1.

0 Abstract

Cooling tower is a device for cooling water process stream in many chemical plants. The
main reason of the water cooling tower is to emit unwanted heat to the atmosphere. The
cooled water can be recycled for other used in the plant. This experiment have 3 main
objective which is to determine the efficiency of the cooling tower based on different water
flow rate and determine the cooling load effect. Lastly to study the effect of different flow
rates on the web bulb approach. The water flow rate was set to 1 LPM, 2 LPM and 3 LPM.
For each water flow rate, different water heater was set which is 0.5kW, 1.0kW and 1.5kW.
all data from T1 to T2 was recorded. Based on data recorded , heat loaded, cooling range and
approach to wet bulb was calculated. Based on data when the flow rate is lower, the higher
the efficiency of the cooling tower. This is because, the water has more contact time with the
air in the pack column, and therefore it can more transfer heat to the surrounding in the pack
column.

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2.0 Introduction

Cooling tower is a device for cooling water process stream in many chemical plants. The
main reason of the water cooling tower is to emit unwanted heat to the atmosphere. The
cooled water can be recycled for other used in the plant. It the help reduce the use of water.
These processes have been used because they are economical and reliable. The most common
unit in plant is counter-current cooling tower. It utilizes atmospheric air circulation to
decrease the temperature of a stream of water. The water stream is pumped to the top of the
tower while the air is push upward from the bottom of the tower. The water and air will
contact in opposite direction.

Cooling tower contains some basic mechanisms that enable the evaporative properties of
water to take place. A standard cooling tower consist sets of packing material, casing and
frame, blower and other various apparatus based on the industrial of the tower. The packing
material used to separate the falling water and maximizes the contact surface area of the
water and airflow. These unit also consist thermocouple for the measurement of water
temperature and the dry and wet bulb temperature. It also can measure the air pressure for the
column and orifice.

3.0 Objective

The main objectives for this experiment are :

1 To determine the efficiency of the cooling tower based on different water flow rate.
2 To determine the cooling load effect.
3 To study the effect of different flow rates on the web bulb approach.

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4.0 Theory

This experiment is about cooling tower. Theoretically, cooling tower operates according to
the First Law of Thermodynamics which is the conservation of energy. The first law is energy
can neither be created nor destroyed, energy just transformed from one form to another. The
energy which enters the system must exit the system as it can be transferred through the
system. Energy that enters the cooling tower is in the high temperature (hot water). There are
certain things that considered negligible which are heat from friction, energy loses through
the pipes and others. This hot water was cooled from temperature T1 to a temperature of T2.
The cooling of the hot water was in the form of forced convection 3 by which ambient air at
T1 was blown over the hot water and exited the cooling tower at some temperature T2. The
data of both the entrance and the exit temperature was recorded

The main component of the energy balance is enthalpy which is defined as:

H = U + PV........................................................(1)

Where

H= enthalpy

U= internal energy,

P = pressure

V= volume.

Enthalpy is heat. Thus, the combined terms U+PV is also heat. Enthalpy can be
calculated by using that equation 1 .The enthalpy also can be refer to the referenced from
tables of data for the fluid being used. In the Engineering 435 laboratory, the fluids used by
the cooling tower are air and water, whose enthalpy values can be obtained from a
thermodynamics textbook. For example: Since both the initial and final temperatures of the
input hot water and the output cool water were measured, the temperature T in can be
referenced and the enthalpy (BTU/lbm, or KJ/kg) can be recorded. The enthalpy of the output

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cooled water can be similarly referenced and an energy balance can be conducted for the
water.

The equation below displays the general method to conduct an energy balance:

in = out ...................................(2)

Equation 2 can be obtained when H=0

Where H = H in - H out. A method is used for conducting the energy balance for air
entering and leaving the system.

The change in enthalpy for air can be determined form either of two methods. Since
the air is at low pressure, it can be treated as an ideal gas and the enthalpy change can be
calculated through the use of the following equation:

H = Cp T .........................................(3)

Where

H = change in enthalpy

T = change in temperature

Cp= specific heat at constant pressure.

A psychrometric chart is used to determine the enthalpy change between the entrance
and exit air since the specific heat relation does not take into account the percent of water in
the air. Additionally, some information is needed about the input and output air in order for
the psychrometric chart to be used effectively.

