This document is a case study report on reducing water consumption of an industrial cooling unit using a hybrid cooling tower. It describes modeling and simulating the wet and dry sections of a hybrid cooling tower. It compares simulation results to data collected from a pilot hybrid tower built with a wet cooling tower and 12 compact air-cooled heat exchangers. The simulation is then applied to an industrial cooling unit to investigate the effect of a dry tower on water loss reduction. A feasibility study is also carried out to determine the best operating conditions for the proposed hybrid cooling tower configuration.
This document is a case study report on reducing water consumption of an industrial cooling unit using a hybrid cooling tower. It describes modeling and simulating the wet and dry sections of a hybrid cooling tower. It compares simulation results to data collected from a pilot hybrid tower built with a wet cooling tower and 12 compact air-cooled heat exchangers. The simulation is then applied to an industrial cooling unit to investigate the effect of a dry tower on water loss reduction. A feasibility study is also carried out to determine the best operating conditions for the proposed hybrid cooling tower configuration.
This document is a case study report on reducing water consumption of an industrial cooling unit using a hybrid cooling tower. It describes modeling and simulating the wet and dry sections of a hybrid cooling tower. It compares simulation results to data collected from a pilot hybrid tower built with a wet cooling tower and 12 compact air-cooled heat exchangers. The simulation is then applied to an industrial cooling unit to investigate the effect of a dry tower on water loss reduction. A feasibility study is also carried out to determine the best operating conditions for the proposed hybrid cooling tower configuration.
This document is a case study report on reducing water consumption of an industrial cooling unit using a hybrid cooling tower. It describes modeling and simulating the wet and dry sections of a hybrid cooling tower. It compares simulation results to data collected from a pilot hybrid tower built with a wet cooling tower and 12 compact air-cooled heat exchangers. The simulation is then applied to an industrial cooling unit to investigate the effect of a dry tower on water loss reduction. A feasibility study is also carried out to determine the best operating conditions for the proposed hybrid cooling tower configuration.
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Case study of HVACR
On
Reducing water consumption of an industrial plant cooling unit
using hybrid cooling tower submitted in partial fulfilment of the requirements
of the Third year semester VI of
Bachelor of Engineering (Mechanical)
By
AMITKUMAR KUSHWAHA
ROLL NO- 3739
MIS NO- 20161042
GUIDE:
(Prof. Prathmesh D Patil)
DEPARTMENT OF MECHANICAL ENGINEERING
BHARATI VIDYAPEETH COLLEGE OF ENGINEERING, NAVI MUMBAI
2022-23 APPROVAL OF REPORT ON CASE STUDY
This project report entitled (Reducing water consumption of an industrial plant
cooling unit using hybrid cooling tower) by (Amitkumar Kushwaha) is approved for the Third Year Semester VI of Bachelor of Engineering (Mechanical).
Internal Examiner: -----------------------
External Examiner: ----------------------
Date:
ABSTRACT Water consumption is an important problem in dry zones and poor water supply areas. For these areas use of a combination of wet and dry cooling towers (hybrid cooling) has been suggested in order to reduce water consumption. In this work, wet and dry sections of a hybrid cooling tower for the estimation of water loss was modeled. A computer code was also written to simulate such hybrid cooling tower. To test the result of this simulation, a pilot hybrid tower containing a wet tower and 12 compact air-cooled heat exchangers was designed and constructed. Pilot data were compared with simulation data and a correction factor was added to the simulation. Ensuring that the simulation represents the actual data, it was applied to a real industrial case and the effect of using a dry tower on water loss reduction of this plant cooling unit was investigated. Finally feasibility study was carried out to choose the best operating conditions for the hybrid cooling tower configuration proposed for this cooling unit. INDEX Sr. no Description Page no 1 Chapter 1 1.1 introduction 1.2 history and background 1.3 problem statement 1.4 objective
2 Chapter 2 2.1 Literature review
