Lab 4 – Cooling Tower

Amy Nur Shafiqah binti Sufian (2022660086)

Anis Nazihah binti Mat Nor (2022830634)
Muhammad Ezzat Syafiq bin Mohd Nizam (2022876074)
Nurul Amira Azwa binti Abusrah (2022855526)
Syahirah binti M.Yussoff (2022874192)

ABSTRACT of water [9]. In closed-circuit dry cooling towers,

This experiment aims to investigate the impact of the working fluid is cooled to almost the dry-bulb
cooling load on wet bulb approach. A cooling tower air temperature by relying only on air. Cooling
is a device for removing heat that lowers the
temperature of a stream of water to discharge waste towers can either utilize water evaporation to
heat to the atmosphere. There are some parameters remove process heat and cool the working fluid to
that may be changed to see how the cooling tower
approach affects water evaporation. The cooling near the wet-bulb air temperature. Cooling towers
load (heater power) and condition of the blower are are frequently used in petrochemical, chemical, and
the parameters used in this experiment which can be
modified. The heater power parameters were set at oil refinery plants in industrial applications [10].
0.5 kW, 1.0 kW and 1.5 kW when the water flow These cooling towers are a particular kind of
rate remains constant at 2.0 LPM and blower at
fully open and partially open condition. As a result, heat exchanger that allows air and water to interact
the cooling range increases along with an increase with one another in order to lower the temperature
in heater power. The cooling range produced results
of 4.1°C, 5.1°C, and 7.7°C when fully opened, and of the hot water. During this process, little amounts
results of 3.9°C, 6.3°C, and 8.7°C when only of water evaporate, lowering the temperature of the
partially opened, with heater power of 0.5 kW, 1.0
kW, and 1.5 kW, respectively. When fully opened, water that is pumped throughout the cooling tower
the values of the approach wet bulb are -1.2K, - [9]. Thus, cooling towers lower the temperature of
0.7K, and 0.2K while for the partially opened are -
1.4K, -0.5K, and 0.8K, respectively. As a result, the water that has become too hot due to industrial
wet bulb approaches will increase along with the machinery and procedures. By only removing a
cooling load. Thus, the experiment conducted was
successful. small quantity of heat from the process, this
approach is inexpensive and extremely effective.
Keywords—Cooling Tower; Heater Power; Blower;
Wet Bulb The cooling tower system is often used for most of
the cooling process in the industry.
I. INTRODUCTION
Cooling towers come in a variety of sizes
and are produced and designed in a wide range of
A cooling tower is a heat removal
designs. Not all applications are acceptable for most
equipment that releases waste heat to the
towers. Crossflow and counterflow cooling towers
atmosphere by lowering the temperature of a stream
are the two main types of cooling tower systems,
whether they are huge or small. We may distinguish
between the various cooling towers by being aware
of and understanding how air and water interact in
crossflow and cooling towers. There are two distinct
ways to describe how air entering a cooling tower
interacts with the process water being cooled and
their fundamental differences: crossflow and
counterflow. The focus is on induced-draft Figure 1: Crossflow and Counterflow cooling towers.

crossflow and counterflow cooling towers that have

In this experiment, which makes use of a
been factory-assembled.
commercial air conditioning system, was carried out
using a laboratory cooling tower unit. The pump is
How air moves through a cooling tower
used to carry the cooled water to the water heater,
interacts with the cooling of water is what
and the laboratory cooling tower helps in
distinguishes counterflow and crossflow cooling
monitoring the speed of fans (blowers) used to chill
towers from one another. As water is falling, air
the heated return water. This experiment is run to
flows horizontally across that direction in a
show how the system transfers mass and heat in a
crossflow tower, but in a counterflow tower, the air
closed system and to find out how changing certain
moves in the opposite (counter) direction [11].
parameters might impact how well the system
Also, it's crucial to remember that not all cooling
works to remove heat from a process.
towers can be managed fairly. Depending on the
application, a counterflow cooling tower has four
OBJECTIVES
II.
air inlets in comparison to two on a crossflow The objective of this study is:
cooling tower. A crossflow cooling tower needs less
• to investigate the effect of the cooling load
space overall than a counterflow cooling tower,
on the wet bulb approach.
even with heat loads under 750 tons. The air inlets
• to ascertain how the flow rates of air and
on each style of the tower are to blame for this [11].
water affect the pressure drop.

