Experiment 4A: Water Cooling Tower

Alagos, Reymund; Condez, Jared Philip; Molina, Shiela Mae; Pasquin, Arlene Joy
LabLab 136, ChE 136, School of Technology, UP Visayas

1. Theory
A cooling tower is a special type of heat exchanger which allows the contact of air and
water inside the tower. Aside from the heat exchange between the two contacting components, a
mass transfer also exists. Generally, it aims to lower down the temperature of one component,
usually hot water, while increasing the temperature of the other component (WebTechs.Net, 2015).
A cooling tower is also considered as a heat rejection device as it discards the waste heat in the
atmosphere while cooling the water stream that gets heat up by different industrial processes and
equipment. During the cooling tower operation, small portion of water being cooled is evaporated
into a moving air stream together with its latent heat, thus resulting to a lower temperature of the
water being circulated throughout the cooling tower. The cooling effect of the ambient air is
determined by its capacity to take up water vapor which is directly related to the air humidity. The
relative humidity should always be less than 100% in order for the cooling by evaporation to take
place (Cooling Technology Institute, 2015).
The cooling tower works by introducing hot water from the air conditioning condensers
and/ or other industrial processes. The structured nozzles installed in the tower sprays the water
which decelerates the flow of water to the labyrinth- like packing, also known as the fill media,
and exposing large amount of water surface area possible for the best air- water contact. The fill
media provides a large air- water interface for the air heating and evaporation. The water cools
down as it moves down through the film due to gravity. Moreover, as the water moves down, a

Figure 1.1. Mechanism of a cooling tower (WebTechs.Net, 2015)

direct contact between the air and water takes place. The cooled water is then collected in a cold
water basin below the fill from which is pumped back to go through the process again to absorb
more heat. The heated air leaving the fill is discharged to the atmosphere at a point remote enough
from the air inlets to prevent it being drawn back into the cooling tower (Proficool FANS, 2016).
While the water flows down, it is exposed to the cooler air by which a motor- driven
electric cooler tower fan pulls the air out. When the air and water come together, a small volume
of water evaporates, creating an action of cooling. The colder water gets pumped back to the
process/equipment that absorbs heat or the condenser. It repeats the loop over and over again to
constantly cool down the heated equipment or condensers (WebTechs.Net, 2015). Figure 1 shows
a diagram on how the cooling towers work.
Cooling towers are commonly used in petroleum refineries, plants, natural gas processing
plants, petrochemical plants and other industrial facilities. They are also used in disposing the heat
from chillers since they are less efficient than that of the water cooled chillers due to the rejection
of heat from tower near wet bulb temperatures. Furthermore, they provide cooled water for air
conditioning, manufacturing and electric power generation (Cooling Technology Institute, 2015).
In addition, to be able to ensure safe operations and high efficiency of the cooling tower, the
maintenance of the important characteristics of the system should be preserved. While the system
continues to operate, the concentration of chemical contaminants increases in the mechanical
cooling circuit (Proficool FANS, 2015).
There are two airflow arrangements of cooling towers according to the Bureau of Energy
Efficiency (2005). One of the airflow arrangements of cooling tower is the cross flow. The water
flows vertically through the fill media while the air is horizontally flowing across the falling water.
Due to the crossing flows, the air does not need to pass through the distribution system allowing
the hot water to flow with gravity. Figure 2 shows the mechanism of a cross flow cooling tower.
The other type is the counter flow cooling tower. In counter flow cooling tower, the air flows
vertically upward in the fill media, countercurrent to the flow of water. The use of gravity flow is

Figure 1.2. Crossflow cooling tower mechanism (WebTechs.Net, 2015)

restricted by the air flowing vertically, thus the towers use spray system to distribute the water on
top of the fill media. Figure 3 presents how a counter flow cooling tower works.

Figure 1.3. Counterflow cooling tower mechanism (WebTechs.Net, 2015)

The cooling tower is operating with accordance to the First Law of Thermodynamics also
known as the conservation of energy. The important parameters in determining the performance
of a cooling tower are enumerated below. Figure 4 shows a diagram to describe the range and
approach.
Range, which is the difference of the inlet and outlet water temperature in the cooling
tower,
Approach, which is the difference between the outlet temperature of water from the cooling
tower and the ambient wet bulb temperature,
Cooling tower effectiveness,
Cooling capacity,
Evaporation loss, and
Liquid/Gas ratio, which is the ratio of the water and air mass flow rates.

Figure 1.4. Range and Approach (Baker et al., 2016)

 First law of thermodynamics state that the heat removed from the water must be equal to
the heat absorbed by the surrounding air. This was qualitatively described by Equation 1.

( ) = ( ) Equation 1.1

=

Where
L/G is the liquid to gas mass flow rate (kg/kg)
T1 is the hot water temperature (C)
T2 is the cold water temperature (C)
h2 is the enthalpy of air- water vapor mixture at the exhaust wet- bulb temperature
h1 is the enthalpy of air- water vapor mixture at the inlet wet- bulb temperature.

