Title of Experiment

Cooling Tower Demonstration.

Objective of Experiment

1. To determine the ‘end state’ properties of air and water from tables or charts.
2. To determine energy and mass balances using steady flow equation on selected
system.
3. To investigate the effect of cooling load on “Wet Bulb Approach”.
4. To investigate the effect of air velocity on (a) Wet Bulb Approach, (b) pressure
drop through the packing.

Introduction

Cooling tower is a heat rejection tower. It is a heat exchanger which extracts and release
the waste heat to the atmosphere through the direct contact of hot water and cool dry air.
The laboratory cooling tower is a cooling tower unit from a commercial air conditioning
system. It is applied to study the principles of cooling tower operation. It is used in
combination with a residential size water heater to supply cool water to an industrial
process by simulating a cooling tower. In the case of laboratory unit, water heater is used
to provide the cooling tower process load.

Consider an air stream passing over the surface of a warm water droplet or film. If
it is assumed that the air is cooler than the warm water, the air will be cooled down by
radiation, convection, conduction and evaporation. However, normally radiation effect is
not significant and may be neglected. Conduction and convection depend on the
temperature difference, air velocity, surface area, etc. The most significant effect is
evaporation in which cooling takes place by the diffusion of water molecules from the
surface into the surrounding air.

Experiment is conducted to study the “Wet Bulb Approach” by varying the

cooling load and air velocity and pressure drop by varying the pressure drop. This report
will also explain the theory behind the operation of cooling tower and how the laboratory
unit is operated. An example of mass and energy balance on the laboratory unit will be
shown.

Material and Equipment

Item Description Item Category Quantity estimation(per

set/group of student)
Cooling Tower Equipment 1
Demonstration
Distilled water Consumable 8 liter
Beaker Lab ware 2

The cooling tower unit contains:

1. Load tank:
- 9 liters tank fitted with 0.5kW and 1.0kW heaters, totaling up to 1.5kW
heating.
2. Make-up tank:
- Tank fitted on top of load tank.
3. Pump:
- 40W centrifugal pump to circulate water.
4. Air distribution chamber:
-Centrifugal fan with the capacity of providing 235cfm air flow.
-Air flow rate can be adjusted by a Perspex intake chamber.

5. Tower:

- Dimension of 15cm × 15cm × 60cm.

- Fitted with 8 decks of inclined packing.

6. Water circuit:

- Circulates water from the load tank to the top of the tower and back to the load
tank for recirculation.
7. Temperature sensors:

- T1 Dry Bulb Inlet Air Temperature.

- T2 Wet Bulb Inlet Air Temperature.

- T3 Dry Bulb Outlet Air Temperature.

- T4 Wet Bulb Outlet Air Temperature.

- T5 Inlet Water Temperature.

- T6 Outlet Water Temperature.

- T7 Make-up Tank Temperature.

- T8 Hot Water Tank Temperature.

8. Differential pressure sensors:

- V5 remains open at all times.

- Orifice differential pressure: open V4.

- Pressure drop across packing: open V3 and V6.

Procedure

Result and Calculation

Experiment 1: Determination of the ‘end state’ properties of air and steady flow
equations with cooling load of 1.0kW and maximum air flow

Table 1: Temperature of each sensors and pressure with cooling load of 1.0 kW and
maximum air flow
 Time Dry bulb Wet bulb Dry bulb Wet bulb Inlet Outlet Make Pressure h (cm)
(min) inlet air inlet air outlet air outlet air water water up tank (Pa)
(T1) (T2) (T3) (T4) (T5) (T6) (T7)
0 25.2 23.1 28.5 27.9 31.7 25.2 24.6 150 0
2 25.4 22.9 27.9 27.3 31.0 25.0 24.5 150 1.1
4 25.3 22.4 27.7 27.1 30.5 24.8 24.7 150 2.1
6 25.3 23.0 27.4 26.8 30.4 24.8 24.6 150 3.1
8 25.2 22.9 27.4 26.7 30.2 24.7 24.6 150 4.1
10 25.0 22.8 27.3 26.5 29.9 24.6 24.7 150 5.0
12 24.8 22.7 27.1 26.5 29.8 24.4 24.7 140 6.0
14 24.7 22.5 27.0 26.4 29.7 24.4 24.8 140 6.8
16 24.4 22.3 26.9 26.3 29.8 24.2 24.6 130 7.8
18 24.4 22.3 26.7 26.1 29.7 24.1 24.7 125 8.7
20 24.4 22.0 26.5 26.0 29.6 24.0 24.6 120 9.6
Average 24.9 22.6 27.3 26.7 30.2 24.6 24.6 141.4

a) Firstly, we need to calculate the make-up rate of system after 20 minute. The
equation to calculate make-up rate is given below:

π d2 1
ṁ E = × ρ× h ×
4 t

Where d = 0.074m, diameter of make-up tank

ρ = 1000kg/m3, density of water

h = 0.096m, height of water loss from make-up tank

π (0.074)2 1
ṁE = ×1000 ×0.096 ×
4 1200

ṁ E =3.441 ×10−4 kg/ s

b) To verify the mass and energy balance, we can use steady flow equation. There
are two kind of system (System A and System B).
 For System A:
Figure 1: System A
The steady flow equation can be written as:
Q−P=ṁ a ( hB −h A )−ṁ E hE

Where Q = heat transfer at load tank

P = work transfer at pump

ṁ a = low humidity air enters at point A / high humidity air leaves at point B

m E = make-up water enter at point E

In this case, Q = 1000W and P = -40W as it is work input, therefore it is negative.

Q−P=1000−(−40)

= 1040W

To calculate ṁ a, equation below is used:

x
ṁa=0.0137
√ v ab (1+ω)
Where x = orifice differential in mm H 2 O

v ab = specific volume of air at the outlet

ω = humidity ratio of mixture

To calculate the specific volume and humidity ratio, we need to use average T3 and T4
which is 27.3˚C and 26.7˚C respectively that obtained from experiment data with the aid
of psychometric chart.

From psychometric chart:

v ab= 0.88m3 /kg

ω = 0.022

x = 14.42 mm H 2 O

14.42
ṁa=0.0137
√ 0.88(1+0.022)

0.0549 kg
ṁ a=
s

To find h B, we need to use T3 and T4 which is 27.3˚C and 26.7˚C respectively with the
aid of psychometric chart :

h B=83.63 kJ /kg

To find h A , we need to use T1 and T2 which is 24.9˚C and 22.6˚C respectively with the
aid of psychometric chart :

h A =66.62 kJ /kg

ṁa ( h B−h A )− ṁE h E

The term ṁE h E can usually be neglected since its value is relatively small.

ṁ a ( h B−h A )− ṁ E h E=0.0549 ( 83.63 ×10 3−66.62× 103 )−0

 = 933.3W

The theoretical value is 1040W whereas the experimental value is 933.3W.

1040−933.3
The percentage error of system A = ×100 %
1040

= 10.26%

For System B:

Figure 2: System B

The steady flow equation can be written as below:

Q= ṁa ( h B−h A ) −ṁ w C p ( t D −t C ) −ṁ E h E

Cp = heat capacity of water

m w = mass flow rate of water

 1min 0.001 m3 1000 kg
m w =2 L/min × × ×
60 s L m3

0.0333 kg
mw =
s

Q = 1000W

The term ṁ E h E can usually be neglected since its value is relatively small.

ṁa ( h B−h A )− ṁw C p ( t D −t C )− ṁE h E=0.0549 ( 83.63 ×10 3−66.62× 103 )−0.0333 ( 4200 )( 24.6−30.2 )=1717.07 W

The theoretical value is 1000W whereas the experimental value is 1717.07W.

