Cooling Tower Info

Indirect Evaporative Cooling Systems Using Cooling Towers Rev.
1 01/16/06
Reinhard Seidl, P.E. Taylor Engineering
Overview
Goals for today Why use systems without compressors? 3 Strategies for multi-stage cooling using cooling towers Where are these applicable? How does it work? Energy and initial cost considerations Wrap up
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Overview
Why use cooling towers instead of refrigeration? Compare 3 models of cooling tower use @ Design Annual Analysis Compare 3 models annual energy use Compare 3 models life cycle cost
Overview
Why use systems without compressors?
Cooling Without Compressors?

Energy consumption can be greatly reduced Air-cooled chiller consumes about 1.2 kW/ton Water-cooled chiller & tower consumes about 0.8 kW/ton. Cooling tower consumes about 0.1 kW/ton.
Where is this applicable?
Applications
Low temperatures cant be achieved Only useful for systems with relatively warm air supply (65F) Wont work in wet climates like Florida, but will work in dry climates like bay area, Arizona and the like Underfloor (UFAD) Systems that move a lot of air by design (Labs, Hospitals)
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Air cooled chiller-design values

Chiller: 1.2 kW/ton CHW pump: 0.05 kW/ton Total: 1.25 kW/ton
Water cooled chiller-design values

Towers: Chillers: 0.1 kW/ton 0.6 kW/ton CW pump: 0.05 kW/ton CHW pump:0.05 kW/ton Total: 0.8 kW/ton
Cooling tower-design values

Towers: 0.1 kW/ton
Note: using an oversized tower dramatically reduces tower energy use. For example, using a tower with twice the surface area results in a reduction of 50% in airflow, which in turn reduces fan energy to ()3 or about 1/8th of the original fan energy. In this sense, any discussion about tower energy is only meaningful when part-load energy consumption values and initial investment are considered along with energy use.
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Cooling tower basic operation

Closed towers (indirect system) and open towers (direct system) Open tower: water falls down and air passing over water evaporates some of it, cooling both air and water. Imagine taking a shower in a strong wind -> evaporation provides cooling effect Open tower: cooling water is exposed to outside air
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The ambient wet-bulb is a measure of the humidity. The higher the wet-bulb, the more humid the air. Wet-bulb temperature can never exceed dry-bulb temperature. Dry-bulb temperature is what we commonly refer to as just temperature The leaving water temperature of the cooling tower can never be less than the wet-bulb temperature of the entering air.
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RANGE: entering water temperature leaving water temperature. In this example: 90F - 80F = 10F APPROACH: difference between leaving water temperature and ambient wet-bulb temperature. In this example: 80F 62F = 18F The closer the approach, the more fan energy the tower will require, and the larger its surface will have to be
Ta (18F)
Tr (10F
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Closed tower: a closed coil isolates the cooling water from the water, circulated through the tower. This means less problems with water treatment for coils served by cooling water Range and approach definitions remain the same A closed circuit tower will be less effective (greater fan energy per unit of cooling) than an open tower at the same size
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Cooling towers work better in dry climates like Arizona, because the ambient wet-bulb there is lower That means colder water leaving the tower, for the same fan energy It also means more water is evaporated
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Psychrometric diagram
More detail on psychrometrics
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120 tons capacity, low airflow

h * tower airflow (lbs/h) = cooling tower capacity (Btu/h) h
Ta,out=70/70F Example: Flow = 160 gpm Range = 18F Capacity =160*18*500/12000 = = 120 tons Airside flow has to be: Ta,in=83/62F h1=(62 wb) = 27.7 Btu/lb h2=(70 wb) = 34.1 Btu/lb =120 tons/h = 3,756 lbs/min Approach=4F Density @ Ta,in = 0.0728 lb/ft3 Airflow = / = 51,590 cfm Range=18F Tw,out=66F Tw,in=84F 17
120 tons capacity, higher airflow