The information needed is the dry bulb and wet bulb temperatures of the inlet and
outlet air to reference the psychrometric chart.A sling psychrometer used to measure both the
input and output air flow . The sling psychrometer is an instrument that has two
thermometers. For measuring the wet bulb temperature, the thermometer that has a wetted

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cotton sleeve over the bulb end is used, while a regular thermometer is for measuring the dry
bulb temperature. Each can be referenced on the psychrometric chart and the enthalpies
obtained once the wet and dry bulb temperatures of the inlet and outlet air have been
measured. Energy balance can be conducted on the system once the enthalpies for the inlet
and outlet water and air conditions are known.

5.0 Apparatus and material

1. Stopwatch
2. Deionized water
3. SOLTEQ Bench Top Cooling Tower Unit (Model: HE152)

1. Orifice

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2. Water distributor
3. Packing column
4. Flow meter
5. Receiver tank
6. Air blower
7. Make-up tank
8. Differential Pressure Transmitter
9. Load Tank
10. Control Panel

6.0 Procedure

1. Valves V1 and V6 were checked and ensured to be closed and valve V7 to be partially
opened.
2. The load tank was filled with deionized water. Firstly, the make-up tank was removed and
deionized water was poured through the opening at the top of the load tank. The make-up
tank was replaced onto the load tank and the nuts were lightly tightened. Then, the tank was
filled with deionized water up to the zero mark and the scale.
3. Deionized water was added to the wet bulb sensor reservoir to the fullest.
4. All appropriate tubing was connected to the differential pressure sensor.
5. The appropriate cooling tower packing was installed for the experiment.
6. Temperature set point of temperature controller was set to 45 oC. The 1.0kW water heater
was switch on and water was heated up to 40 oC.
7. After the temperature reached 40 oC , switch off the 1.0kW water heater and switch on the
0.5kW water heater.
8. The pump was switched on and the control valve V1 was slowly opened and the water
flow rate was set to 1LPM to start the experiment.
9. The damper was fully opened and the fan was switched on.
10. Blower switch was switched on after the water already went through the cooling tower.
11. All data from T1 to T6 was recorded after 15 minute .
12. To measure the differential pressure across the orifice , valves V4 and V5 were opened
while valves V3 and V6 were closed.

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13. To measure the differential pressure across the column, valves V3 and V6 were opened
while V4 and V5 were closed.
14. Repeat step 9 to 15 using 1.0kW and 1.5kW water heater.
15. Step 8 to 16 was repeated using different water flow rate which are 2 LPM and 3 LPM.

7.0Result
Water flowrate : 1 LPM

Heater power(kW) 0.5 1.0 1.5

Temperature (c)
T1 29.6 29.5 29.7
T2 26.3 26.2 26.0
T3 28.0 28.0 29.2
T4 28.6 28.5 29.4
T5 37.0 38.8 43.3
T6 26.6 26.3 26.6
Differential pressure access 74 71 70
(orifice)
Differential pressure access 103 96 86
(column)

Water flowrate : 2 LPM

Heater power(kW) 0.5 1.0 1.5

Temperature (c)
T1 30.0 30.3 30.9
T2 26.1 26.1 26.2
T3 26.7 28.3 28.7
T4 28.0 29.2 29.3
T5 30.7 33.8 34.5
T6 26.4 27.3 27.6
Differential pressure(orifice) 68 68 67
Differential pressure access 62 62 64
(column)

Water flowrate : 3 LPM

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 Heater power (kW) 0.5 1.0 1.5

Temperature (c)
T1 31.0 31.2 31.4
T2 26.7 26.8 26.9
T3 27.1 28.6 30.3
T4 28.0 29.2 30.7
T5 29.9 32.7 35.8
27 27.0 28.2 29.5
Differential pressure access 64 65 66
(orifice)
Differential pressure access 82 70 80
(column)

8.0 CALCULATIONS

Heater power: 0.5 KW

For water flowrate at 1.0LPM

Fully opened blower:

Inlet water bulb, T2 = 26.3C

Outlet water temperature, T6 = 26.6C

Appr oach wet bulb=outlet water temperature inlet water temperature

26.6 C 26.3 C

0.3 C

Water flow rate, m = 1.0 LPM

= 1.0 L/min x 1kg/1L x 1 min / 60 s

= 0.0167 kg/s

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Cooling range ,T = ( Thot water - Tcold water )

= T5 T6

= (37.0 26.6)