17170.7−1000
The percentage error of system B = ×100 %
1000

= 71.71%

Experiment 2: Determination of the effect of cooling load to the wet bulb approach

Table 2: Temperature of each sensors and pressure with cooling load of 1.5 kW and
maximum air flow

Time Dry bulb Wet bulb Dry bulb Wet bulb Inlet Outlet Make Pressure h (cm)
(min) inlet air inlet air outlet air outlet air water water up tank (Pa)
(T1) (T2) (T3) (T4) (T5) (T6) (T7)
 Graph of Wet Bulb Approach against Total Cooling Load
3.5

Wet Bulb Approach

0 24.3 22.0
2.5 26.8 26.1 30.3 24.0 24.8 120 0
2 24.1 22.0
2 27.5 26.6 31.3 24.2 24.7 120 1.1
4 24.2 22.0 28.1 27.0 32.1 24.6 24.6 120 2.0
1.5
6 24.1 22.0 28.5 27.3 32.4 24.7 24.6 115 3.1
8 24.0 21.8
1 28.7 27.8 32.8 24.8 24.7 115 4.3
10 23.9 21.7 28.8 27.8 33.0 24.8 24.5 115 5.4
0.5
12 24.0 21.8 28.9 27.9 33.2 24.8 24.5 115 6.5
14 24.0 21.9
0 29.0 27.9 33.7 24.9 24.5 120 7.7
16 24.0 21.8 28.9 27.8 Axis Title33.1 24.9 24.5 117.5 9.0
18 24.0 21.7 28.9 27.8 33.0 24.9 24.5 120 10.2
20 23.9 21.5 29.0 27.8 33.3 24.8 24.6 120 11.5
Average 24.0 21.8 28.5 27.4 32.6 24.7 24.6 117.95

Wet Bulb Approach = Outlet water temperature – wet bulb inlet air temperature

= T6 - T2

Wet bulb approach for cooling load of 1.5kW = 24.7 – 21.8

= 2.9˚C

Wet bulb approach for cooling load of 1kW in experiment 1 = 24.6 - 22.6

=2˚C

With this two group of data, we can tabulate both group of data and draw the graph of
wet bulb approach against total cooling load.

Table 3: Wet Bulb Approach of System with varies Total Cooling Load

Total Cooling Load(kW) Wet Bulb Approach (˚C)

1 2
1.5 2.9

Figure 3: Graph of Wet Bulb Approach against Total Cooling Load

 Experiment 3: Determination of the effect of air velocity to the wet bulb approach
and pressure drop

Table 4: Temperature of each sensors and pressure with cooling load of 1.0 kW and
50% of maximum air flow

Time Dry bulb Wet bulb Dry bulb Wet bulb Inlet Outlet Make Pressure h (cm)
(min) inlet air inlet air outlet air outlet air water water up tank (Pa)
(T1) (T2) (T3) (T4) (T5) (T6) (T7)
0 24.1 21.8 29.1 27.9 32.7 24.9 25.6 115 0
2 24.2 21.8 28.5 27.6 31.7 24.9 25.4 120 1.3
4 23.9 21.7 27.8 27.0 31.1 24.5 25.5 115 2.5
6 23.8 21.5 27.4 26.4 30.3 24.2 25.4 115 3.5
8 23.9 21.6 27.0 26.2 30.0 24.0 25.5 110 4.6
10 23.8 21.5 26.8 26.1 29.8 23.9 25.2 115 5.6
12 23.9 21.7 26.6 25.9 29.4 23.8 25.4 115 6.5
14 23.8 21.6 26.5 25.8 29.0 23.9 25.3 115 7.5
16 23.9 21.6 26.5 25.9 29.3 23.8 25.4 115 8.3
18 24.0 21.7 26.4 25.7 29.6 23.8 25.2 115 9.2
20 24.3 21.9 26.5 25.7 29.3 23.9 25.2 120 10.0
Average 24.0 21.7 27.2 26.4 30.2 24.1 25.4 115.45

For fully open centrifugal fan, it provides maximum 235cfm of air flow. To calculate the
nominal air velocity of fully open centrifugal fan:

The area contacted = 0.15×0.15 = 0.0225m 2

 Graph of Wet Bulb Approach against Nominal Air Velocity
2.5

2.4

2.3

Wet Bulb Approach

2.2

2.1

1.9

1.8

235 ft 3 0.0283 m 3 1min 2

v= × 3
× ÷ 0.0225 m = 4.926m/s
min 1 ft 60 s

For 50% open of centrifugal fan,

v=0.5 × 4.926 = 2.463m/s

Table 5: Nominal air velocity of varies opening of centrifugal fan

Nominal Air Velocity (m/s)