Ta,out=68/68F Example: Flow = 160 gpm Range = 18F Capacity =160*18*500/12000 = = 120 tons Airside flow has to be: Ta,in=83/62F h1=(62 wb) = 27.7 Btu/lb h2=(68 wb) = 32.4 Btu/lb =120 tons/h = 5,085 lbs/min Approach=4F Density @ Ta,in = 0.0728 lb/ft3 Airflow = / = 69,845 cfm Range=18F Tw,out=66F Tw,in=84F 18
Pre-cooling effect
Leaving air, no pre-cooling
Example: When pre-cooling is not applied, the tower operates at roughly 70,000 cfm and 120 tons capacity to bring water within 4F of entering air wetbulb temperature (4F approach). Note that the physical size of the tower determines the approach. A smaller tower, operating with the same airflow, would produce a higher approach (a higher leaving water temperature, less range) and would require a higher water flow rate for the same capacity.
Outside air
Approach=4F
Range=18F Tw,out=66F Tw,in=84F 19
Pre-cooling effect
Leaving air, no pre-cooling
With pre-cooling, the entering air wet-bulb is reduced. The same tower can now produce colder leaving water temperatures. This also means a larger range, and less water flow for the same capacity. Note that, as the pre-cooling effect pushes the condition of air entering the tower closer to the saturation line, the sensible/total heat ratio of air passing through the tower changes, to maintain the same h and tower capacity.
Outside air
Pre-cooled air
Approach=4F
Overview
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Overview
Why use cooling towers instead of refrigeration? Compare 3 models of cooling tower use @ Design Annual Analysis Compare 3 models annual energy use Compare 3 models life cycle cost Direct 1-Stage model (Loek Vaneveld) Indirect 1-Stage model (Mark Hydeman) 2-Stage model (Shlomo Rosenfeld)
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3 Strategies for multi-stage cooling using cooling towers
Direct 1-Stage Design

Note this is an open tower design. This may not be acceptable in some cases where concerns over water treatment and fouling of coils exist. In such a case, the use of a plate heat exchanger (typically employed on open towers) will not work, since the temperature losses inherent in such an approach make the design impractical.
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Pre-cooling effect-special case

h hp h
Leaving air
Dashed line = tower without pre-cooling, for same process load with same tower airflow
Note this slide shows the principle. The actual values for the tower under consideration are different (next slide) Note that tower pre-cooling energy extracted from the air is reintroduced into the tower through the water, and has to be cooled within the tower. Leaving air temperature is the same with or without pre-cooling, for the same airflow through the tower. h = Building or Process Load
Outside air Pre-cooled air
hp
Approach=4F
hp = Pre-cooling Load
Direct 1-Stage Design

Actual Values Note this is an open tower design. This may not be acceptable in some cases where concerns over water treatment and fouling of coils exist. In such a case, the use of a plate heat exchanger (typically employed on open towers) will not work, since the temperature losses inherent in such an approach make the design impractical.
200 tons tower capacity
79.7 tons pre-cooling ?
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Indirect 1-Stage Design
CT1/2: 180 gpm 78F - 62F = 120 tons @ 50 Hp CT3/4: 172 gpm 81F 66F at 15 Hp, relate to orig.120 tons requires 7.5 Hp and 3.0 Hp spray pumps Total Evaporation water usage
0.311 0.093 0.065 0.469
kW/ton kW/ton kW/ton kW/ton

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0.037 gpm/ton
Indirect 1-Stage Design
CT1/2: 180 gpm 78F - 62F = 120 tons @ 50 Hp CT3/4: 172 gpm 81F 66F at 15 Hp, relate to orig.120 tons requires 7.5 Hp and 3.0 Hp spray pumps Total Evaporation water usage
0.311 0.093 0.065 0.469
kW/ton kW/ton kW/ton kW/ton

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0.037 gpm/ton
2-Stage Design
Note: all kW/ton calculations are based on the total output (120 tons) of the system, not on the individual capacity of each tower
CCT1/2 each: CCT3/4 each:
180 gpm 78F - 67F = 82.5 tons @ 25 Hp 180 gpm 67F - 62F = 37.5 tons @ 50 Hp requires 5 Hp, 5 Hp, 2 Hp spray pumps Total Evaporation water usage
0.155 0.311 0.075 0.541
kW/ton* kW/ton kW/ton kW/ton

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0.027 gpm/ton
2-Stage Design
73.4 tons heat re-gain
111 tons tower capacity
73.4 tons pre-cooling
CCT1/2 each: CCT3/4 each:
180 gpm 78F - 67F = 82.5 tons @ 25 Hp 180 gpm 67F - 62F = 37.5 tons @ 50 Hp requires 5 Hp, 5 Hp, 2 Hp spray pumps Total Evaporation water usage
0.155 0.311 0.075 0.541
kW/ton* kW/ton kW/ton kW/ton

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0.027 gpm/ton
Energy and Water Usage at Design Conditions