The general concept of cooling tower which are usually accepted was developed by Merkel
(Baker & Shyrock, 2016). The analysis combines the sensible and latent heat transfer based on
enthalpy as the driving force. The particles of bulk water in the cooling tower is assumed to be
surrounded by an interface to which the heat is transferred from the water (Perry & Green, 2008).
The process of transferring heat is described by Equation 2.

= = ( + + + ) Equation 1.2

Where
hw is the enthalpy of air water vapor mixture at bulk water temperature
ha is the enthalpy of air- water vapor at wet bulb temperature
is the value of hw- ha at T2 + 0.1 (T1 T2)
is the value of hw- ha at T2 + 0.4 (T1 T2)
is the value of hw- ha at T1 - 0.1 (T1 T2)
is the value of hw- ha at T1 - 0.1 (T1 T2)
2. Objectives
Generally, the objectives of this experiment is to provide supplementary learning
experiences to chemical engineering students particularly on the concept of lowering water
temperature through evaporative cooling. Also, the experiment aims to promote the development
of social, leadership and camaraderie among the group.
The specific objectives of the experiment are
1. To measure the tower characteristic parameter, KV/L, for various liquid and air
flow rates (L/G) in a counter- current forced draft cooling tower.
2. To determine the effect of varying L/G ratio to the tower characteristic parameters.

3. Scope and Limitations

The water cooling tower experiment was limited to be performed, only virtually. The
simulator from Sakshat Virtual Labs, which is a forced draft counter current cooling tower, was
utilized using a Lab View Runtime engine. In performing the virtual experiment, only the raw data
provided by the simulator such as the dry and wet bulb temperatures of air and water, coefficient
of discharge, and other physical properties were studied. The experiment was performed for five
times; each run studying the effect of different mass velocity of water and air (L/G) ratio. However,
since only the given simulator data can be treated by the simulator, other crucial factors to the
tower characteristic cannot be determined.
The assumptions considered in the virtual experiment is that the inlet water is warmer than
the air. In addition, it is assumed that each particle of water is surrounded by a film of air and that
the difference in enthalpy of the fluids is the driving force for the cooling process. This ensures
that there is a driving force (difference in enthalpy) for the cooling process to take place.
The experiment is also restricted in determining only the effect of L/G ratio using different
approach since the values of L/G varies per experimental runs; thus the effect of different air
conditions could not be studied. Furthermore, the heat capacity of water all throughout the column
is assumed to be constant.

4. Methodology
A. Preparation
In order to perform the virtual water cooling tower experiment the following materials were
prepared: computer (laptop), scientific calculator, pen, and paper. The necessary software tools
such as Lab View Runtime engine and the water cooling tower application must be installed. To
start the experiment, the water cooling tower application was opened. The application opened a
new window consisting of several tabs, from thereon, the experiment was straightforward.
 The first few sections of the application showed the theory, objectives, and the
nomenclatures used.

B. Experiment Proper
The next section showed the first step in the experiment proper. Virtual data for orifice and
pipe diameters were given in addition to the coefficient of discharge, and densities for water and
air. Then the corresponding cross-sectional areas of the orifice and pipe was calculated and entered
into the designated input boxes. Afterwards, virtual data for dry- and wet-bulb temperature of the
inlet and outlet streams of air were given. Also, the inlet and outlet temperature of the water as
well as the flow rate and water level inside the tank were given.
Next, the head loss (H), flow rate of air (Qa), mass velocities of water (L) and air (G), and
the ratio of L/G were calculated and entered in the boxes. Then, the application automatically
calculated the enthalpy of air at the outlet wet bulb temperature (h1), while the enthalpy of air at
the inlet wet bulb temperature (h2) was calculated by the user and entered in the designated box.
Then the application showed the enthalpy of water at varying temperatures, these were noted down.
The next section required the user to input the enthalpy of air, and the difference in enthalpies of
water and air at the specified points.
Lastly, the tower characteristic (KV/L) was calculated based on the given Equation 2. A
comparison of the user and the applications calculated data was summarized at the end of the
virtual experiment.
Five experimental runs were made wherein different L/G ratios were generated by the
application. To assist in the calculations to be performed by the user, every data gathered was
placed in a Microsoft Excel spreadsheet to automate some calculations.

C. Post-Experiment
The application showed a self-assessment at the end of the experiment. Finally, the
experiment was stopped and the application was closed.

