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Analysis
A Novel
Integrated Approach
Ilayaraja Palani
Aditya Birla Mgmt Corp Pvt Ltd
System Description
Design
Operating
Plant Load
- 65%
CT Thermal Load - 55 %
Supply Temp
- 34.7 C
Return Temp
- 38.2 C
VFD inline for CT fans
No flow meter
Problem Statement
For Cooling tower less than 2 years old , Supply temperature remains high at around 35
C. Approach of ~ 8 C.
Limits Production ramp up plan.
Plant tried to improve the performance of cooling tower with the CT supplier.
Actions like increasing Blade angle did not yield results.
To augment increase in production, unit decided to invest in additional cell and pumps.
Additional Cell requires Capex of around 1 Cr and increase in load ~ 150 KW
Can we fix it ?
L/G
Fills
CT
Performance
CW
Network
Water
Quality
Enthalpy Driving
Force
Enthalpy
Operating Line
L/G is slope. Hot and
cold water temp (T2 and
T1) is the terminal points
L/G>1.66
L/G=1.66
L/G<1.66
T1
T3
T2
Water Temperature
29
L/G ratio
1.2
Water in temp
41
UOM
Design
Operatin
g
m3/hr
2000
2600
Inlet Temperature
41
38.2
Outlet Temperature
33
34.7
Range
3.5
Approach
8.7
1.6
29
26
L/G
Cooling Break Up
Source: CTI TP88-07
`KaV/L
Spray Zone-6%
Fill Zone-86%
Rain Zone-8%
Munters 12060
Design:
Heat Load: 16 Gcal/hr
Flow: 2000 m3/hr
CWS: 33 C
CWR: 41 C
Cooling Tower
HCL Furnace
CCU HE
Process Building
P-1
P-2
Rectifier
CL2 Liquefaction
Intercoolers
(Air Compressors)
HE 1
HE 2
T
HE 3
T2
Parallel Arrangement
HE 1
T1
HE 2
HE 3
Series/Parallel Arrangement
Revised CW
Return Temp.
Composite Curve
CW Supply Line
44
42.70
42
39.48
40
36.70
38
36
35.00
34
33.00
32
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
Qcas (kW)
Parameters
Total Heat Load
Cooling Water Supply Temperature
Cooling Water Return Temperature
Cooling Water Flow rate
Potential Reduction in CW Flow Rate
Existing
16
33.0
39.5
2430
Proposed
16
33.0
41.0
1960
470
Units
Gcal/h
C
C
m3/hr
m3/hr
Cooling Tower
33C
891 m3/hr
HCL Furnace
CCU HE
417 m3/hr
471 m3/hr
Process Building
P-1
461 m3/hr
153 m3/hr
CWS = 33 C
P-2
Rectifier
CL2 Liquefaction
35 m3/hr
Intercoolers
(Air Compressor)
CWR 41 deg C
CWR = 40 C
34.5 C
891 m3/hr
Cooling Tower
HCL Furnace
CCU HE
417 m3/hr
420 m3/hr
471 m3/hr
Process Building
P-1
461 m3/hr
153 m3/hr
CWS = 33 C
P-2
Rectifier
CL2 Liquefaction
35 m3/hr
Summary
Thank You.