Direct 1-Stage Indirect 1-Stage 2-Stage 0.167 kW/ton 0.469 kW/ton 0.541 kW/ton 0.032 gpm/ton 0.037 gpm/ton 0.027 gpm/ton
Note that these values are fairly easily derived, but dont show the whole picture.
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Coil Calculations
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Annual Simulation
Could use a spreadsheet, maybe DOE2. Spreadsheet offers more flexibility Look at bin weather data file to run a simulation Use approximation of coil performance to arrive at results for varying airflows and air entering temperatures. Use LMTD and -NTU methods.
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Bin Data and Building Load

Match each temperature bin with a building load. This building load doesnt necessarily have to be exact a rough approximation is sufficient since were trying to find a comparison between models rather than an absolute number. Use the dry-bulb and coincident wet-bulb to predict how coil performance at tower inlets will vary.
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Sample Bin Data

SAN FRANCISCO, CLIMATE ZONE 3
MAY Obsn Hours Total M 01 09 17 Obsn C to to to Hrs W 08 16 24 B 0 0 0 0 0 0 0 0 0 0 0 0.3 0 0.7 0.1 2.9 0.5 4 1.2 19.1 5.7 49.6 26 140 88 215 116 258 11 54 0 0.9 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 67 65 66 60 58 58 56 52 50 46 59 0 0 0 0 0 JUN Obsn Hours Total M 01 09 17 Obsn C to to to Hrs W 08 16 24 B 0 0 0 0 0 0 0 0 0.4 2 5.4 31 83 109 8.8 0 0 0 0 0 0 0 0 0 0.5 0.2 1.9 4.1 8.7 16 32 70 83 24 0.9 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.5 0 0.2 0.1 2 0.6 4.7 1.3 10 2.4 18.7 5.1 39.1 17 91.7 51 164 103 209 60 170 0.8 9.6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 70 71 71 66 62 61 60 59 56 53 51 47 0 0 0 0 0 0 DEG N JULY Obsn Hours Total 01 09 17 Obsn to to to Hrs 08 16 24 0 0 0 0 0 0 0 0 0.1 0.6 3 31 123 91 0.2 0 0 0 0 0 0 0 0 0 0 0.1 1 2.8 4.6 14 50 100 61 13 0.7 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.1 0 1 0 2.8 0.6 5.2 1.8 16.1 4.8 55.8 19 122 63 155 120 255 40 131 0 0.2 0 0 0 0 0 0 0 0 0 0 0 0 M C W B 0 0 0 0 67 65 65 63 61 60 59 57 54 52 48 0 0 0 0 0 0 LAT 38 ELEV 52 FT SEP Obsn Hours Total M 01 09 17 Obsn C to to to Hrs W 08 16 24 B 0 0 0 0 0 0 0 0 0.2 2.3 11 52 109 62 4.2 0 0 0 0 0 0 0 0 0 0 0.2 2.6 6.8 12 20 54 85 48 11 0.6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.2 0 2.6 0.3 7.1 1.2 13 4.9 25 11 67.4 30 125 79 179 87 207 26 88.5 0.2 4.4 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 66 65 60 62 60 59 59 57 55 52 47 0 0 0 0 0 0 OCT Obsn Hours Total M 01 09 17 Obsn C to to to Hrs W 08 16 24 B 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.7 0 0.7 0 2 0.2 2.2 0 6.9 0.5 7.4 0.1 12 1.9 13.7 0 29 5.1 34.1 5.5 76 19 101 32 87 66 184 100 32 110 242 94 2.8 44 140 17 0 1.8 18.3 0.8 0 0 0.8 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 66 65 62 60 58 57 56 54 51 46 41 0 0 0 0 0 TEMP RANGE AUG Obsn Hours Total M 01 09 17 Obsn C to to to Hrs W 08 16 24 B 0 0 0 0 0 0 0 0 0 0.3 4.9 39 137 63 3.5 0 0 0 0 0 0 0 0 0 0 0 0.3 1.9 6.5 19 58 98 55 9.3 0.1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.3 0 1.9 0.5 7 1.2 19.9 6.7 64.8 24 127 76 170 114 261 25 88.3 0.3 3.8 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 65 65 60 61 61 59 57 55 52 48 0 0 0 0 0 0 TEMP RANGE 115/119 0 0 110/114 0 0 105/109 0 0 100/104 0 0 95/99 0 0 90/94 0 0.3 85/89 0 0.7 80/84 0 2.8 75/79 0 3.5 70/74 0 18 65/69 1.9 42 60/64 12 101 55/59 56 71 50/54 134 7.9 45/49 43 0.2 40/44 0.9 0 35/39 0 0 30/34 0 0 25/29 0 0 20/24 0 0 15/19 0 0 115/119 110/114 105/109 100/104 95/99 90/94 85/89 80/84 75/79 70/74 65/69 60/64 55/59 50/54 45/49 40/44 35/39 30/34 25/29 20/24 15/19
