CAPE PENISULA UNIVERSITY OF TECHNOLOGY

BELLVILLE CAMPUS

DEPARTMENT OF CHEMICAL ENGINEERING

ND : CHEMICAL ENGINEERING

SUBJECT : CHEMICAL PLANT III

LECTURER : Mr L. Kloppers, Mr. W Maree
STUDENT : Richardt Johan Loots
STUDENT NO. : 214196585

Topic Mark allocation Mark

Title Page 5

Synopsis 5

Introduction 5

Experimental Set-up and

10
Procedure

Results and Discussion

60
Calculations

Conclusions 10

Bibliography 5

Total 100

I certify that this report is my own unaided work, except for the assistance received from
the teaching staff. I undertake not to pass this report onto any other studen
Contents

List of Symbols.......................................................................................................................................ii
I.Synopsis..............................................................................................................................................iii
1.Introduction........................................................................................................................................1
2.Experimental Set-up and Procedure...................................................................................................2
2.1 Experimental Setup.....................................................................................................................2
2.2 Procedure....................................................................................................................................2
3. Results and Discussion.......................................................................................................................3
3.1 Recorded Values..........................................................................................................................3
3. 2 Mass Balance Results..................................................................................................................3
3.3 Energy Balance Results................................................................................................................4
3.4 Calculations.................................................................................................................................4
3.4.1 Mass Balance Calculations........................................................................................................4
1.Mass flow rate of water..............................................................................................................4
2.Density of Air..............................................................................................................................5
3. Total Area calculation for orifice and column............................................................................5
4. Volumetric flowrate of Air.........................................................................................................5
5. Air mass flow rate......................................................................................................................6
6. Dry Air mass flow rate................................................................................................................6
7. Mass of Vapour exiting column.................................................................................................6
8.Mass of Vapour entering column...............................................................................................6
9. Mass of evaporated water 10. Mass of water Cooled...............................................................6
3.4.2 Energy balance Calculations.....................................................................................................7
1. Enthalpy of dry air leaving 3. Enthalpy of dry Air entering...................................................7
2. Enthalpy of Vapour leaving 4. Enthalpy of Vapour entering.................................................7
5. Enthalpy of water leaving 6. Enthalpy of water entering.....................................................7
7. Overall energy balance..............................................................................................................7
3.5 Discussion...................................................................................................................................8
3.6 Conclusions......................................................................................................................................8
3.7 References.......................................................................................................................................9

i
Symbol Description Unit

h Enthalpy kJ/kg
ṁ Mass flow rate m3/hr
n moles mol
p Pressure Pa
PT Total Pressure Pa
Q Flow rate m3/hr
-1 −1
R Ideal gas constant J . K .mol
T Temperature K
VT Total Volume m3
l Height m
w Specific Humidity Kgv/kg

Greek Symbols

ρ Density Kg/m3
ɛ Efflux coefficient (0.63)

Subscripts

1 Bottom boundary of Column

2 Top boundary of Column

a Air
atm Atmospheric
s Property of the superheated vapour at the dry bulb temperature

w Water
o Orifice

ii
List of Symbols

I.Synopsis

The purpose of the experiment was to understand the workings of cooling towers and the
factors that affect the efficiency of a cooling tower. Factors such as the water flow rate and
air flow rate and how this variables affect the mass and energy contained in the system by
calculating the losses that occurred during the experiment.