CHAPTER 1 Introduction : There are two types of cooling towers commonly used in various plants: wet and dry cooling towers. In general, cooling towers may operate either counter currently or with the air entering at the side of the tower and flowing across the water stream. The motive force needed for the air to pass the tower is provided naturally or by forced or induced draft fans. Wet cooling towers have been introduced as one of the direct contact heat exchangers based on the evaporation of water into air in a packing media. Although the water stream cools somewhat as a result of sensible heat, most of the heat rejection in a wet cooling tower is caused by evaporation of some water into the air .one of the advantages of wet cooling towers over the dry towers is evaporative cooling where the water temperature may approach the atmospheric wet bulb temperature rather than the dry bulb temperature. However, use of wet cooling towers causes water loss which is an intolerable issue in dry regions with poor water supplies. Also visible plume may occur when the saturated exhaust air from wet cooling towers is confronted with ambient air in the case that the ambient air is very humid or the temperature is low. Nowadays, the visible plume attracts the public attention with increasing concern of environmental issues. For example under the air pollution control ordinance of Hong Kong, the visible plume is not allowed. The visible plume can be extremely serious extending up to 100 m and some times causes visibility and darkness under unfavorable atmospheric conditions. It is also a nuisance and may result in misconception of a fire accident or hazardous pollutant for the local people in the highly dense cities . Dry cooling towers include compact heat exchangers in which water flows in tubes and air passes through the exchangers. These towers have no water loss and are very suitable to operate under cold and moderate climates. Except of their high investment cost, the main problem with dry towers is that their efficiency decreases with the increase of the ambient air temperature. This occurs in hot summer days when the heat transfer driving force decreases. Much attention has been paid to issues on wet cooling towers relating to modeling and simulation of wet cooling towers study the effect of different packing types on the characteristics and thermal performance of cooling towers, use of neural network in the prediction of cooling tower performance, evaluation of thermal efficiency of cooling towers with respect to fouling and other aspects which are mostly related to the design of new wet cooling units.
2. Wet section modeling and simulation
The wet section of a hybrid cooling tower is a wet cooling tower that cools water by the combination of heat and mass transfer. The water to be cooled is pumped into the tower and is distributed into a fill in which air is passed either naturally or mechanically. The Poppe method accurately predicts the water content of the exit air which is a very important factor in the design of hybrid cooling towers This method leads to the following four equations for unsaturated and supersaturated air
Inlet air temperature (_C) 25.0
Inlet air humidity (kg/kg) 0.0100 Inlet water temperature (_C) 40.0 Outlet water temperature (_C) 21.1 Air flow rate (kg/s) 650.0 Water flow rate (kg/s) 450.0
Outlet air temperature (_C) 31.5 30.7
Outlet air humidity (kg/kg) 0.030 0.029 Evaporation (kg/s) 12.5 12.4
A good agreement can be seen by the comparison of this work
with in the estimation of outlet conditions. It is good to note that although profiles of the air temperature and humidity are available by the simulation, only the exit air condition is presented for the comparison.
Wet section in system
Dry section modeling and simulation
The dry section of a hybrid cooling tower includes compact heat exchangers which are widely used in the industry especially as gas-to-gas or liquid-to-gas heat exchangers. Some examples are vehicular heat exchangers, condensers and evaporators in air conditioning, oil coolers, radiators, intercoolers of compressors and aircraft and space applications [14]. In such exchangers, the heat transfer surface area is increased by fins to increase the area per unit volume of an exchanger. Compact heat exchangers are divided into plate-fin and tube-fin heat exchangers. In the plate-fin type, each channel is defined by two parallel plates separated by fins or spacers. Fins or spacers are sandwiched between parallel plates. Fins are attached to the plates by brazing, soldering or welding [14]. In a tube-fin exchanger, round, rectangular and elliptical tubes are used and fins are employed either on the outside or on the inside, or on both sides and inside of the tubes, depending on the application. In a gas-to-liquid exchanger, which is employed in this work, the gas side heat transfer coefficient is very low compared with the liquid side heat transfer coefficient; therefore no fins are needed on the liquid side [14]. Fins on the outside tubes may be categorized as (1) flat or continuous (plate, wavy or interrupted) external fins on an array of tubes, (2) normal fins on individual tube, and longitudinal fins on individual tube
Authors Have Studied The Performance of Water Cooling Towers by Analyzing The Influence of Cooling Media On The Surrounding Environment Based On Experimental Techniques
Authors Have Studied The Performance of Water Cooling Towers by Analyzing The Influence of Cooling Media On The Surrounding Environment Based On Experimental Techniques