NOV Obsn Hours Total M 01 09 17 Obsn C to to to Hrs W 08 16 24 B 0 0 0 0 0 0 0 0 0 0 0 2.5 40 78 81 35 4.1 0 0 0 0 0 0 0 0 0 0 0 0.4 3.1 8.5 28 58 85 46 10 0.2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.4 0 3.1 0.5 9 2.7 30.9 23 82.8 76 201 95 219 39 130 4.4 39.4 0.1 4.2 0 0 0 0 0 0 0 0
DEC Obsn Hours Total M 01 09 17 Obsn C to to to Hrs W 08 16 24 B
JAN Obsn Hours Total M 01 09 17 Obsn C to to to Hrs W 08 16 24 B
FEB Obsn Hours Total M 01 09 17 Obsn C to to to Hrs W 08 16 24 B 0 0 0 0 0 0 0 0 0 58 52 55 53 49 45 40 37 33 0 0 0
MAR Obsn Hours Total M 01 09 17 Obsn C to to to Hrs W 08 16 24 B 0 0 0 0 0 0 0 0 0 0 0.3 0.8 15 84 105 40 3.5 0 0 0 0 0 0 0 0 0 0 0 0 1.4 5.3 12 38 113 71 5.8 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1.4 0.7 6 2.9 15.3 6.6 45.7 46 174 127 281 62 173 3.1 44.3 0 3.5 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 56 56 53 52 51 48 45 40 37 0 0 0 0
APR Obsn Hours Total M 01 09 17 Obsn C to to to Hrs W 08 16 24 B 0 0 0 0 0 0 0 0 0 0 0.5 4.3 29 104 87 15 0.3 0 0 0 0 0 0 0 0 0 0 0.3 2.1 5.8 12 28 65 92 33 2 0.1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.3 0.1 2.2 0.6 6.4 2.1 14 4.7 33.5 15 83.6 54 174 121 258 41 130 1.6 16.9 0 0.3 0 0 0 0 0 0 0 0 0 0 0 0 0 0 63 65 60 59 57 54 52 49 45 41 36 0 0 0 0
TEMP RANGE
ANNUAL TOTAL Obsn Hours Total 01 09 17 Obsn to to to Hrs 08 16 24 0 0 0 0 0 0 0 0 0.8 5.2 32.1 214 748 962 563 297 90.9 9.2 0 0 0 0 0 0 0 0 0 0 0 0 0.5 0 0.5 0.5 0 0.5 6.8 0.1 6.9 18.6 1.1 19.7 43.8 4.3 48.1 94.3 13.3 108 269 37.4 312 555 126 714 668 421 1303 667 927 2341 400 892 2255 159 384 1107 35.3 102 435 3.2 11.5 106 0.4 0.6 10.2 0 0 0 0 0 0 0 0 0
M C W B 0 73 71 70 68 66 65 63 61 58 56 54 51 48 44 40 36 31 26 23 0
SUMMER WINTER Obsn Hours Total Obsn Hours Total 01 09 17 Obsn 01 09 17 Obsn to to to Hrs to to to Hrs 08 16 24 08 16 24 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.5 0 0.5 0 0 0.5 0 0.5 0 0 6.8 0.1 6.9 0 0 18.3 1.1 19.4 0 0 41.3 4.2 45.5 0 0.8 83.9 12.7 97.4 0 5.2 241 34.1 280 0 31.3 471 114 617 0.8 198 435 360 992 16 607 161 621 1389 140 552 13 310 875 410 76.1 0.2 14 90.3 487 1.7 0 0 1.7 295 0 0 0 0 90.9 0 0 0 0 9.2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.3 0 0.3 2.5 0.1 2.6 10.4 0.6 11 28.1 3.3 31.4 84.2 11.9 96.9 234 61.5 311 506 306 952 387 582 1380 159 370 1017 35.3 102 433 3.2 11.5 106 0.4 0.6 10.2 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 60 0 0 0 0 60 0 0.1 0 0.1 56 0 1.9 0 1.9 56 0 5.3 0.8 6.1 55 4.4 24 6.7 34.6 52 17 69 38 125 49 42 82 78 202 44 82 53 87 222 40 75 12 35 123 36 26 0.5 2.4 29 0 1.4 0 0 1.4 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 55 0 0 0 0 56 0 0.2 0 0.2 53 0 2.3 0.3 2.6 56 2.4 13 3.5 19.3 53 12 55 32 98.5 49 41 88 73 201 45 61 67 87 214 40 82 20 44 146 36 43 2.5 8 53.1 33 7.4 0.4 0.6 8.4 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 59 0 0.3 0 0.3 55 0 8 0.5 8.5 56 1.6 36 7.6 45.1 53 29 91 60 180 49 62 68 88 218 44 72 21 55 148 40 48 1.9 14 63.6 35 14 0.2 1 15.5 31 0.4 0 0 0.4 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
115/119 110/114 105/109 100/104 95/99 90/94 85/89 80/84 75/79 70/74 65/69 60/64 55/59 50/54 45/49 40/44 35/39 30/34 25/29 20/24 15/19
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Sample Bin Data