50% opening of centrifugal fan 2.463
Fully opening of centrifugal fan 4.926

For Experiment 3 with nominal air velocity of 2.463m/s, the wet bulb approach is T6-T2
= 24.1-21.7 = 2.4˚C

For Experiment 1 with nominal air velocity of 4.926m/s, the wet bulb approach is T6-T2
= 24.6-22.6 = 2˚C

Table 6: Wet bulb approach of varies nominal air velocity

Nominal Air Velocity(m/s) Wet Bulb Approach (˚C)

2.463 2.4
4.926 2

Figure 4: Graph of Wet Bulb Approach against Nominal Air Velocity

 Graph of Pressure drop across packing against nominal air
velocity
160

Pressure drop across packing(Pa)

140

120
For 100

80

60

40

20

Experiment 3 with nominal air velocity of 2.463m/s, the pressure drop across packing is
115.45Pa.

For Experiment 1 with nominal air velocity of 4.926m/s, the pressure drop across packing
is 141.4Pa.

Table 7: Pressure drop across packing varies with nominal air velocity

Nominal Air Velocity(m/s) Pressure drop across packing(Pa)

2.463 115.45
4.926 141.4

Figure 5: Graph of Pressure drop across packing against nominal air velocity

Discussion
 In experiment 3, the centrifugal fan is half opened to determine the effect of air
velocity to wet bulb approach and pressure drop. The conditions used in this experiment
is 2.0 LPM of water flow rate and 1.0 kW of cooling load which is similar to conditions
of experiment 1. From the calculation above, we know that the nominal air velocity for
fully opened centrifugal fan is 4.926 m/s while the half opened centrifugal fan has a
nominal air velocity of 2.463 m/s. By subtracting outlet air temperature and wet bulb inlet
air temperature, we obtain the wet bulb approach temperature. A graph is plotted with
wet bulb approach against nominal air velocity. As we can see in Figure 4, the wet bulb
approach decreases with the increase of nominal air velocity, which means the half
opened centrifugal fan has a higher wet bulb approach.

From the results obtained from the experiment, the pressure drop of nominal air
velocity of 4.926 m/s is 141.4 Pa while for nominal air velocity of 2.463 m/s is 115.45
Pa. A graph of pressure drop across packing against nominal air velocity is plotted with
the data obtained. From Figure 5, we can observe that the pressure increase with the
increase of nominal air velocity. In other words, the pressure drop of fully opened
centrifugal fan is higher compared to the half opened one.

In real life, there are some applications that are similar to the cooling tower
demonstration system. Some common applications include cooling of the circulating
water applied in oil refineries, petrochemical plants, thermal power stations and HVAC
systems for cooling buildings. First of all, thermoelectric power plants used to generate
electricity requires cooling for coal, natural gas and oil. Thermoelectric power plants
generate steam by boiling water from burning of a fuel, which then generates electricity
by spinning the turbine. The steam must be cooled back to water once it has passed
through the turbine for reuse purpose. Colder water can cool the steam more efficiently
and more effective electricity is allowed. Then, air-conditioning system apply cooling
tower technology to dissipate heat. A stream of cold water created runs through a heat
exchanger and cools the hot condenser coils. Air is blown through a stream of water that
causes evaporation which cools the water stream. Lastly, some modern power stations
come with flue gas purification such as Rostock Power Station use cooling tower as flue-
gas stack (industrial chimney) to save the cost of a separate chimney structure. In
contrast, at plants without flue gas purification, corrosion might occur since raw flue gas
reacts with water to form acids.

Cooling tower packing is known as heat transfer pack which provides a large
surface area for cooling effect by evaporation. The location is below the water
distribution layer and above the sump of the cooling tower. Cooling tower packing
density affects its performance based on the heat transfer capacity. When the packing
density increases which indicates a larger surface area allowed for heat exchange between
cold water and hot air stream to happen, the efficiency of the cooling tower also
increases.

Conclusion
From the experiments above, we are able to obtain some effect from the varying
operating conditions. For experiment 1, . For experiment 2, the increase of total cooling
load will results in increase of wet bulb approach. For experiment 3, the wet bulb
approach will decreases and pressure drop will increase with the increase of nominal air
velocity.