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ITM GURGAON
ABSTRACT
The aim of the project is to fabricate a forced draught cooling tower, to study and perform experiments of existing induced draught cooling tower and to predict the performance of the both cooling towers by using the 1st law efficiency and 2nd law efficiency concepts. Attempts shall be made to suggest the remedial actions to improve the performance.
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TABLE OF CONTENTS
Chapter no No.
1 1.1 1.2 2 2.1 2.2 2.3 2.4 2.4.1 2.4.2 3 4
Title
Introduction Importance Applications Literature Review Components Types of cooling tower Heat and moisture Transfer Principle Performance analysis Merkels Theory The volume Transfer Coefficient Performance of Cooling Tower Reference
Page
1 1 2 3 3 5 7 9 9 11 12 15
1. INTRODUCTION
1.1 IMPORTANCE
The cooling towers are used to reduce the temperature of a water stream by extracting heat from water and emitting it to the atmosphere. Cooling towers (1) are basically an open system direct heat exchanger, where it is used to reclaim circulating water for reuse in power plant condensers, refrigerant condensers and other heat exchangers. The warm water is admitted to the top of the tower and moves counter flow to the air. Waste heat is rejected to the atmospheric air through convection and evaporation heat transfer. Without a cooling tower, it would require a large amount of water per hour and the amount of water would have to be continuously returned to the ocean, lake or river from which it was obtained. 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 more cost-effective and energy efficient.
1.2 APPLICATIONS
Cooling towers are mainly used in the areas like power plants, petroleum refineries, petrochemical plants, natural gas processing plants, food processing plants, semi conductor plants, coal fired plants, nuclear power plants, geothermal plants, carbon black plants, fertilizer plants. Some coal fired and nuclear power plants also make use of cooling towers to cool down the recirculating water. The major use for these systems is in the cooling of big buildings and industrialized processes that require a lot of heat removal. The theory behind this configuration lies in the design of thermodynamic concepts and fluid mechanics optimization. Chemicals are also aggregated to the pool in order to help maintain the performance of the pipes working in the system. There are some other applications of cooling tower which are given as: Air conditioning Plants Air refrigeration Plants
1 Process water cooling in Power Plants Air compressors Diesel Generating Machines Plastic Molding Machines Electrical Induction Machines Water Cooling of any furnace or Machines Chemical and Oil Refineries Geothermal Plants Coal fired Plants Nuclear Power Plants Fertilizer Plants Food Processing Plants Natural Gas Processing Plants Semi conductor Plants These are major applications of cooling tower in certain industries.
2. LITERATURE REVIEW
The cooling tower may be shown as:
2.2.1.2. Fill.
Most towers employ fills (made of plastic or wood) to facilitate heat transfer by maximizing water and air contact. There are two types of fill:
(i) Splash fill: waterfalls over successive layers of horizontal splash bars,
continuously breaking into smaller droplets, while also wetting the fill surface. 3 Plastic splash fills promote better heat transfer than wood splash fills. (ii) Film fill: consists of thin, closely spaced plastic surfaces over which the water spreads, forming a thin film in contact with the air. These surfaces may be flat, corrugated, honeycombed, or other patterns. The film type of fill is the more efficient and provides same heat transfer in a smaller volume than the splash fill.
2.2.1.6. Louvers.
Generally, cross-flow towers have inlet louvers. The purpose of louvers is to equalize air flow into the fill and retain the water within the tower. Many counter flow tower designs do not require louvers.
2.2.1.7. Nozzles.
These spray water to wet the fill. Uniform water distribution at the top of the fill is essential to achieve proper wetting of the entire fill surface. Nozzles can
either be fixed and spray in a round or square patterns, or they can be part of a rotating assembly as found in some circular cross-section towers.
4 2.2.1.8. Fans.
Both axial (propeller type) and centrifugal fans are used in towers. Generally, propeller fans are used in induced draft towers and both propeller and centrifugal fans are found in forced draft towers. Depending upon their size, the type of propeller fans used is either type of propeller fans used is either fixed or variable pitch. A fan with non-automatic adjustable pitch blades can be used over a wide kW range because the fan can be adjusted to deliver the desired air flow at the lowest power consumption. Automatic variable pitch blades can vary air flow in response to changing load conditions.
2.2 Types of cooling tower: The types of cooling tower (3) are gives as:
2.2.1. Natural draft cooling tower:The natural draft or hyperbolic cooling tower makes use of the difference in temperature between the ambient air and the hotter air inside the tower. As hot air moves upwards through the tower (because hot air rises), fresh cool air is drawn into the 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. There are two main types of natural draft towers: a).Cross flow tower: Air is drawn across the falling water and the fill is located outside the tower.
b).Counter flow tower: Air is drawn up through the falling water and the fill is
therefore located inside the tower, although design depends on specific site conditions. 2.2.2. 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.
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2.2.2.1 Types of Mechanical Draft Cooling Tower: a). Forced Draft Cooling Tower: Air is blown through the tower by a fan located in the air inlet.
Advantages: These are suited for high air resistance due to centrifugal blower fans and
fans are relatively quit.
Disadvantages:
Recirculation due to high air-entry and low air-exit velocities, which can be solved by locating towers in plant rooms combined with discharge ducts.