TEMP RANGE ANNUAL TOTAL Obsn Hours Total 01 09 17 Obsn to to to Hrs 08 16 24 0 0 0 0 0 0 0 0 0.8 5.2 32.1 214 748 962 563 297 90.9 9.2 0 0 0 0 0 0 0 0 0 0 0 0 0.5 0 0.5 0.5 0 0.5 6.8 0.1 6.9 18.6 1.1 19.7 43.8 4.3 48.1 94.3 13.3 108 269 37.4 312 555 126 714 668 421 1303 667 927 2341 400 892 2255 159 384 1107 35.3 102 435 3.2 11.5 106 0.4 0.6 10.2 0 0 0 0 0 0 0 0 0 M C W B 0 73 71 70 68 66 65 63 61 58 56 54 51 48 44 40 36 31 26 23 0
115/119 110/114 105/109 100/104 95/99 90/94 85/89 80/84 75/79 70/74 65/69 60/64 55/59 50/54 45/49 40/44 35/39 30/34 25/29 20/24 15/19
Temperature values below the 65F mark can be ignored for the simulation, since the system will be in economizer.
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Calculation for Off-Design Values

115/119 110/114 105/109 100/104 95/99 90/94 85/89 80/84 75/79 70/74 65/69 60/64 55/59 50/54 45/49 40/44 35/39 30/34 25/29 20/24 15/19
Successively enter db/wb combinations into tower selection to simulate operation

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115/119 110/114 105/109 100/104 95/99 90/94 85/89 80/84 75/79 70/74 65/69 60/64 55/59 50/54 45/49 40/44 35/39 30/34 25/29 20/24 15/19
? ? 92 ?

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115/119 110/114 105/109 100/104 95/99 90/94 85/89 80/84 75/79 70/74 65/69 60/64 55/59 50/54 45/49 40/44 35/39 30/34 25/29 20/24 15/19
? ? 87 ?

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115/119 110/114 105/109 100/104 95/99 90/94 85/89 80/84 75/79 70/74 65/69 60/64 55/59 50/54 45/49 40/44 35/39 30/34 25/29 20/24 15/19
? ? 82 ?

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115/119 110/114 105/109 100/104 95/99 90/94 85/89 80/84 75/79 70/74 65/69 60/64 55/59 50/54 45/49 40/44 35/39 30/34 25/29 20/24 15/19
? ? 77 ?

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115/119 110/114 105/109 100/104 95/99 90/94 85/89 80/84 75/79 70/74 65/69 60/64 55/59 50/54 45/49 40/44 35/39 30/34 25/29 20/24 15/19
? ? 72 ?

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115/119 110/114 105/109 100/104 95/99 90/94 85/89 80/84 75/79 70/74 65/69 60/64 55/59 50/54 45/49 40/44 35/39 30/34 25/29 20/24 15/19
? ? 67 ?
Lower wb means: Tower fan can run at less than 100%. How will coil react to less airflow, and what will precooling effect be?
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Coil Calculations
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Coil Calculations
Why use cooling towers instead of refrigeration? Compare 3 models of cooling tower use @ Design Annual Analysis Compare 3 models annual energy use Compare 3 models life cycle cost Skip coil calculations Take desired design values and calculate what coil overall heat transfer needs to be LMTD method Explanation of -NTU method Verify design condition with calculated coil heat transfer -NTU method Verify other condition with calculated coil heat transfer -NTU method
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Coil Calculations-Step 1
Why use cooling towers instead of refrigeration? Compare 3 models of cooling tower use @ Design Annual Analysis Compare 3 models annual energy use Compare 3 models life cycle cost Take desired design values and calculate what coil overall heat transfer needs to be LMTD method Explanation of -NTU method Verify design condition with calculated coil heat transfer -NTU method Verify other condition with calculated coil heat transfer -NTU method
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Coil Calculation - LMTD