During the experiment 2 runs were completed with a 15 minute duration for each and mass
and energy balances was carried out

For run 1 The amount of energy supplied by water was 2741.12 kJ/h and the amount of
energy gained by the air was 2223.6 kJ/h . A loss of 0.736 kg water and a energy loss of
517.52 kJ per hour was calculated

For run 2 now with the air flow rate doubled, The amount of energy supplied by water was
3461.5 kJ/h and the amount of energy gained by the air was 2621 kJ/h . A loss of 0.88kg
water and a energy loss of 517.52 kJ per hour was calculated

The above results was discussed and conclusions were drawn

iii
1.Introduction

Cooling towers are used to remove excess heat that is generated in places such as power stations,
chemical plants and even domestically in air conditioning units. In power stations, electricity is
generated when steam drives a turbine. This steam must be condensed before it can be returned to
the boiler to continue the cycle of steam and electricity generation. The condensation process
happens in a heat exchanger. Cooling water is needed in the heat exchanger and it is this cooling
water that is cycled through the cooling tower

Large cooling towers, like the ones seen in power stations, are called Natural Draft towers. they
create an updraft of air which cools the water as it falls down the inside of the tower. Natural draft
towers do not contain any fans to drive the air flow.

Forced draft cooling towers contain large fans which force air through a smaller tower.These are
also the types of cooling towers that may be seen on buildings which is used for air conditioning

A basic diagram to show the principles of a cooling tower

Figure 1: Basic cooling tower

1
2.Experimental Set-up and Procedure
2.1 Experimental Setup

The Cooling tower in figure 1 was used during the experiment aided by a computer which displays all
the temperature readings and flow rates.

Figure 2 : Cooling tower schematic

2.2 Procedure

1. It was ensured that the level of water in the tank was above the level sensor.
2. The Wet and Dry bulb Temperatures of water levels was checked.
3. A set point temperature was selected for water.
4. The water allowed to reach the set point temperature.
5. The level in the tank was recorded.
6. air flow and water flow rates was selected .
7. Once steady state was reached the water level was recorded and the timer
started.
8. Ater 15 minutes the values was recorded
9. Steps 3 to 8 was repeated with a different flow rate.

