ABSTRACT

Laboratory-scale cooling tower experiment is a replication of cooling tower that is being used
in industries processes. The aim of this experiment is to identify the performance of the cooling
tower based on the load at different ranges, the inlet temperature of the cooling tower and also
to approach wet bulb. Besides, the amount of heat energy transfer and mass and energy
balance can also be studied in this closed system. By changing the parameter on the
laboratory-scale cooling tower, the cooling performance of the cooling tower can be affected.

From this experiment, it is known that the change in enthalpy of air and water is much higher
at a higher blower speed at a constant flow rate of water. At the same blower speed, the
change in enthalpy also increases as the flow rate of water increases. The results also obeys
the first law of thermodynamic which also known as the law of conservation of energy.
INTRODUCTION

A cooling tower is a heat rejection device that rejects waste heat to the atmosphere through
the cooling of a water stream to a lower temperature. In this experiment, SOLTEQ Water
Cooling Tower (Model: HE 152) has been used. This model has been designed to allow
engineering students to be familiarized with the processes related to industrial force draught
cooling tower. The construction, design and operational characteristic of this model are same
as the modern cooling system, but it is design in smaller scale. The basic unit can be used
with another four types of packing column, which were designed to facilitate study of water
and air conditions at different situations. The difference is mainly on the surface contact area
of the water with the air indifferent column. Cooling towers may either use the evaporation of
water to remove process heat and cool the working fluid to near the wet-bulb air temperature
or in closed circuit dry cooling towers, rely solely on the air to cool the working fluid to near the
dry-bulb air temperature.

There are many types of cooling towers that been used. The difference of the cooling towers
are known by how the air and water interact in open cooling tower and closed cooling towers.
Open cooling towers is also called the direct cooling tower in which it allows the water to
contact with outside air. Some water must be added when cooled water is returned from the
cooling tower to be used again. During the process, the pollutant will able to enter into the
tower, thus this pollutant need to filter out.

The laboratory cooling tower allows the speed of fans either blower or damper to be controlled
for cooling the warm return water and the pump is used to return the cooled water to the water
heater. This experiment is conducted to show the mass and heat transfer in the system and
also the mass and the energy balance for the closed system and to study how the adjustment
of difference parameters can a affect the performance of the system in removing the heat from
the process.

In a counter current cooling tower, the water stream is introduced at the top of the tower and
falls over or circulated in the packing materials, which are used to increase the surface area
for the heat transfer process. This water stream is exposed to the air that is flowing upward
through the tower in order to remove the hot air. The gas-liquid interface in contact with each
other will evaporate the water into the air stream
OBJECTIVES

To identify the performance of the cooling tower based on the load at different ranges, the inlet
temperature of the cooling tower and also to approach wet bulb.
THEORY

The cooling tower experiment operates according to the First law of Thermodynamics, which
is the conversation of energy. Energy can neither be destroy nor created, just transformed
from one another to another. The unit is supplied with a packed column having packing density
of approximately 110 m2/m3. The unit mainly consists of a load tank with of 1.5 kW electric
heater, an air distribution chamber, a make-up tank and a test column. Energy that enters the
cooling tower is in the form of hot water. Warm water is pumped from the load tank to the top
of the column before being uniformly distributed over the top packing. The thin film of water is
cooled, as it passes downward, due to evaporation. The cooled water falls into the basin
before going back into the load tank where it is reheated and re-circulated. The load-tank water
level is maintained by means of a make-up tank. A blower is installed on the unit to deliver air
into the air distribution chamber. The air passes a wet and dry bulb thermometers before
entering the column. As the air passes up the column, its moisture content increases and the
water is cooled. At the top of the column, the air passes a mist eliminator before being
discharged to the atmosphere. The cooling of the hot water was in the formed of forced
convection by which ambient air at T0 was blown over the hot water and exited the cooling
tower at some temperature T6.

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

H = U + PV

H = enthalpy

U = internal energy

P = pressure

This equation is related to the heat as it is used to calculate the enthalpy of the system.
Enthalpy can be calculated or reference from tables of data for the fluid being used. In this
experiment, we used the air and water as the fluids in the cooling tower. Enthalpy values can
be obtained from a thermodynamic textbook. The enthalpy of the output-cooled water can be
similarly reference and an energy balance can be conducted for the water. The equation below
displays the general method to conduct an energy balance:
∑ ∆𝐻𝑖𝑛 = ∑ ∆ 𝐻𝑜𝑢𝑡

Where,

∆𝐻 = 𝐻𝑖𝑛 − 𝐻𝑜𝑢𝑡

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

∆𝐻 = 𝐶𝑃 ∆ 𝑇(3)

Where ∆𝐻 is the change in enthalpy, ∆T is the change in temperature and Cp is the specific
heat with respect to constant pressure.

