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Cooling Tower Explained: Types, Applications, and How They Work

A Cooling tower is the type of heat exchanger in which water and air are brought into contact naturally or forcefully depending upon the type of cooling tower you are using. The warm water comes in contact with cooled air and this heat is transferred to the air which flows outside of the cooling tower while the cold water remains in the basin of the cooling tower. A heat transfer phenomenon is taking place in the area where packing is installed. A small volume of water is evaporated while the remaining water is collected in the basin.

Why Cooling towers are installed in industries?

They are installed mainly for the following purposes:

  • To remove heat from various machines and industrial processes
  • Improve overall efficiency of the process
  • Provide a cost-effective method to remove heat from the water
  • Protects equipment from overheating as heat is dissipated

Cooling water systems are divided into two parts:

  1. Primary Cooling water system
  2. Secondary Cooling water system

Primary Cooling Water System:

Primary Cooling water systems have two types.

(a) Once through type:

The source of Once through type may be a canal, river, or sea. The Water from these sources will be passed through an Exchanger where water has to be cooled. After cooling this water will be sent to the back source. No Special treatment is required only sodium hypo chloride is added to kill and stop the growth of pathogens like bacteria, algae, etc.

(b) Open Recirculating

This method of cooling water will be used where fresh and cold water is short. The water passing through a heat exchanger for cooling will pass through a cooling tower where it will be cooled by evaporation. Here water will be lost due to evaporation. Overall there will be three types of losses.

  • Drift or windage loss
  • Evaporation loss
  • Blowdown loss

Secondary Cooling Water System

A secondary Cooling water system is also called a closed cooling water system. The closed Cooling water is used for several purposes in the industry especially Powerplants like the cooling of generators, Lube Oil Cooling, and Pump cooling.

This Close Cooling water will be cooled by Auxiliary Cooling water which will be primary cooling water. The take is taken in an expansion tank and will used as closed cooling water. This closed-cooling water will used again and again. Make water will be added due loss of CCW water. A corrosion inhibitor will be added.

Important Terms related to Cooling Tower:

Cooling Range:

Cooling range is the difference between temperature of hot water entering and Temperature of cold water leaving.

Approach:

Difference between the temperature of Cold water leaving and Wet Bulb Temperature.

Pumping Head

The minimum head needed to lift water from basin to top of the tower and force it into distribution system.

Application

Types of Cooling Tower:

Natural draft cooling a Tower

In natural draft cooling tower, the air and water come in contact naturally. No external medium is required for their interconnection. Water comes from upward and air comes in contact naturally. Cooled water moves towards the basin while some of the water is evaporated.

  • It has lower operating costs since no fan so there is no use of electricity usage
  • It requires less maintenance cost.
  • Strong draft when cold airflow
  • High air flow
  • Good thermal performance
  • No power consumption to induce airflow

Mechanical draft Cooling Tower:

In a mechanical draft cooling tower air and water come in contact by mechanical means like Fan will be used.

• The air flow is induced by fans located at the air outlet (Induced draft) or at the air inlet (Forced draft).

• The air flow is almost constant regardless ambient  air temperatures.

• Need mechanical equipment: fans, gearboxes, transmissions (shaft), motors Power consumption

Types of Mechanical Cooling Tower:

  • Forced Draft Cooling Tower
  • Induced Draft Cooling Tower

Forced Draft Cooling Tower

  • Air is blown through tower by a centrifugal fan at air inlet
  • Best suited for high air resistance
  • Recirculation due to high air-entry and low air-exit velocities

Induced draft cooling tower

  • Hot water enters at the top
  • Air enters at the bottom and exits at top

Counter Flow & Cross Flow

Our Power plant has an Induced Draft counter Flow type Cooling tower.

Cooling Tower Technical Data

Manufacturer Hamon Korea
TypeInduced draft counter flow
No. of Cell6 (5 working, 1 standby)
No. of fan per cell1
Size of cell14m x14m
Tower Dimensions 84.2m x 14.2m
Flow2500m3/hr (for 1 cell)
Hot water inlet temperature35.65°C
Cold water outlet temperature25.92°C
Delta ΔT                                              9.73°C

Components of Cooling Tower

Main components of the cooling tower are as follows:

  • Structure
  • Drift Eliminator
  • Sprinkler
  • Fills
  • Fan
  • Motor
  • Gearbox
  • Fan Stack
  • Basin

The cooling tower have structural frame that supports the exterior enclosures (casings), motors, fans, and other components. The material of the structural frame and casing is FRP which has the following advantages:

  • Light-weight for transportation and construction
  • No severe limitations on profile length
  • Bracing in one piece
  • No limitation in the water quality (any pH)
  • Fire protected

Drift Eliminator

The drift eliminator is a device that prevents the circulating water losses in the exhaust air.

Sprinkler

Through the sprinkler head, hot water will be uniformly distributed over the PVC fills. They are designed for maximum water sprinkling through the nozzle tip .

Fills

Fill is the main heat exchange media of the cooling tower which maximize water air contact

There are two types of fill:

            Film Fill              Splash Fill

Fan

The fan is a device used to induce airflow through the cooling tower. In an induced draft cooling tower, the fan is located at the top of the tower in the exhaust air.

Fan Specs:

ManufacturerCOFIMCO/ITLAY
Fan Speed129.7 rpm
No. of Blade6
Blade Angel11.5°
Blade MaterialFRP
Air Delivery442.6m/sec
Diameter7.925m

Motor

The motor is a driving element which gives mechanical power to the gear – fan.

Gear Box

A gearbox is an enclosed system of assembled gears that transmits mechanical energy from a prime mover to an output device. A gearbox can also change the speed and direction.

Gear Box Specs;

ManufacturerSUMITOMO/JAPAN
No. of Reduction2
Reduction Ratio11.375      (1470/129.25)
TypeSpiral Bevel
Lube OilOMALA 320

Fan Stack

A fan stack is a closed enclosure in which the fan rotates. Fan Stack is an integral part of the cooling tower. The height of fan stack plays an important role in cooling tower’s efficiency.

  • Material of fan Stack: FRP
  • Height of Fan Stack: 2.2 m

Basin

The cold-water basin is located at the bottom of the tower, and it receives the cooled water that flows down through the tower and fill.

Basin dimension(m):                           84.6 x 17

Material of basin:   RCC

Chemical dosing is done in cooling tower basin for following purposes:

  • Sulphuric Acid: To maintain pH
  • Sodium Hypochlorite Solution: To stop Biological growth
  • Scale & Corrosion Inhibitor: To prevent Scaling & Corrosion

Important Terms Related to Cooling Tower:

Range

The difference between the temperature of Hot water entering the Cooling Tower and Cooled water leaving the cooling tower.

Range = Temperature of Hot water Entering – Temperature of Cold Water Leaving

Bonus

Download the API of Cooling tower for free from here .

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