THEORY
III.
Distillation operations are performed in columns,
which are cylindrical pressure vessels with large
height-to-diameter ratios and internals of various The load tank, where water is heated to feed
types that have been carefully chosen and arranged temperature, is where most of the heat transfer
to enable the cost-effective separation of binary or occurs. The rate of evaporation from a wet surface
multicomponent feed mixtures, primarily liquids, into the surrounding air is determined by the
into desired pure products or specified fractions. [2] difference between the vapor pressure at the liquid
surface, the saturation pressure corresponding to the
The First Law of Thermodynamics, which states surface temperature, and the vapor pressure in the
that energy is converted, governs how the cooling surrounding air. Absolute humidity and total air
tower is used. It is impossible to produce or destroy pressure both have an impact on it. In a closed
energy. It may, however, be moved from one place environment, evaporation can proceed until both
to another and changed into other types of energy. vapor pressures are equal, the air is saturated, and
Energy must leave the system as it arrives in order the surface temperature is reached. If unsaturated air
for it to spread through it.[6] Hot water is sent into is continuously circulating, the temperature on the
the cooling tower where it is cooled from wet surface will eventually reach equilibrium. The
temperature T1 to T2 as it receives energy. load tank, where water is heated to feed
Convection was used to cool the heated water, temperature, is where heat is transported most
which involved blasting ambient air over the hot effectively.
water at T1 before it left the cooling tower at T2.
Enthalpy, which is defined as the following, is the The basis and theoretical direction for the cooling
primary element of the energy balance. tower's optimization control is quick and precise
calculations of the heat and mass transfer process.
Numerical simulation and artificial neural network
(black box) modeling are the two most often
utilized techniques in the thermal calculation for
cooling towers because of the nonlinear relationship
between the saturated air enthalpy and
temperature.[3]

Figure 2: A counterflow wet cooling tower

schematic.[3]
 IV. PROCEDURES distributed and flowing uniformly through
General Start-Up Procedures the packing.

1. Valves V1 to V6 were ensured fully closed 8. The fan damper was fully opened, and the
while V7 was partially opened. fan was switched on. The differential
pressure sensor was checked and was giving
2. The load tank was filled with distilled water
readings when the valve manifold was
or deionized water. It was done by first
switched to measure the orifice differential
having the make-up tank removed and water
pressure.
poured through the opening at the top of the
load tank. The make-up tank was replaced 9. Let the unit run for about 20 minutes, for the
with the load tank and lightly tightened the float valve to correctly adjusted the level in
nuts. The tank was filled with distilled or the load tank. The makeup tank was refilled
deionized water up to the zero mark on the as required.
scale. 10. Now, the unit is ready for use.
3. Distilled or deionized water was added to the General Shut-Down Procedures
wet bulb sensor reservoir to the fullest.
1. Heaters were switched off and let the water
4. All appropriate tubing was connected to the circulate through the cooling tower system
differential pressure sensor. for 3-5 minutes until the water cooled down.

5. The appropriate cooling tower packing was 2. The fan was switched off and the fan damper
installed for the experiment. was fully closed.