=10.4 C

Heat load , Q = mcpT

Q = (0.0167 kg/s) x (4.186 kJ/kg.oC) x (10.4 oC)S

Q = 0.727 kW

heat load
x 100
Efficiency = heat supply

0.727
x 100
= 0.5

= 145.4 %

Water flow rate : 1 LPM

Heater (kW) Heat load (kW) Cooling range ( Efficiency ( % ) Approach to wet

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 C bulb ( C )
0.5 0.727 10.4 145.4 0.3
1.0 0.874 12.5 87.4 0.1
1.5 1.160 16.6 77.33 0.6

Water flow rate : 2 LPM

Heater (kW) Heat load (kW) Cooling range ( Efficiency ( % ) Approach to wet

C
bulb ( C )
0.5 0.600 4.3 120.0 0.3
1.0 0.906 6.5 90.6 1.2
1.5 0.962 6.9 64.1 1.6

Water flow rate : 3 LPM

Heater (kW) Heat load (kW) Cooling range ( Efficiency ( % ) Approach to wet

C
bulb ( C )
0.5 0.607 2.9 121.4 0.3
1.0 0.942 4.5 94.2 1.4
1.5 1.329 6.3 88.6 2.6

9.0 DISCUSSION

From this experiment, the instrument was used in this experiment is Water Cooling Tower
HE152 unit. All cooling towers operate on the principle of removing heat from water by
evaporating a small portion of the water that is recirculated through the unit. The heat that is
removed is called the latent heat of vaporisation. The experiment can be done when the
blower is in three conditions which is fully open, half open and fully closed. But, this
experiment only focused on fully open conditions. The power of heater for this experiment is
same for all 3 trial which is 0.5kW, 1.0 kW and 1.5kW. The temperature reading of cooling

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tower from T1 to T6 will be taken. All the reading only can be taken after the process have
done for 15 minutes. The pressure difference at orifice and column also will be taken.

For 1 LPM water flowrate, the reading of temperature and pressure differences was taken for

heater power 0.5kW, 1.0kW and 1.5kW. For 0.5 kW, the cooling range was 10.4 C and,

the difference pressure orifice was 74 and at column was 103. The efficiency was the highest

which is 145.5 %. Next, for 1.0kW heater power, the cooling range was 12.5 C and, the

difference pressure orifice was 71 and at column was 96. The efficiency was 87.4 % .For

1.5kW heater power, the cooling range was 16.6 C and, the difference pressure orifice is

70 and at column was 86. The efficiency was 77.3 %

For 2 LPM water flowrate, the reading of temperature and pressure differences was taken for

heater power 0.5kW, 1.0kW and 1.5kW. For 0.5 kW, the cooling range was 4.3 C and, the

difference pressure orifice was 68 and at column was 62. The efficiency was 120 %. Next, for

1.0kW heater power, the cooling range was 6.5 C and, the difference pressure orifice was

68 and at column was 62. The efficiency was 90.6 % .For 1.5kW heater power, the cooling

range was 6.9 C and, the difference pressure orifice is 67 and at column was 64. The

efficiency was 64.1 %

For 3 LPM water flowrate, the reading of temperature and pressure differences was taken for

heater power 0.5kW, 1.0kW and 1.5kW. For 0.5 kW, the cooling range was 2.9 C and, the

difference pressure orifice was 64 and at column was 82. The efficiency was 121.4 %. Next,

for 1.0kW heater power, the cooling range was 4.5 C and, the difference pressure orifice

was 65 and at column was 70. The efficiency was 94.2 % .For 1.5kW heater power, the

cooling range was 6.3 C and, the difference pressure orifice is 66 and at column was 80.

The efficiency was 88.6 %.

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10.0 Conclusion

This experiment have 3 main objective which is to determine the efficiency of the cooling
tower based on different water flow rate and determine the cooling load effect. Lastly to
study the effect of different flow rates on the web bulb approach. Based on data that were
recorded when the flow rate is lower, the higher the efficiency of the cooling tower. This is
because, the water has more contact time with the air in the pack column, and therefore it can
more transfer heat to the surrounding in the pack column. The objective of this experiment is
achieved by two variables which is heat power and water flow rate.

11.0 Recommendations

1. Make sure the condition of all the equipment that will be used in a good condition before
running the experiment

2.The water level in the load tank must be filled constantly at the minimum level because it
tends to fall due to evaporation.

3. Choose the more effective pack column in this experiment in order to increase the
efficiency of the cooling tower

12.0 Reference

1. Lab manual
2. A. Mandal, J. Nataraj and T.K. Bera, Controlling of Cooling Tower Return
Temperature and Energy Saving

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13.0 Appendix

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