Cooling Tower Performance Amns

COOLING TOWER & IT’S
PERFORMANCE
BY- Bijay Kumar Mohanta, CPP OPERATION
1
Introduction
 Cooling tower is a structure in
which hot water is made
droplets with the help of
nozzles to increase contact
surface of water and allowed to
come in contact with
atmospheric air.
 The primary task of a cooling
tower is to reject heat into the
atmosphere.
 The make up water source is
used to replenished the water
loss to evaporation.
2
Cooling Water System
3
Types of Cooling tower
4
Atmospheric Cooling tower
5
Natural draft Cooling tower
• Concrete-Height 400 ft
(120 m)
• Water flow above 45000
m^3/hr
• Utility power station
• Density difference create
a current of air (hot moist
air).
6
Mechanical draft Cooling tower
• Mechanical draft cooling tower utilize large fans to force or suck air
through circulated water.
• On the basis of air flow arrangements, following types of Mechanical
draft cooling towers available
1. Counter flow induced draft
2. Counter flow forced draft
3. Cross flow induced draft
7
Cross flow vs. Counterflow
8
9
10
11
Components of Cooling tower
• Frame and Casing
• Fills
• Cold water basin
• Drift eliminator
• Louvers
• Nozzles
• Fans
12
Frame and Casing
 Most towers have

structural frames that
support the exterior
enclosures (casings),
motors, fans, and
other components.
With some smaller
designs, glass fiber
structures are used,
the casing may
essentially be the
framed.
13
Fills
 The fills facilitates heat transfer by
maximizing water and air contact.
 Made in wood or plastic (mainly PVC ).
 2 types-
- Film types
- Splash type
Film types
• Film fill cooling tower

consists of thin, closely
placed plastic surfaces
over which the water
spreads.
• The surface may be
flat/corrugated/honeycom
bed etc.
15
Splash Types
• Splash Fill Cooling Tower consists of

layers of horizontal splash bars into
which the water spreads and breaks
into small droplets.
• Plastics are better than wood.
16
So, which one is
better??? Splash
Fill or Film Fill
 Film Fill is more efficient in heat transfer in a smaller
volume than the splash fill.
TYPICAL COMPARISONS BETWEEN VARIOUS FILL MEDIA
Splash Fill Film Fill
Possible L/G Ratio 1.1 – 1.5 1.5 – 2.0
Effective Heat Exchange
Area 30 – 45 m2/m3 150 m2/m3
Fill Height Required 5 – 10 m 1.2 – 1.5 m
Pumping Head
Requirement 9 – 12 m 5–8m
Quantity of Air Required High Much low
18
Cold water basin
• The cold water basin,

located at or near the
bottom of the tower,
receives the cooled
water that flows down
through the tower and
fill. The basin usually
has a sump orlow
point for the cold
water discharge
connection.
19
Drift eliminator
• These capture water

droplets entrapped in
the air stream that
otherwise would be
lost to the
atmosphere.
20
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.
21
Nozzles
These provide the water

sprays to wet the fill.
Uniform water
distribution at the top of
the fill is essential to
achieve proper wetting
of the entire fill surface.
22
Fan
• The purpose of cooling tower fan
is to move a specified quantity of
air through the system.
• Fan efficiency greatly depends on

the profile of blade.
• As the metallic fans are

manufactured by adopting either
extrusion or casting process it is
always difficult to generate its
profile. So FRP or GRP blades are
used. (Steel,wood, plastic,FRP).
• FRP- hand moulded- optimum
aerodynamic profile-20/30%
energy saving. Light weight- less
starting torque.
23
Cooling Tower Performance
• Range
• Approach
• Effectiveness/Efficiency
• Cooling capacity
• Evaporation loss
• Cycle of concentration (COC)
• Blow down loss
• Drift loss
24
25
• Range (T1-T2)-: it is the difference between the
cooling tower inlet and outlet temperature. High
range means the cooling tower has been able to
reduce the water temperature effectively and is thus
performing well.
• Approach(T2-WBT)-: it is the difference between
the cooling tower outlet cold water temperature and
ambient wet bulb temperature. Although both the
range and approach should be monitor, the “
approach” is a better indicator of cooling tower
performance.
 Low approach= Good performance.
26
Cooling tower effectiveness or efficiency(%):- it is
the ratio of range to the ideal range. i.e. 100X
range/(range+ approach).
 High effectiveness= Good performance
Cooling capacity:- it is measure in Kcal/hr. it

depends on heat load and it can be calculated
as
Q= mXCpX(T1-T2).
High Cooling capacity = Good performance.