6. Then, the temperature set point of the 3. The pump and power supply was switched
temperature controller was set to 50°C. The off.
1.0 kW water heaters were switched on and 4. The water in the reservoir tank was retained
the water was heated up to approximately for the following experiment.
40°C.
5. The water was completely drained off from
7. The pump was switched on and the control the unit if it is not in use.
valve V1 was slowly opened, and the water
flow rate was set at 2.0 LPM. A steady
operation was obtained where the water was
Experiment Procedures V. RESULTS AND DISCUSSIONS

1. The cooling tower was prepared and started Blower

Fully Opened (100% Capacity)
according to Section 4.1.1. Opening
Heater
0.5 1.0 1.5
2. The system under the following conditions Power (kW)
was set and stabilized were allowed for Air inlet dry
bulb, T1 27.0 27.0 27.4
about 15 minutes. Water flow (˚C)
rate: 2.0 LPM Air inlet
wet bulb, T2 24.6 24.6 24.8
Air Flow: Maximum (˚C)
Air outlet
Cooling Load: 0 kW dry bulb, T3 25.4 24.8 25.5
(˚C)
Column installed: C.
Air outlet
3. A few sets of measurements (i.e., air inlet wet bulb, T4 24 24.8 26.6
(˚C)
dry bulb and wet bulb temperature (T1 and Water inlet
T2), water outlet temperature (T6), orifice temperature, 27.5 29.4 32.7
T5 (˚C)
differential pressure (DP1), water flowrate
Water outlet
(FT1) and Heater Power (Q1)) were recorded temperature, 23.4 23.9 25.0
after the system stabilizes, then the mean T6 (˚C)
Water
value for calculation and analysis were
flowrate, 2.0 2.0 2.0
obtained. (LPM)
Differential
4. The cooling load was increased to 0.5 kW pressure 85 84 84
without changes in the conditions. All data orifice (Pa)
Differential
were recorded when the system stabilized.
pressure 320 314 313
5. Similarly, the experiment was repeated at 1.0 column (Pa)
Table 1.1
kW and 1.5 kW.
Fully Opened (100% Capacity)
6. Finally, the cross-sectional area of the
From the data obtained when 100% flow air was
column was measured.
employed,
7. The four tests may be tested at another Heater Power = 0.5kW
airflow which is partially airflow. Total Cooling Load = Applied Load + Pump Input
= (500+65) W
= 0.565kW
Inlet wet bulb temperature, T2 = 24.6˚C Air volume flowrate, vB = 0.0426 × 0.8684 =
= (24.6 +273) K 0.0370 m3s-1
= 297.6 K The cross-sectional area of the empty tower, A =
0.0225 m2
Water outlet temperature, T6 = 23.4˚C
= (23.4 +273) K
= 296.4 K Air velocity = 0.0370 m3s-1 / 0.0225 m2 =
1.6444 ms-1

