
difference between cooling water inlet temperature and ambient wet bulb temperature, or in
other words it is = Range / (Range + Approach). The higher this ratio, the higher the cooling
tower effectiveness.
d) Cooling capacity : This is the heat rejected in kCal/hr or TR, given as product of mass
e) Evaporation loss : This is the water quantity evaporated for cooling duty. Theoretically
the evaporation quantity works out to 1.8 m3 for every 1,000,000 kCal heat rejected. The
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f) Cycles of concentration (C.O.C) : This is the ratio of dissolved solids in circulating water
g) Blow down : Blow down losses depend upon cycles of concentration and the evaporation
h) Liquid/Gas (L/G) ratio : The L/G ratio of a cooling tower is the ratio between the water
and the air mass flow rates. Cooling towers have certain design values, but seasonal
variations require adjustment and tuning of water and air flow rates to get the best cooling
tower effectiveness. Adjustments can be made by water box loading changes or blade angle
adjustments. Thermodynamic rules also dictate that the heat removed from the water must be
equal to the heat absorbed by the surrounding air. Therefore the following formulae can be
used:
Where:
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6. FACTORS AFFECTING PERFORMANCE:
Capacity
Heat dissipation (in kCal/hour) and circulated flow rate (m3/hr) are not sufficient to
understand cooling tower performance. Other factors, which we will see, must be stated along
with flow rate m3/hr. For example, a cooling tower sized to cool 4540 m3/hr through a 13.9C
range might be larger than a cooling tower to cool 4540 m3/hr through 19.5C range.
Range
Range is determined not by the cooling tower, but by the process it is serving. The range at
the exchanger is determined entirely by the heat load and the water circulation rate through
Thus, Range is a function of the heat load and the flow circulated through the system.
Cooling towers are usually specified to cool a certain flow rate from one temperature to
another temperature at a certain wet bulb temperature. For example, the cooling tower might
be specified to cool 48000 m3/hr from 44C to 34C at 26.7C wet bulb temperature.
As a generalization, the closer the approach to the wet bulb, the more expensive the cooling
tower due to increased size. Usually a 2.8C approach to the design wet bulb is the coldest
water temperature that cooling tower manufacturers will guarantee. If flow rate, range,
approach and wet bulb had to be ranked in the order of their importance in sizing a tower,
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approach would be first with flow rate closely following the range and wet bulb would be of
lesser importance.
The range increases when the quantity of circulated water and heat load increase. This means
that increasing the range as a result of added heat load requires a larger tower. There are two
The inlet water temperature is increased (and the cold-water temperature at the exit remains
the same). In this case it is economical to invest in removing the additional heat. The exit
water temperature is decreased (and the hot water temperature at the inlet remains the same).
In this case the tower size would have to be increased considerably because the approach is
Heat Load
The heat load imposed on a cooling tower is determined by the process being served. The
degree of cooling required is controlled by the desired operating temperature level of the
process. In most cases, a low operating temperature is desirable to increase process efficiency
or to improve the quality or quantity of the product. In some applications (e.g. internal
combustion engines), however, high operating temperatures are desirable. The size and cost
of the cooling tower is proportional to the heat load. If heat load calculations are low
undersized equipment will be purchased. If the calculated load is high, oversize and more
costly, equipment will result. Process heat loads may vary considerably depending upon the
process involved. Determination of accurate process heat loads can become very complex but
proper consideration can produce satisfactory results. On the other hand, air conditioning and
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Tower Size
If heat load, range, approach and wet-bulb temperature are held constant, changing the fourth
a) Tower size varies inversely with approach. A longer approach requires a smaller tower.
the effect upon tower size begins to become asymptotic. For that reason, it is not customary
in the cooling tower industry to guarantee any approach of less than 5F.
In a cooling tower, hot water is distributed above fill media and is cooled down through
evaporation as it flows down the tower and gets in contact with air. The fill media impacts
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*Electricity is used for pumping above the fill and for fans that create the air draft. An
efficiently designed fill media with appropriate water distribution, drift eliminator, fan,
* Heat exchange between air and water is influenced by surface area of heat exchange,
intermixing. The fill media determines all of these and therefore influences the heat
exchange. The greater the heat exchange, the more effective the cooling tower becomes.
a) Splash fill media. Splash fill media generates the required heat exchange area by splashing
water over the fill media into smaller water droplets. The surface area of the water droplets is
b) Film fill media : In a film fill, water forms a thin film on either side of fill sheets. The
surface area of the fill sheets is the area for heat exchange with the surrounding air. Film fill
can result in significant electricity savings due to fewer air and pumping head requirements.
c) Low-clog film fills : Low-clog film fills with higher flute sizes were recently developed to
handle high turbid waters. Low clog film fills are considered as the best choice for sea water
in terms of power savings and performance compared to conventional splash type fills.
Optimize cooling water treatment : Cooling water treatment (e.g. to control suspended
solids, algae growth) is mandatory for any cooling tower independent of what fill media is
used. With increasing costs of water, efforts to increase Cycles of Concentration (COC), by
cooling water treatment would help to reduce make up water requirements significantly. In
large industries and power plants improving the COC is often considered a key area for water
conservation.