As water going into the cooling tower it loses energy. The enthalpy of the water going into the
tower can be determined using the enthalpy of saturated liquid water in a steam table. The
enthalpy of the water coming out of the tower can be determined in the same way. The data
in the steam tables are usually not given for every temperature so linear interpolation must be
performed to determine the enthalpy at the desired temperature. Then the enthalpy of the
water is multiplied by the mass flow rate. ) basis of an operation of 1 minute was chosen to
make the calculation easier. The change in enthalpy for the water is determined by:

∆𝐻𝑤𝑎𝑡𝑒𝑟 = ∆𝐻𝑤𝑎𝑡𝑒𝑟−𝑜𝑢𝑡 − ∆𝐻𝑤𝑎𝑡𝑒𝑟−𝑖𝑛

The change in energy of the air can be determined using the same methodology as was used
for water. The enthalpy change is shown as:

∆𝐻𝑎𝑖𝑟 = ∆𝐻𝑎𝑖𝑟−𝑜𝑢𝑡 − ∆𝐻𝑎𝑖𝑟−𝑖𝑛

However, the determination of the enthalpy of air is more complicated than the determination
of the enthalpy values of the water stream. Now that the mass flow rate of dry air is known,
the enthalpy values of the in and out streams can be determined. The change in enthalpy of
the water should have a negative value, and the change in enthalpy of the air should have
positive value. Theoretically, when two values are added together, the result should be zero.
This can be shown by the first law of thermodynamics where:

∆𝐻𝑤𝑎𝑡𝑒𝑟 = ∆𝐻𝑎𝑖𝑟

and

∆𝐻𝑤𝑎𝑡𝑒𝑟 + ∆𝐻𝑎𝑖𝑟 = 0
APPARATUS & MATERIALS

1. SOLTEQ Bench Top Cooling Tower Unit

2. Deionized water
3. Stopwatch
PROCEDURE

1. Valves V1 and V6 were checked to ensure they are closed while valve V7 were partially
opened.
2. The deionized water was filled in the load tank. Firstly, removed the make-up tank and
then the deionized water was poured through the opening at the top of the load tank
and tightened the nuts slightly. Next, the deionized water were filled in the tank up to
the zero mark of the scale.
3. Deionized water was added to the wet bulb sensor reservoir until full.
4. Differential pressure sensor was connected with all appropriate tubing.
5. The appropriate cooling tower packing was installed for the experiment.
6. Temperature controller was to 45˚C for the temperature set point. The 1kW water
heater was switched on and water was heated up to 40˚C.
7. The pump was switched on and slowly opened the control valve V1 and later the water
flow rate was set to 2LPM.
8. The damper was fully opened and the fan was switched on.
9. The blower immediately was switched on after the water went out through the cooling
water.
10. The unit was run for approximately 20 minutes for the valve float correctly adjusted the
level in the load tank. The make-up tank was refilled as required.
11. The damper and the flow rate were set to constant.
12. The 1kW heater later was switched off to set the power to 0kW.
13. The data were all recorded after 10 minutes to ensure the unit is stabilized. for the first
trial and another 10 minutes for the second trial.
14. Valve V3 and V6 were closed while V4 and V5 were opened to measure the differential
pressure across the orifice.
15. Next, V3 and V6 were opened while V4 and V5 were closed to measure the differential
across the column.
16. The water heater power then were set to 0.5kw, 1.0Kw and 1.5Kw.
17. When the experiment is done, the heater was switched off and the water were let to
circulate through the cooling tower system for 3-5 minutes until the water is cooled
down.
18. The fans was switched off and the damper was closed fully.
19. The pump and power supply were switched off.
RESULTS

Heater (kW) 0.5 1.0 1.5

Air Inlet Dry Bulb,T1

(°C) 29.6 31.4 32.8

Air Inlet Wet Bulb,T2

(°C) 38.2 28.9 29.3

Air Outlet Dry Bulb,

T3 (°C) 30.5 37.2 43.5

Air Outlet Wet

Bulb,T4 (°C) 29.4 35.9 42.3

Water Inlet
Tepmeperature,T5
34.2 42.2 49.9
(°C)

Water Outlet 3
Temperature,T6 (°C) 31.6 7.2 41.7

DP Orifice (Pa) 0 0 0
DP Column (Pa) 62 49 43
Data for fully closed blower
 Blower Fully Opened Partially Open Fully Closed

Air Inlet Dry Bulb,T1

(°C) 28 28.3 29.8

Air Inlet Wet Bulb,T2

(°C) 27.3 27.3 38.3

Air Outlet Dry Bulb,

T3 (°C) 24.9 24.5 38.3

Air Outlet Wet

Bulb,T4 (°C) 26.2 25.2 29.4

Water Inlet
Tepmeperature,T5
29.2 28.1 34.3
(°C)

Water Outlet
Temperature,T6 (°C) 24.5 24.6 31.6

DP Orifice (Pa) 68 61 0

DP Column (Pa) 144 124 62

Data for three blower condition at 0.5 kW

Table for Heat Load at 0.5 kW:

Temperature Change , ∆T
Blower Condition Heat Load ,Q (kW)
(°C)

Fully opened 4.7 0.649

Partially open 3.5 0.483

Fully closed 2.6 0.359

CALCULATIONS

Sample Calculation for Fully Closed Blower Change in temperature for each power
supply (cooling range)

Water Flow rate = 2.0 LPM

𝐶ℎ𝑎𝑛𝑔𝑒 𝑖𝑛 𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 ∆T (𝐶𝑜𝑜𝑙𝑖𝑛𝑔 𝑅𝑎𝑛𝑔𝑒)

= 𝑤𝑎𝑡𝑒𝑟 𝑖𝑛𝑙𝑒𝑡 𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒, 𝑇5 − 𝑤𝑎𝑡𝑒𝑟 𝑜𝑢𝑡𝑙𝑒𝑡 𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒, 𝑇6

For 0.5 kW:

∆T = T5-T6

= 34.2 – 31.6

=2.6

For 1.0 kW

∆T =T5-T6

= 42.2-37.3

=5

For 1.5 kW

∆T =T5-T6

=49.9-41.7

=8.2

Heat Load, Q = mCp∆T

M = 0.033kg/s

Cp = 4.186

Q = 0.033×4.186×2.6

= 0.359 kW
Sample Calculation for heat load, Q at fully opened, partially open and fully closed at
0.5kW:

For fully opened:

∆T =T5-T6

=29.2-24.5

=4.7°C

Q =mCp∆T

=0.033 x 4.186 x 4.7

=0.649 kW

For partially open:

∆T =28.1-24.6

=3.5°C

Q = 0.033 x 4.186 x 3.5

=0.483 kW

For fully closed:

∆T = 34.2-31.6

=2.6°C

Q =0.033 x 4.186 x 2.6

= .0.359 kW
DISCUSSION

At a constant water flow rate of 2.0 LPM, the blower’s speed can affect the cooling tower’s
performance. The temperature that is measured from the outlet water is vary with flow rate of
water and the speed of the blower. Cooling range is the difference of temperature in the inlet
water, T5 and outlet water,T6. The value of heat load is obtained from the amount of heat loss
during circulation in the cooling tower. The lower speed also affecting the value of heat load.

During the experiment, the water flow rate remained constant for 2.0 LPM. The heater power
is set to three values which are 0.5kW, 1.0kW and 1.5kW. For 0.5kW of the heater speed, the
values of outlet water temperature is increasing. It is remained increasing for the next value of
1.0kW and 1.5kW. The inlet water temperature also increased. The blower condition is in three
conditions which are fully opened, partially opened and fully closed. With these blower speed
and the heater power, the values of cooling range or known as temperature difference of inlet
water temperature and outlet water temperature can be calculated. The values of heat load
also calculated in the experiment which give a positive value for each blower’s condition.

In the experiment, the heater power is set to 0.5kW. The water inlet temperature,T5 is
increasing from 29.2oC to 34.4 oC accordingly to the blower’s condition. The outlet water
temperature,T6 is increasing from 24.5oC to 31.6oC accordingly to the blower’s condition. The
values keep increasing for the next 1.0kW and 1.5kW of the heater power. For the fully opened
condition of the blower, the temperature change is 4.7 oC and the heat load value is 0.649kW.
For partially opened condition of the blower, the temperature change is 3.5 oC and the value
of heat load is 0.483kW. For the fully closed condition of the blower, the temperature range is
2.6oC and the heat load’s value is 0.359kW. As the water flowrate increased, the temperature
difference decreased.
CONCLUSION

The experiment is conducted at the constant value of water flowrate of 2.0 LPM. The values
of inlet water temperature and outlet water temperature is increasing for three values of heater
power which are at 0.5kW, 1.0kW and 1.5kW. For fully opened of the blower’s condition, the
temperature range is 4.7oC, blower’s condition of partially opened gave a value of temperature
range of 3.5oC and for fully closed of blower’s condition, the temperature range is 2.6 oC. The
values of heat load are 0.649kW, 0.483kW and 0.359kW for fully opened condition, partially
opened condition and fully closed condition respectively.
RECOMMENDATION

As a recommendation, several factors were identified as key factors, which can deviate the
results of this experiment. One of those was the water that used in the unit only deionised
water or distilled water. Then, when using the tap water in the system, the impurities exist in
the tap water may cause the depositing in the cover tower and then may affect the efficiency
of system. Next is to make sure that there is no water in the pressure tubing for accurate
differential pressure measurement. When installing the cooling tower column or make-up tank,
the nuts must ensure not tighten too hard because it may cause the crack or not to tight lightly
which can cause spilling of water out from the column. Besides that, after completed the
experiment, ensure that the water inside the tower was cooled down first before draining it
off because if water still hot when draining off the water, the unit’s efficiency will decrease.
Lastly, avoid any mistake and error when conducting the experiment to get best result, must
be alert to the time taken for every ten minutes running.
REFERENCE
appendix