Water inlet temperature, T5 = 27.5˚C

= (27.5 +273) K
= 300.5 K Water flowrate = [(2.0 LPM) x (1kg/L) x (min
/60s)] / 0.0225 m2 = 1.4815 kgs-1m-2
Approach to wet bulb = Water outlet temperature, Heater
T6 – Air inlet wet bulb, T2 Power 0.5 1.0 1.5
(kW)
Approach to wet bulb, K = (296.4 – 297.6) K Packing
= -1.2 K Density 200 200 200
Cooling range, ∆T = Water inlet temperature, T5 – (m-1)
Water outlet temperature, T6 Water
Flow Rate
Cooling range, ∆T = (300.5 – 296.4) K Per Unit 1.4815 1.4815 1.4815
= 4.1K Area (kg s-
1
m-2)
The specific volume of air at the outlet, vB (by Total
plotting the air outlet dry bulb and wet bulb on the Cooling 0.565 1.065 1.565
psychometric chart) = 0.8684 m3/kg Load (kW)
Cooling
4.1 5.5 7.7
Range (˚C)
Approach
to Wet -1.2 -0.7 0.2
x= 85 Pa × 1mm H2O / 10.13 Pa = 8.3909 mm H2O
Bulb (˚C)
Air mass flowrate = 0.0426 kgs-1
 Pressure Partially Open (50% Capacity)
Drop From the data obtained when 50% flow air was
8.3909 8.2922 8.2922
Orifice employed,
(mmgH2O) Heater Power = 0.5kW
Table 1.2 Total Cooling Load = Applied Load + Pump Input
= (500+65) W
Blower = 0.565kW
Partially Opened (50% Capacity)
Opening
Inlet wet bulb temperature, T2 = 25.1˚C
Heater
0.5 1.0 1.5
Power (kW) = (25.1 +273) K
Air inlet dry = 298.1 K
bulb, T1 26.7 26.8 26.8
(˚C)
Air inlet Water outlet temperature, T6 = 23.7˚C
wet bulb, T2 25.1 24.8 24.7
= (23.7 +273) K
(˚C)
Air outlet = 296.7 K
dry bulb, T3 25.2 25.7 27.2
(˚C)
Air outlet Water inlet temperature, T5 = 27.6˚C
wet bulb, T4 24.2 25.7 27.6 = (27.6 +273) K
(˚C) = 300.6 K
Water inlet
temperature, 27.6 30.6 34.2
T5 (˚C) Approach to wet bulb = Water outlet temperature,
Water outlet
T6 – Air inlet wet bulb, T2
temperature, 23.7 24.3 25.5
T6 (˚C)
Water Approach to wet bulb, K = (296.7 – 298.1) K
flowrate, 2.0 2.0 2.0
(LPM) = -1.4 K
Differential Cooling range, ∆T = Water inlet temperature, T5 –
pressure 83 84 83
Water outlet temperature, T6
orifice (Pa)
Differential
pressure 313 313 314 Cooling range, ∆T = (300.6 – 296.7) K
column (Pa)
= 3.9K
Table 1.3
The specific volume of air at the outlet, vB (by Cooling
3.9 6.3 8.7
plotting the air outlet dry bulb and wet bulb on the Range (˚C)
psychometric chart) = 0.8705 m3/kg Approach
to Wet -1.4 -0.5 0.8
Bulb (˚C)
Pressure
x= 83 Pa × 1mm H2O / 10.13 Pa = 8.1935 mm H2O
Drop
Air mass flowrate = 0.0420 kgs -1 8.1935 8.2922 8.2922
Orifice
Air volume flowrate, vB = 0.0420 × 0.8705 =
(mmgH2O)
0.0366 m3s-1
The cross-sectional area of the empty tower, A =
The SOLTEQ Water Cooling Tower (Model
0.0225 m2
HE152) unit was used for this experiment. Air is
utilized in cooling towers to remove heat from the
water. The latent heat of vaporization is released
when warm water and cooler air interact, cooling
Water flowrate = [(2.0 LPM) x (1kg/L) x (min
the water as a result [7]. One experiment was
/60s)] / 0.0225 m2 = 1.4815 kgs-1m-2
conducted using the cooling tower device.