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Install drift eliminators : It is very difficult to ignore drift problems in cooling towers.
Nowadays most of the end user specifications assume a 0.02% drift loss. But thanks to
technological developments and the production of PVC, manufacturers have improved drift
eliminator designs. As a result drift losses can now be as low as 0.003 0.001%.
Fans : The purpose of a cooling tower fan is to move a specified quantity of air through the
system. The fan has to overcome the system resistance, which is defined as the pressure loss,
to move the air. The fan output or work done by the fan is the product of air flow and the
pressure loss. The fan output and kW input determines the fan efficiency.
The fan efficiency in turn is greatly dependent on the profile of the blade. Blades include:
Metallic blades, which are manufactured by extrusion or casting processes and therefore it
is difficult to produce ideal aerodynamic profiles Fibre reinforced plastic (FRP) blades, are
normally hand moulded which makes it easier to produce an optimum aerodynamic profile
tailored to specific duty conditions. Because FRP fans are light, they need a low starting
torque requiring a lower HP motor, the lives of the gear box, motor and bearing is increased,
A 85-92% efficiency can be achieved with blades with an aerodynamic profile, optimum
twist, taper and a high coefficient of lift to coefficient of drop ratio. However, this efficiency
is drastically affected by factors such as tip clearance, obstacles to airflow and inlet shape,
etc. Cases reported where metallic or glass fibber reinforced plastic fan blades have been
replaced by efficient hollow FRP blades. The resulting fan energy savings were in the order
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7. COOLING WATER CHEMISTRY :
Cooling towers are dynamic systems because of the nature of their operation and the
environment they function within. Tower systems sit outside, open to the elements, which
makes them susceptible to dirt and debris carried by the wind. Their structure is also popular
for birds and bugs to live in or around, because of the warm, wet environment. These factors
present a wide range of operational concerns that must be understood and managed to ensure
optimal thermal performance and asset reliability. Below is a brief discussion on the four
primary cooling system treatment concerns encountered in most open re-circulating cooling
systems.
of the system metallurgy. Figure illustrates the nature of a corrosion cell that may be
encountered throughout the cooling system metallurgy. Metal is lost at the anode and
deposited at the cathode. The process is enhanced by elevated dissolved mineral content in
the water and the presence of oxygen, both of which are typical of most cooling tower
systems.
There are different types of corrosion encountered in cooling tower systems including pitting,
pervasive enough, can result in failed heat exchangers, piping, or portions of the cooling
tower itself.
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7.1. COROSION CONTROL METHOD:
1. Cathodic Polarization
Process of changing the anodic or cathodic potential or both to reduce the driving force of the
corrosion reaction is called polarization. Polarization reduces the driving force of the
corrosion reaction and minimizes metal loss by changing the potential of either the anode or
the cathode or both so that the difference in potential between them is reduced to a minimum.
If the amount of oxygen diffusion to the metal surface can be controlled, the corrosion
reaction can be polarized. This is achieved by cathodic corrosion inhibitors. They form a film,
2 Anodic Polarization
Anodic surfaces can be polarized by formation of an oxide layer. This film formation is
films. This unfortunately is not always the case with all metals. Most metals must be aided by
3. Passivation
When corrosion reactions are completely polarized, the metal is said to be at passive state
At this point there is no difference in potential between the anode and cathode areas, and
corrosion ceases. When polarization is disrupted in a passive metal at a given point, a very
active anodic site is set up, with resultant accelerated local corrosion, particularly if the metal
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Corrosion Inhibitors
chemical corrosion inhibitors. Their function in preventing corrosion lies in their ability to
insulate the electric current between the cathode and anode. If the insulation effect occurs at
the anodic site, then the inhibitor is classified as an anodic inhibitor and if the cathodic site is
Corrosion inhibitors are classified as anodic, cathodic or both depending upon the corrosion
reaction each controls. Inhibition usually results from one or more of three general
mechanisms. In the first, the inhibitor molecule is adsorbed on the metal surface by the
process of chemisorption, forming a thin protective film either by itself or in conjunction with
metallic ions. In second mechanism inhibitors however merely cause a metal to form its own
protective film of metal oxides, by increasing its resistance. In the third type inhibitor reacts
Anodic inhibitors build a thin protective film along the anode increasing the potential at the
anode and slowing the corrosion reaction, the film is initiated at the anode although it may
eventually cover the entire metal surface. Because this film is not visible to the naked eye so
Cathodic inhibitors are generally less effective than the anodic type. But they often form a
visible film along the cathode surface, which polarizes the metal by restricting the access of
dissolved oxygen to the metal substrate. The film also acts to block hydrogen evolution sites
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Examples include:
Chromates
Orthophosphates
Zinc
Polyphosphates
zinc-chromates
chromate-polyphosphates
chromate-orthophosphate
7.2. SCALING:
Scaling is the precipitation of dissolved minerals components that have become saturated in
solution. Factors that contribute to scaling tendencies include water quality, pH, and
temperature. Scale formation reduces the heat exchange ability of the system because of the
insulating properties of scale, making the entire system work harder to meet the cooling
demand. Deposits typically consist of mineral scales (i.e.CaCO 3. CaSO4 CaF2, etc), corrosion
products (i.e. Fe2O3, Fe3O4, CuO etc), particular matter (i.e. clay, slit), and
microbiological mass.
