Fundamentals of Cooling Tower Heat Transfer – Part 2 _ IHS Engineering360

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2/17/2016 Fundamentals of Cooling Tower Heat Transfer – Part 2 | IHS Engineering360

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Images courtesy of Rich Aull, Brentwood Industries.

Schematics of a counter-flow and cross-flow cooling tower. Source: Reference 1.

Click to enlarge. Schematic of a typical

cooling tower.

Energy and Natural Resources

Fundamentals of Cooling Tower Heat Tr ansfer –

Part 2

By Brad Buecker, Process Specialist, Kiewit Engineering and Design Co.

06 November 2015

Cooling towers are ubiquitous around the world as a method for in dustrial plant cooling. In Part 1 of this series, weexamined fundamental heat transfer calculations in cooling towers. In Part 2, we look at design features that

maximize heat transfer, and particularly fill selection and the importance of selecting the proper design. Part 3 will

outline correct chemistry control methods to maintain reliable operation.

Cooling Tower Design

For standard cooling towers, two types

dominate industrial applications, the

counter-flow and the cross-flow types. Of

these, counter-flow towers are more

numerous. The f igures depict the general

water and air flow paths in these towers.

Both of these designs are of the induced-

draft type, in which fans pull air through the

towers. This is common for large towers.

The other type is the forced-draft design, inwhich fans push air through the towers.

The key heat transfer concept with any

cooling tower is to maximize (as much as the water quality will permit) interaction between the incoming air and the

warm water being discharged above. Cooling tower fill increases the surface area of the incoming water and

improves heat transfer. In the early days of cooling towers, splash fill was the configuration of choice. The common

design then was to use wooden bars or slats to break up the falling water into small droplets.

Splash fill improves heat transfer, and in some cases is still used, albeit with

plastic instead of wood as the construction material and for use with water

with high fouling potential. However, in most cases film fills are the common

choice. The figures illustrate three specific varieties of film fill.

As

the

name implies, film fill induces the cooling water to form a film on the material

surface. The filming mechanism maximizes liquid surface area. A guiding

principle behind fill design and selection is to increase air-to-water contact,

driving up convection and evaporative cooling while reducing pressure drop in

the system. [2] Typical fills are made of PVC because of its low cost, durability, good wetting characteristics and

inherently low flame spread rate.

The underlying design element that changes for each of the fill types is the flute geometry. Flutes are the air-water

passageways that influence the effectiveness of the fill’s thermal and fouling characteristics. Flute spacing is

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important, and for the designs shown may range from 19 mm for high-efficiency fill to perhaps 38 mm for low-fouling

fill. Flute size and flow path must be considered together when designing for the best combination of heat transfer

and fouling resistance.

Some Process Physics

The underlying goal of tower design is to supply the coolest water possible to power plant condensers and industrial

plant heat exchangers. Part 1 of this article outlined standard cooling tower heat transfer calculations, and notes that

most heat is removed by evaporation of a slight amount of the inlet return water.

An impor tant concept is “wet bulb” temperat ure. Consider being in a shady spot outdoors on a 90 o F day at 40%

relative humidity. A standard thermometer would read 90oF, which is the “dry bulb” temperature. However, if another

thermometer was attached alongside the dry bulb thermometer with a soaked piece of cloth placed around the bulb

and with both on a device that allows them to be swirled rapidly through the air. This second instrument is a deviceknown as a sling psychrometer. Although the dry bulb thermometer will still read 90oF after it has been rotated for a

while, the other thermometer will read 71.2o F. This latter reading is known as the “wet bulb” temperature, and

represents the lowest temperature that can be achieved by evaporative cooling.

No matter how efficient, a cooling tower can never chill the recirculating water to the wet bulb temperature, and at

some point costs and space requirements limit cooling tower size. The separation in temperature between the

cooling tower-chilled water and the wet-bulb value is known as the “approach.” The data in the table show the

relative size of a cooling tower for a range of approach temperatures.

As is evident, tower size beco mes

asymptotic as approach temperature

decreases.

Approach temper ature plays an important

role in the ongoing debate over wet cooling

vs dry cooling. In arid areas of the world, an

air-cooled condenser (ACC) may be the

only logical selection because of the lack of

makeup water for wet cooling. However,

ACCs are sometimes installed at power

plants where water is not scarce, but where the designers wish to avoid large makeup due to cost, or to avoid

regulatory issues related to cooling tower plume and blowdown discharges.

With this in mind, reconsider our earlier example with a wet cooling tower that has a 10oF approach. The water

leaving the tower to cool a power plant condenser will have a temperature of 81 oF. However, for an ACC operating

at an ambient temperature of 90oF, the turbine exhaust steam will only be cooled to a temperature that relatively

approaches 90o, but is likely to be higher. The effect on condenser performance and unit heat rate can be dramatic.

Part 3 of this series will examine the reasons why cooling tower water treatment and chemistry are vitally important

for maintaining system reliability.

References

1. Post R. and B. Buecker, “Power Plant Cooling Water Fundamentals”; the pre-conference seminar for the 33 rd

Annual Electric Utility Chemistry Workshop June 13-15, 2013, Champaign, Ill.

2. Wallis, J. and R. Aull, “Getting Your Fill”; Process Cooling & Equipment , July/August 2005.

3. J.C. Hensley, ed., Cooling Tower Fundamentals, 2 nd Edition; The Marley Cooling Tower Co. (now part of SPX

Cooling Technologies, Overland Park, Kansas), 1985.

To contact the author of this article, email [email protected]

By posting a comment you confirm that you have read and accept our Posting Rules and our Terms of Use of this site.

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Fundamentals of Cooling Tower Heat Transfer – Part 2 _ IHS Engineering360