LMTD method:
T1= Thot,in Tcold,out and T2= Thot,out Tcold,in Tlmtd = T2 T1 ----------------ln (T2/ T1)
Q = UA Tlmtd
Use this method to determine UA, based on the temperatures we expect from design. In other words, we dont care exactly how the U and A are derived (fin spacing, number of rows etc). Well just assume that for the given problem, a coil can be purchased with the right UA. We will then use this number to simulate how that coil will operate under different conditions.
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Coil Calculation LMTD Example

LMTD method:
T1= 83 80 and T2= 68.2 65 Tlmtd = 3.2-3.0 ----------------- = 3.1 ln (3.2/ 3.0)
Q = UA * 3.1 = 125 gpm * 15= 937.5 MBH
UA = 302,524 Btu/hF
This number UA, which represents the overall heat transfer coefficient of the coil, can now be used to calculate performance under different conditions.
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Coil Simulation -NTU

-NTU method:
UA C 1 min 1 exp C max C min = UA C min C 1 min 1 exp C max C max C min
T Hot ,out = T Hot ,in

TCold, out TCold,in
Qact C Hot
QMax = C Min (T Hot ,in T Cold ,in ) Qact = QMax
Q act + C Cold
By taking the UA we calculated earlier, and using the mass flow rates for each medium and the specific heat, we can determine what the leaving temperatures will be, based on the calculated effectiveness
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Coil Simulation -NTU

-NTU method: Note that the formula shown below for only holds for a perfect counterflow heat exchanger. For other types (most real heat exchangers are somewhere between a counter flow and parallel-flow exchanger). For such a case, the NTU is calculated, and is read off a chart
C min =0 C max
UA C 1 min 1 exp C max C min = UA C C 1 min 1 min exp C max C max C min
C min =1 C max
NTU =
Perfect Counter-flow
UA Cmin
Parallel flow Counter-flow
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Coil simulation -NTU

-NTU method: Note that the formula shown below for only holds for a perfect counterflow heat exchanger.
We will use only For other types (most real heat exchangers are somewhere between a counter flow and parallel-flow exchanger). this method
For such a case, the NTU is calculated, and is read off a chart
C min =0 C max
UA C 1 min 1 exp C max C min = UA C C 1 min 1 min exp C max C max C min
C min =1 C max
NTU =
Perfect Counter-flow
UA Cmin
Parallel flow Counter-flow
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Coil Simulation -NTU Example

Design at 83 / 68.2F for 57,700 cfm of air and 65 / 80F for 125 gpm of water (78.3 tons or 937 MBH) Reduce fan speed, use 40,000 cfm and Ambient reduced to 67F Performance now: Air at 67 / 65.1F for 40,000 cfm and 65 / 66.3F for 125 gpm of water (7 tons or 84 MBH)
-NTU method:
53

-NTU method:
Design at 83 / 68.2F for 57,700 cfm of air and 65 / 80F for 125 gpm of water (78.3 tons or 937 MBH) Reduce fan speed, use 40,000 cfm and Ambient reduced to 67F Performance now: Air at 67 / 65.1F for 40,000 cfm and 65 / 66.3F for 125 gpm of water (7 tons or 84 MBH) =0.96 Qmax = 88 MBH =0.83 Qmax = 1,126 MBH
Note that Qmax is the amount of heat that could be exchanged with an infinitely large (or perfect) heat exchanger. is a measure of how well the actual exchanger under consideration approximates this ideal exchanger, and varies with selected temperatures and flows.
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55