6 b). Induced Draft Cross Flow Cooling Tower: The induced draft cross flow cooling tower has following properties: i). water enters at top and passes over fill ii). air enters on one side (single-flow tower) or opposite sides (double-flow tower) iii). an induced draft fan draws air across fill towards exit at top of tower Advantages: Less recirculation than forced draft towers because the speed of exit air is 34 times higher than entering air.
Disadvantages:
Fans and the motor drive mechanism require weather-proofing against moisture and corrosion because they are in the path of humid exit air.
7 Advantages: Less recirculation than forced draft towers because the speed of exit air is 34 times higher than entering air.
Disadvantages:
Fans and the motor drive mechanism require weather-proofing against moisture and corrosion because they are in the path of humid exit air.
Fig 2.3 Induced Draft Counter Flow Cooling Tower 2.3 HEAT AND MOISTURE TRANSFER PRINCIPLE
When heat (4) is transferred between unsaturated air and dry surface the driving force is difference in dry bulb temperature of air and the temperature of the surface, but when the heat is transferred between unsaturated air and wet surface, now the driving force is the difference in the vapour pressure in the unsaturated air and saturated vapour pressure at the temperature of wet surface. When both the driving forces are present, we find both sensible and sensible heat are transferred in total heat transfer such that Qt = Qs + Q1
T2 = water outlet temperature oc The heat dissipation from the water will equal the heat gained by the air. a = La (Hg1-Hg2) (2.3) 9 La = airflow rate (kg/s) Hg1 = enthalpy of outlet air (kJ/kg) Hg2 = enthalpy of inlet air (kJ/kg)
Fig. 2.4 Driving Force Diagram The heat loss to surrounding may be neglected hence: Lw x cpw (T1-T2) = La (Hg1 Hg2) which can be written as Hg1 = ((Lw x cpw x (T1 T2))/La) + Hg2 (2.4)
As this is linear equation, the air condition line on chart must be straight. The vertical distance between the saturation line and the air condition line gives the difference in enthalpy at any cross section through the packing. The mean driving force is related to the average vertical distance between the air condition line and the saturation curve. It can be derived from mathematical
equations using integration, or graphical methods can also be used to measure the area between the line and the curve. By adopting the concept of mean driving force and using a factor related to the volume of the pack, the equation for total heat transferred becomes: 10 A = Kg x A x I x a x Hm (2.5) Where I = height of the pack (m) a = area of the pack (m2) KgA = volumetric heat transfer coefficient (kg/m3s) Hm = mean driving force (kJ/kg)
So,
KgA = La(Hg1 Hg2) / (L x a x Hm) And as a = Lm x cpw x (T1 T2) We know that KgA x I x a x Hm = Lw x cpw x (T1 T2) i.e. KgA = Lw x cpw (T1 T2) / (I x a x Hm) (2.6)
The equations assume that La and Lw remains constant but due to evaporation this is not true in practice, however, at normal temperatures the error from this assumption is not significant.
Lw and La are water and air flow rates in kg/s a is the horizontal cross sectional area of the pack C, m and n are constants (or performance coefficients) for the pack as determined by the manufactures.
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i).Capacity:
This is the heat rejected in kCal/hr or TR, given as product of mass flow rate of water, specific heat and temperature difference. Heat dissipation (in kCal/hour) and circulated flow rate (m3/hr) are an indication of the capacity of cooling towers. However, these design parameters are not sufficient to understand the cooling tower performance. For example, a cooling tower sized to cool 4540 m3/hr through a 13.9oC range might be larger than a cooling tower to cool 4540 m3/hr through 19.5oC range. Therefore other design parameters are also needed.
ii). 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 temperature effectively, and is thus performing well. CT Range (C) = [CW inlet temp (C) CW outlet temp (C)]
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 4540 m3/hr from 48.9oC to 32.2oC at 26.7oC wet bulb temperature.
iii). 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 is a better indicator of cooling tower performance. CT Approach (C) = [CW outlet temp (C) Wet bulb temp (C)] When the size of the tower has to be chosen, then the approach is most important, closely followed by the flow rate, and the range and wet bulb would be of lesser importance.
iv). Effectiveness:
This is the ratio between the range and the ideal range (in percentage), i.e. difference between cooling water inlet temperature and ambient 13 wet bulb temperature, or in other words Effectiveness = Range / (Range + Approach). The higher this ratio, the higher the cooling tower effectiveness.
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REFERENCES
Sarabhai.R, International Journal on thermodynamics engineering on external factors, 2005, pp1-23.
1.
Bureau of Energy Efficiency, Ministry of Power, India, Cooling Towers in Energy Efficiency in Electrical Utilities, Chapter 7, 2004, pp135 - 151.
2. 3.
Ramarao, R.A. Paltech cooling towers and equipment, Chapter 3, 2003, pp18-22. Zimmer, Maintenance of cooling tower, Arihant Publications, vol. 3, 2008, pp 27-
4.
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5. Sarabhai Journal on Efficiency & Effectiveness, Dhanpat Rai Publications, vol. 14, 2009, pp 56-80 6. Dennylias, Cleaning on cooling towers, Umesh Publications, 2007, pp. 48-88
7.
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