• Evaporation loss:- It is calculated as
E=0.00085X1.8X Circulating ratex(T1-T2)
• COC:- it is the ratio of TDS of circulating water to TDS of make up

water. COC is vital parameter to reduce the make up water.
• Drift loss:- Cooling tower designed to minimize the drift/windage

loss up to 0.02%.
• Blow down loss:- it is calculated as

B= E/COC-1
• Make up water:- Evaporation loss+ Blow down loss
28
Cooling water treatment
 Condenser of a Turbine is a critical component in power plant.
Cooling water is circulated in its tubes. Scale deposition in this tube
may affect heat transfer.
 So it is very important to avoid scaling of condenser tubes.
 There may be growth of algae and bacteria in the water. This growth
may choke the circulation system.
 SA249TP304-SS/ AD BRASS/MS
29
Cooling water treatment
• Antiscale and corrosion
treatment
• Biocide treatment/hypo
(Algae)
• Acid treatment (pH)
30
Anti scale and corrosion treatment
• Deposits of scale in cooling water system reduces efficiency of heat

transfer and restrict water distribution of pipe line.
• Salts of calcium and magnesium are responsible for scale
formation.
• Anti scale chemicals prevents scale forming compounds present in
the cooling water. (Zn/PO4 based chemicals).
• Corrosion inhibitors are used in the cooling water which effectively
decreases the corrosion rate.
• Dispersants are used in cooling water to control fouling. The
absorption of dispersants makes particles more hydrophilic (water
loving) and less likely to adhere to the surface.
• Dispersants affect both particle to particle and particle to surface
interactions.
31
Biocide treatment
• To control growth of slime, organic bacteria and algae biocide is

dosed in cooling water.
• Oxidizing biocide:- it attacks the cell components and kill the
organism. Commonly used oxidising biocides are Chlorine, bromine,
chlorine dioxide (ClO2).
• Cl2+H2OHCl+HOCl (hypochlorous acid) HOCL and OCL(-)
are oxidants and
• HOCl H(+)+OCl(-) (Hypo chlorite) attcks the micro
organism). Called
free chlorines.
• Non oxidizing biocides:- it damages the cell wall and restrict the
cells metabolic processes. MBT (Methylene BisThiocyanate) is
commonly used.
32
Acid Treatment
• PH of Cooling water increases due to continuous evaporation and

concentration of salts. (maintain 7.3 to 7.8).
NaHCO3- Sodium bicarbonate

Na2CO3- Sodium carbonates (Alkaline)
Responsible for increasing the pH.
• NaHCO3 – NaOH+ CO2+H2O (Sodium hydroxide)
• 2NaHCO3- Na2CO3+CO2+H2O (Sodium carbonate)
• Both NaOH and Na2CO3 are alkaline, so cooling water PH
increases. To maintain PH of Cooling water H2SO4 is dosed.
33
Corrosion coupon
• To measure corrosion rate of CW.

• SS and CS metal
• Corrosion is mainly depends(inversely)
on the pH.
• measured weight (before and after-60-
90-120 days).
• CR= Wt (loss)/(DXAXT). Measured in
Mpy.
• For CS corrosion limit <3 Mpy. And for
SS <1 Mpy.
• Mpy= 0.0254 mm per year
34
THANK YOU
35

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COOLING TOWER & IT’S

 Most towers have

• Film fill cooling tower

• Splash Fill Cooling Tower consists of

• The cold water basin,

• These capture water

These provide the water

• Fan efficiency greatly depends on

• As the metallic fans are

 High effectiveness= Good performance

Cooling capacity:- it is measure in Kcal/hr. it

High Cooling capacity = Good performance.

• COC:- it is the ratio of TDS of circulating water to TDS of make up

• Drift loss:- Cooling tower designed to minimize the drift/windage

• Blow down loss:- it is calculated as

• Deposits of scale in cooling water system reduces efficiency of heat

• To control growth of slime, organic bacteria and algae biocide is

• PH of Cooling water increases due to continuous evaporation and

NaHCO3- Sodium bicarbonate

• To measure corrosion rate of CW.

• Mpy= 0.0254 mm per year

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