formation)
Side stream filtration (Side stream filters are used in some cooling tower applications,
with 1 to 5 % of the cooling water flow passing through the filter. Several type of
media are used but sand is the most common, operating at a 10 % to 20 % efficiency
level. For greater efficiency, anthracite or mixed media can be substituted. If the
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suspended solids are in the range of 10 to 30 ppm, 50~75 % removal can be achieved,
and in highly turbid waters, 90 % removal is possible. In general a side stream filter
allows cooling water turbidity to approach the turbidity of the filter effluent. With oil
contamination side stream filters are impractical because of rapid fouling of the filter
medium.
building blocks. These units are referred to as monomers. Modern technology has made it
possible to build chains of various lengths and compositions by varying the polymerization
conditions and the monomer groups incorporated into the structure. The behaviour of a
polymer results primarily from two factors: its chain length or molecular weight and its
functional group.
These polymeric deposit control agents include, Scale inhibitors, Dispersants, Flocculants
Almost all well-managed cooling towers use a water treatment program. The goal of a water
treatment program is to maintain a clean heat transfer surface and preserve capital while
minimizing water consumption and meeting discharge limits. Critical water chemistry
parameters that require review and control include pH, alkalinity, conductivity, hardness,
microbial growth, biocide and corrosion inhibitor levels. Depending on the quality of the
make-up water, treatment programs may include corrosion and scaling inhibitors, such as
organo-phosphate types, along with biological fouling inhibitors. Historically, chemicals have
been fed into the system by automatic feeders on timers or actuated by conductivity meters.
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demand. This ensures results and can allow cycles to be increased. Where overfeed is
prevalent, it can reduce chemical feed, too. Water treatment is required in cooling towers to
prevent corrosion of the system, build up of scale and for microbiological control. Typically
The following could be fruitful options to improve energy efficiency of cooling towers:
ii. Optimize cooling tower fan blade angle on a seasonal and/or load basis
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iii. Correct excessive and/or uneven fan blade tip clearance and poor fan balance
iv. In old counter-flow cooling towers, replace old spray type nozzles with new square spray
ix. Cover hot water basins to minimize algae growth that contributes to fouling
x. Optimize the blow down flow rate, taking into account the cycles of concentration (COC)
limit
xi. Replace slat type drift eliminators with low-pressure drop, self extinguishing PVC
cellular units
xiii. Keep the cooling water temperature to a minimum level by (a) segregating high heat
loads like furnaces, air compressors, DG sets and (b) isolating cooling towers from sensitive
applications like A/C plants, condensers of captive power plant etc. Note: A 1Ccooling water
2.7%. A 10C drop in cooling water temperature can give a heat rate saving of 5 kCal/kWh in a
xiv. Monitor approach, effectiveness and cooling capacity to continuously optimize the
cooling tower performance, but consider seasonal variations and side variations
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xv. Monitor liquid to gas ratio and cooling water flow rates and amend these depending on
the design values and seasonal variations. For example: increase water loads during summer
and times when approach is high and increase air flow during monsoon times and when
approach is low.
xvii. Consider energy efficient fibre reinforced plastic blade adoption for fan energy savings
xviii. Control cooling tower fans based on exit water temperatures especially in small units
9. CONCLUSION:
After operating the cooling tower in Natural Draft Mode and Induced Draft Mode, it was
found that the temperature of the cooling pond decreases more rapidly when the cooling
tower is operated in Induced Draft mode than than the Natural Draft Mode. It is because,
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when the induced draft fan is switched ON at that time the induced fan creates a pressure
decrease inside the cooling tower so more air from the atmosphere enter into the cooling
tower from all the four end, so the water air surface area increase, and the air takes the heat of
It was also concluded that, the performance of the natural draft cooling tower varies
according to the seasonal changes like the summer and winter. But the induced draft cooling
So it is better to use induced draft cooing tower in plant than the natural draft cooling
tower.
9. REFERENCES :
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3. Daeil Aqua Co., Ltd. (2004, May 10). Cooling Tower Thermal Design Manual.
http://myhome.hanafos.com/~criok/english/publication/thermal/thermallisteng.html
4. Federal Energy Management Program. (2011). NASA Marshal Space Flight Center
Energy.
5. General Services Administration. (2011). Water Management: A Comprehensive
Approach for Facility Managers. In Water Management Guide (pp. 1-140). Kansas
City.
6. Ken Mortensen. (2003, May). How to Manage Cooling Tower Water Quality. RSE
Department of Energy.
10. Ray Congdon, Rand Conger, Mike Groh, Roger van Gelder. (2011). Cooling Tower
Efficiency Manual. In R. C. Ray Congdon, Cool Tunes (pp. 1-26). Washington DC:
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