5. Results and Discussion

In the virtual experiment, high temperature water is introduced to the cooling tower and is
cooled by air using a forced-draft countercurrent cooling tower. The difference in enthalpies of
water and air is the driving force of the cooling process.
The effect of the different ratios of mass velocities of water and air (L/G ratio) to the tower
characteristic (KV/L) was determined. Table 5.1 shows the calculated and virtual data gathered
from the experiment and is visualized in Figure 5.1.
 Table 5.1 Calculated and virtual results of tower characteristic (KV/L)
L/G KV/L calculated KV/L virtual
0.8486 1.4189 1.0264
0.8539 1.4001 1.0149
0.9513 1.6297 1.0855
0.9760 1.7222 1.1122
1.0787 1.9905 1.1534

KV/L results vs. L/G ratio

2.50

2.00

1.50
KV/L

1.00
KV/L actual
0.50
KV/L virtual
0.00
0.80 0.85 0.90 0.95 1.00 1.05 1.10
L/G

Figure 5.1 Plot of tower characteristics (KV/L) against L/G ratio

It can be observed in Figure 5.1 that as the L/G ratio increases the KV/L ratio also increases.
This emphasizes the direct relationship between L/G and the tower characteristic (KV/L). This is
an expected result since KV/L or the characteristic of the tower relating to tower design and to the
amount of heat that can be transferred is directly affected by the flow rate of air and water. The
L/G ratio dictates the slope of the air operating line. If L/G increases (slower air flow), the air
operating line approaches the water operating line. Thus, it would be harder to cool the water
stream since the driving force, which is the difference between the air and water operating lines,
will be smaller. Based on the definition of the tower characteristic which is the degree of difficulty
to cool or the performance demand of the tower; thus physically, an increase in L/G ratio or a
decrease in the flow rate of air, it will be harder to cool down the water.
As the flow rate of air approaches infinity, the ratio of L/G approaches zero. This results
to the maximum driving force of the cooling process. Meanwhile, as the air rate decreases, the L/G
ratio increases. This decreases the driving force of the cooling process (Baker & Shryock, 2016).
6. Conclusion and Recommendations
6.1 Conclusion

In this experiment it can be concluded that the tower characteristic, KV/L, can be estimated
using the method described by Marley Co. (Equation 2). In addition, the tower characteristic was
determined to be directly proportional to the ratio of water and air flow rates (L/G). This implies
that the water cooling tower becomes more effective at cooling water when the air flow rate is
large.
6.2 Recommendations

For this virtual experiment, several problems were encountered due to the unitless
parameters. The experimenters therefore suggests that the application should be fixed or improved
by presenting the units used in each text box where the values are being entered. Furthermore, it
is also recommended that the next experimenters should check the units of the variables and
parameters used to avoid problems in the following steps.
Since the textboxes limits the number of digits that can be inputted, inaccuracy of the
results is produced. The deviation of the users answer from the virtual answer were also found to
be quite far, thus, this deviations could be minimized if the number of digits that could be entered
will be increased.

7. References
Bureau of energy and efficiency (2005). Cooling tower. pp. 135- 151
Cooling Technology Institute (2015). What is cooling tower?. Retrieved from
https://www.cti.org/whatis/coolingtowerdetail.shtml last March 22 2017
iitg.vlab.co.in,. (2011). Water cooling tower. Retrieved 21 March 2017, from
iitg.vlab.co.in/index.php?sub=58&brch=160&sim=763&cnt=1
Perry, R. & Green, D. (2008). Perrys chemical engineering handbook, 8th Ed. pp. 12- 19
12- 30
Proficool FANS (2016). Principles of cooling tower operation. Retrieved from
http://www.proficool-fans.com/en/principles-of-cooling-tower-operation/ last
March 22 2017
WebTechs.Net (2015). How cooling tower works. Retrieved from
http://www.coolingtowerproducts.com/blog/how-cooling-towers-work-diagram-
pictures-2015.htm last March 22, 2017
8. Appendix

Figure A.1. Objectives of the experiment

Figure A.2. Background of the experiment

Figure A.3. Nomenclature

 Figure A.4 First Step

Figure A.5 Virtual data

Figure A.6. Users data

 Figure A.7. Enthalpy values

Figure A.8. Data calculated virtually

Figure A.9. Calculated enthalpy value

 Figure A.10.Tower characteristic

Figure A.11. Comparison of the user and virtual data

Figure A.12. Self- assessment

Table A.1. Raw data
Trial 1 Trial 2 Trial 3 Trial 4 Trial 5
Parameter Value Value Value Value Value Unit
T1 20.7 20.59 20.49 20.6 20.81 C
T2 19.2 19.09 18.99 19.1 19.31 C
T3 36.5 36.07 35.68 36.09 36.95 C
T4 35.1 34.89 34.69 34.9 35.33 C
T5 44.71 44.6 44.5 44.6 44.82 C
T6 30.1 29.99 29.89 30 30.21 C
R1 12.71 12.06 11.47 12.09 13.38 cm
R2 5.445 4.99 4.576 5.014 5.913 cm
Qw 68.88 76.17 77.17 86.41 70.27 LPH
w 1000 1000 1000 1000 1000 kg/m3
a 1.128 1.128 1.128 1.128 1.128 kg/m3
Cd 0.6 0.6 0.6 0.6 0.6
d1 34 34 34 34 34 orifice mm
d2 68 68 68 68 68 pipe mm