Design at 83 / 68.2F for 57,700 cfm of air and 65 / 80F for 125 gpm of water (78.3 tons or 937 MBH)
C1 = c11 = 0.24
-NTU method:
=0.83 Qmax = 1,126 MBH
lb min Btu Btu * 60 = 63,396 * 57,700cfm * 0.0763 lbF cuft h hF
Btu min lb Btu = 62,550 * 60 * 125gpm * 8.34 C 2 = c 22 = 1.0 hF h gal lbF
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Design at 83 / 68.2F for 57,700 cfm of air and 65 / 80F for 125 gpm of water (78.3 tons or 937 MBH)
302,524 62,550 1 exp 1 63,396 62,550 = 302,524 62,550 62,550 exp 1 1 63,396 62,550 63,396
-NTU method:
=0.83 Qmax = 1,126 MBH
THot , out
THot ,in
Q act CHot
68.2 = 83
938,126 63,396 Q act C Cold
QMax = 62,550(83 65) = 1,126 MBH Q act = QMax = 0.83 * 1,126 = 938 MBH
TCold, out
TCold,in +
938,126 80 = 65 62,550
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Coil simulation -NTU example

Design at 67 / 65.1F for 40,000 cfm of air and 65 / 66.3F for 125 gpm of water (7.0 tons or 84 MBH)
C1 = c11 = 0.24
-NTU method:
=0.96 Qmax = 88 MBH
min Btu Btu lb * 40,000cfm * 0.0763 * 60 = 43,949 lbF cuft h hF
C 2 = c 22 = 1.0
Btu Btu lb min * 125gpm * 8.34 * 60 = 62,550 lbF gal h hF
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Coil simulation -NTU example

Design at 67 / 65.1F for 40,000 cfm of air and 65 / 66.3F for 125 gpm of water (7.0 tons or 84 MBH)
302,524 43,949 1 exp 1 62,550 43,949 = 302,524 43,949 43,949 exp 1 1 62,550 43,949 62,550
-NTU method:
=0.96 Qmax = 88 MBH

=
THot , out
THot ,in
Q act CHot
65.1 = 67
84,186 43,949 Q act C Cold
QMax = 43,949(67 65) = 87.8MBH Q act = QMax = 0.96 * 87.8 = 84.2MBH
TCold, out
TCold,in +
84,186 66.3 = 65 62,550

60
Annual Energy Use

Why use cooling towers instead of refrigeration? Compare 3 models of cooling tower use @ Design Annual Analysis Compare 3 models annual energy use Compare 3 models life cycle cost Back to coil calculations
61
Energy Usage from Annual Simulation

Direct 1-Stage 2-Stage 1.7 MWh per year 17.5 MWh per year
Indirect 1-Stage 20.4 MWh per year
62
Life Cycle Cost

63
Initial Cost
Direct 1-Stage CT1/2 Coils (59,320 cfm)x2 Total Indirect 1-Stage CT1/2 CT3/4 Coils (78,500 cfm)x2 Total 2-Stage CCT1/2 CCT3/4 Coils (114,000 cfm)x2 Total $ 36,000 $ 72,000 $ 108,000 $ $ $ $ $ $ $ $ 40,000 120,000 92,000 252,000 125,000 105,000 145,000 375,000
Note: pricing is for towers, and estimated coil + custom coil installation. Pricing does not include piping, valves and associated controls.
64
Simplified Life-Cycle Cost

Direct 1-Stage first cost Energy cost, 20 years Total Indirect 1-Stage first cost Energy cost, 20 years Total 2-Stage CCT1/2 Energy cost, 20 years Total $ 108,000 $ 4,100 (1.7 MWh/a) $ 112,100 $ 252,000 $ 49,000 (20.4 MWh/a) $ 301,000 $ 375,000 $ 42,000 (17.5 MWh/a) $ 417,000
Note: pricing is for equipment only. This includes towers, and estimated coil + installation of coil on tower. Pricing does not include piping, valves, rigging, setting, startup or associated controls. Direct 1-Stage also has lower water usage and maintenance costs (not included in this simple analysis)
65
Comparison to Refrigerated Model Aircooled chiller

Chiller first cost, 240 tons Energy cost, 20 years Total $ 132,000 $ 193,000 (80.6 MWh/a) $ 325,000
Note: pricing is for equipment only. This includes towers, and estimated coil + installation of coil on tower. Pricing does not include piping, valves, rigging, setting, startup or associated controls. Note: Chiller energy cost derived from IPLV data, published in manufacturers literature for a 240 ton screw chiller. Use IPLV by taking EER at 100%, 75%, 50% and 25% load to estimate energy use at each temperature bin.
EER =
Btuout Btuout Win = Win EER

66
20-year life cycle cost

20-year Life cycle cost
$700,000
$600,000
$500,000 Life cycle cost
$400,000
Direct Indirect 2-Stage Chiller
$300,000
Break-even at around $ 0.19/kWh