Heater To carry out the experiment perfectly, some

Power 0.5 1.0 1.5 basic cooling tower knowledge is required. First and
(kW) foremost, the cooling range is the difference in
Packing temperature between the inlet (T5) and the outlet of
Density 200 200 200 the water (T6) [7]. The second method is to
-1
(m ) approach a wet bulb. This can be determined by
Water subtracting the temperature of the outlet, which is
Flow Rate the cold water leaving the tower (T6), from the
Per Unit 1.4815 1.4815 1.4815 temperature of the inlet wet bulb (T2). Following
-
Area (kg s that is the heat or cooling load. This is also an
1 -2
m ) important parameter to consider in cooling tower
Total experiments. The amount of heat drained from the
Cooling 0.565 1.065 1.565 flowing water inside the tower is referred to as the
Load (kW) heat load or cooling load [8].
 Cooling tower with a packing density of The packed column that was used in this experiment
roughly 200m2/m3, the unit comes with a packed is packed column C which consists of 200m-1 of
column. The load tank, an air distribution chamber, density. The total cooling load and wet bulb
a make-up tank, and a test column are the primary approach for fully opened air intake were calculated
components of the cooling tower unit. The tank as well as cooling range data as shown in Table 1.2.
includes an electric heater that has a 1.5 kW output.
Warm water is pushed from the load tank all the
way to the top of the column, where it is then
evenly dispersed at the top packing, which starts the
unit running. The evaporation cools the thin coating
of water as it moves lower. The water is cooled as it
flows into the basin, where it is reheated and
circulated before returning to the load tank. A
make-up tank is used to keep the water level in the Figure 1.1 Graph Wet Bulb Approach Temperature vs Cooling
Load for Fully Openend Blower
load tank consistent. The cooling tower has a
blower attached to move air into the air distribution The graph relationship between wet bulb
chamber. The air flows through the wet and dry temperature and cooling load is plotted as shown in
bulb thermometers before it enters the column. The Figure 1.1 above. The difference in heater power
water is cooled as the air rises up the column, delivers different approaches to wet bulbs,
increasing its moisture content. The air travels respectively. For the heater 0.5kW, the approach
through a mist eliminator at the top of the column wet bulb is -1.2K. For the heater 1.0kW, the
before it is released into the atmosphere. approach wet bulb is -0.7K. For the heater 1.5kW,
the approach wet bulb is 0.2K. Based on Figure 1.1
In this experiment, the main objective was to shows that when the power heater supply was
investigate the effect of the cooling load on the wet increased, hence the cooling load was also
bulb approach. To ensure this experiment is increased. Therefore, the approach to wet bulbs will
successful, the heater power was set into three also increase.
different values as manipulated variable data which
are 0.5kW, 1.0kW, and 15kW. Furthermore, the
airflow rates are also the variables that change in
this experiment. The airflow rate was controlled by
a fan damper that could be fully or partially opened.
 in heater power, the cooling range also increases.
The cooling range yielded results of 4.1˚C, 5.1˚C,
and 7.7˚C when fully opened, and results of 3.9˚C,
6.3˚C, and 8.7˚C when just partially opened, with
heater outputs of 0.5 kW, 1.0 kW, and 1.5 kW,
respectively. The approach wet bulb's results are -
1.2K, -0.7K, and 0.2K when fully opened,

Figure 1.2 Graph Wet Bulb Approach Temperature vs respectively. The results of the approach wet bulb
Cooling Load for Partially Opened Blower
are -1.4K, -0.5K, and 0.8K, respectively, for
Figure 1.2 shows the relationship between the partially opened. Hence, the wet bulb approaches
wet bulb approach temperature towards the cooling will rise as the cooling load does.
load for the partially opened blower. Another set of
RECOMMENDATIONS
variables of this experiment was conducted to
To obtain more accurate results, any reading or
determine the different approaches to wet bulb
values obtained shall be taken at least three times to
temperature. As a result, Figure 1.2 indicates a
get the average of the values. This is to avoid any
linear line graph same as Figure 1.1. The difference
inaccurate result obtained from the experiment that
in heater power delivers different approaches to wet
has been performed. Besides, a timer also can help
bulbs, respectively. For the heater 0.5kW, the
the student to get more accurate results by taking
approach wet bulb is -1.4K. For the heater 1.0kW,
each reading or value in an approximate time scale.
the approach wet bulb is -0.2K. For the heater
Furthermore, students could also take pictures of the
1.5kW, the approach wet bulb is 0.8K. This
results or values at each time scale to get more
experiment showed that the different airflow rates
accurate results. In addition, every temperature
do not affect the cooling load and wet bulb
change throughout the experiments shall be
temperature since the air flow rate indicates a
observed so that it will not affect the result in the
-1
constant air velocity at 1.6 ms as shown in Table
end. Finally, the equipment used in the experiment
1.2.
shall be checked before the experiment starts to
CONCLUSION avoid any unwanted incidents occurring.
In conclusion, the experiment successfully
achieved its primary goals, which were to
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APPENDIX

Figure 1.3 Raw Data for Experiment

Figure 1.4 Psychometric Chart