$200,000

$100,000
Note: For a more realistic calculation, piping materials & labor have to be added to the calculation. This makes the chiller model look even better, and break-even occurs at higher electricity prices.
$0 0.06 0.08 0.1 0.12 0.14 0.16 0.18 0.2 0.22 0.24 0.26 0.28 0.3 0.32 Cost $ / kWh
67
15-year life cycle cost

15-year Life cycle cost
$700,000
$600,000
$500,000 Life cycle cost

Direct
$400,000
Indirect 2-Stage Chiller
$300,000

$200,000

$100,000
Note: For a more realistic calculation, piping materials & labor have to be added to the calculation. This makes the chiller model look even better, and break-even occurs at higher electricity prices.
$0
0.06 0.08 0.1 0.12 0.14 0.16 0.18 0.2 0.22 0.24 0.26 0.28 0.3 0.32
Cost $ / kWh
68
Questions
?
69
WET
Back to cooling tower principles
DRY
70
COLD
HOT
71
Flo rid a
San Francisco
Las Vegas
72
90
70 50
Temperature
73
Absolute Humidity
1.6 lb water/100 lb air
0.45 lbs water/100 lb air
Temperature
Absolute Humidity
74
2.7 lb water/100 lb air
90% RH
FOG
50% RH
20% RH
Temperature
Absolute Humidity
75
FOG
90% RH
50% RH
20% RH
1.08 lbs water/100 lb air
Temperature
Absolute Humidity
76
For the same moisture content, warmer air has a lower relative humidity or a lower saturation rate because hot air can absorb more moisture
Wet bulb temp.

87 wb
90/90%
68 wb 90/33%
Temperature
Absolute Humidity
77

Cooling Tower Info

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Indirect Evaporative Cooling Systems Using Cooling Towers Rev.

Reinhard Seidl, P.E. Taylor Engineering

Why use systems without compressors?

Cooling Without Compressors?

Where is this applicable?

Air cooled chiller-design values

Water cooled chiller-design values

Cooling tower-design values

Cooling tower basic operation

Cooling tower basic operation

Cooling tower basic operation

Cooling tower basic operation

Cooling tower basic operation

More detail on psychrometrics

120 tons capacity, low airflow

120 tons capacity, higher airflow

Range=18F Tw,out=66F Tw,in=84F 19

Range=23F Tw,out=61F Tw,in=84F 20

3 Strategies for multi-stage cooling using cooling towers

Direct 1-Stage Design

Pre-cooling effect-special case

Outside air Pre-cooled air

Range=23F Tw,out=61F Tw,in=84F 25

Direct 1-Stage Design

200 tons tower capacity

79.7 tons pre-cooling ?

Indirect 1-Stage Design

0.311 0.093 0.065 0.469

kW/ton kW/ton kW/ton kW/ton

Indirect 1-Stage Design

0.311 0.093 0.065 0.469

kW/ton kW/ton kW/ton kW/ton

CCT1/2 each: CCT3/4 each:

0.155 0.311 0.075 0.541

kW/ton* kW/ton kW/ton kW/ton

111 tons tower capacity

73.4 tons pre-cooling

CCT1/2 each: CCT3/4 each:

0.155 0.311 0.075 0.541

kW/ton* kW/ton kW/ton kW/ton

Energy and Water Usage at Design Conditions

Bin Data and Building Load

Sample Bin Data

DEC Obsn Hours Total M 01 09 17 Obsn C to to to Hrs W 08 16 24 B

JAN Obsn Hours Total M 01 09 17 Obsn C to to to Hrs W 08 16 24 B

FEB Obsn Hours Total M 01 09 17 Obsn C to to to Hrs W 08 16 24 B 0 0 0 0 0 0 0 0 0 58 52 55 53 49 45 40 37 33 0 0 0

Sample Bin Data

Calculation for Off-Design Values

Successively enter db/wb combinations into tower selection to simulate operation

Calculation for Off-Design Values

Successively enter db/wb combinations into tower selection to simulate operation

Calculation for Off-Design Values

Successively enter db/wb combinations into tower selection to simulate operation

Calculation for Off-Design Values

Successively enter db/wb combinations into tower selection to simulate operation

Calculation for Off-Design Values

Successively enter db/wb combinations into tower selection to simulate operation

Calculation for Off-Design Values

Successively enter db/wb combinations into tower selection to simulate operation

Calculation for Off-Design Values

Coil Calculation - LMTD

Coil Calculation LMTD Example

Q = UA * 3.1 = 125 gpm * 15= 937.5 MBH

Coil Simulation -NTU