2
3. Results and Discussion

3.1 Recorded Values

Run 2
Run 1

Top of column Top of column

Inlet temperature (°C) 39.5 Inlet temperature (°C) 37.7

WB₂ (°C) 29.3 WB₂ (°C) 26.9

DB₂ (°C) 32.1 DB₂ (°C) 29

0.0359
Specific Humidity (kgv/kg) 1 Specific Humidity (kgv/kg) 0.03127

Bottom of column Bottom of column

Outlet temperature (°C) 31 Outlet temperature (°C) 28.4

WB₁ (°C) 20.9 WB₁ (°C) 21.7

DB₁ (°C) 21.9 DB₁ (°C) 23

0.0150
Specific Humidity (kgv/kg) 4 Specific Humidity (kgv/kg) 0.02287

Tank Level Tank Level

∆Tank height (mm) 3 ∆Tank height (mm) 3

Flowrates Flowrates

Air flow Rate (kg/s) 0.0156 Air flow Rate (kg/s) 0.0312

3
 0.0012
Water flow Rate (m³/min) 5 Water flow Rate (m³/min) 0.00145

Table 1 :Values For Run 1&2

3. 2 Mass Balance Results

Table 2: : Mass Balance of Run 1&2

ρ water @ 39.5°C (kg/m3) 992.4 ρ water @ 37.7°C (kg/m3) 993.1

Rate Rate
Water Water
(kg/h) (kg/h)
Run 1

Run 2

in 74.43  in 86.4 

cooled  73.694 cooled 85.52 

evaporated 0.736  evaporated 0.88 

3.3 Energy Balance Results

Table 3: Enthalpy Results of Run 1&2

Run 1

Run 2

Top of column Top of column

74.43
mw2¿) mw2¿) 86.4

ma2 ¿) 46.8 ma2 ¿) 92.66

ms2¿) 1.44 ms2¿) 2.95

4
 kJ kJ
ha2 ( ) ha2 ( )
kg 32.3 kg 29.17

kJ kJ
hw2 ( ) hw2 ( )
kg 165.07 kg 157.58

kJ kJ
hs2 ( ) hs2 ( )
kg 2319.71 kg 2313.9

Bottom of column Bottom of column

mw1 ¿) 73.694 mw1 ¿) 85.52

ma1 ¿) 46.8 ma1 ¿) 92.66

ms1 ¿) 0.704 ms1 ¿) 2.07

kJ kJ
ha1 ( ) ha1 ( )
kg 21.22 kg 23.14

kJ kJ
hw1 ( ) hw1 ( )
kg 129.52 kg 118.71

kJ kJ 2302.7
hs1 ( ) hs1 ( )
kg 2297.7 kg 8

3.4 Calculations

Calculations will be based on Run 1

3.4.1 Mass Balance Calculations

1.Mass flow rate of water

mw 2=ρ water x Qwater *Values from psychrometric chart

5
 kg m3
m w 2=992.4 X 0.00125
m3 min

kg
m w 2=74.43
hr

2.Density of Air

( 1+w ) kg
ρair = ¿ Mmair =0.02897
1 w mol
( )
( +
M air M water
× R × ( T WB 1 )

( Patm+ ∆ Po ) )
( 1+0.03591 ) kg
ρair = ¿ Mmwater =0.01802
1 0.03591 mol
( 0.02897 0.01802 )
( + ×8.3145 × (302.45 )

( 101325+160 ) )
kg
ρair =1.15
m3

3. Total Area calculation for orifice and column

Ao total =[ ( A0 ×n 1) + ( A 0 ×n2 ) ]−( A p ×n p ) * Values used from Table 2

π d2 π d2 π d2
Ao total = [( 4
×16 +)(4
×3 −
4)] (
×3 )
π (0.0078)2 π ( 0.0118)2 π (0.0061)2
Ao total =
4[( ×16 +
4 )(×3 −
4
×3 )] ( )
Ao total =[ ( 0.007645 ) + ( 0.0032807 ) ]−( 0.00008767 )

Ao total =0.001005 m2

Acolumn =Width 2 *Width Measured from unit

Acolumn =162.5 mm2

6
Acolumn =4.3 x 10−3 m 2

4. Volumetric flowrate of Air

2 ( p− p 0)
Q=ϵ A 0
A
1
√)
2 ρ
√ (
1− 0
A

1 2 ( 160 )
Q=(0.63)(0.001005)
0.001005 √)
2 1.15
√ 1−( 0.0043

Qair =0.0109 m3 /s

5. Air mass flow rate

kg
ma 1=ρ a x Q am a 1=1.15 3
x 0.0109 m 3 /sm a 1=46.8 kg
m h

6. Dry Air mass flow rate

*For dry air : m a 1 ¿ m a 2

1
¿ m a 1,2 x
1+ w

1 kg
¿ ×0.013
1+ 0.03591 s

kg
¿ 0.0126
s

kg
¿ 45.36
h

7
7. Mass of Vapour exiting column

m s 2=ms1 −ma 1

kg kg kg
¿ 46.8 −45.36 ¿ 1.44
h h h

8.Mass of Vapour entering column

ms 1=w1 × ma 1

kg kg kg
¿ 0.01504 ×0.013 ¿ 0.704
s s h

9. Mass of evaporated water 10. Mass of water Cooled

mw lost =m s 2−ms 1 mw 1=ms 2−ms 1

kg kg kg kg
m w lost =1.44 −0.704 m w 1=74.43 −0.736
h h hr h
kg kg
m w lost =0.736 m w 1=73.694
h h

3.4.2 Energy balance Calculations

1. Enthalpy of dry air leaving 3. Enthalpy of dry Air entering

h a2 =C p dry air ×T DB 2 h a1 =C p dry air ×T DB 1

h a2 =1006 ×32. h a1 =1006× 21.1
kJ kJ
h a2 =32.3 h a1 =21.22
kg kg

2. Enthalpy of Vapour leaving 4. Enthalpy of Vapour entering

h s 2=C p vapour ×T DB 2+ L v h s 1=C p vapour ×T DB 1 + Lv

8
h s 2=1.860 ×32.1+2260 h s 1=1.860 ×21.9+2257
kJ kJ
h s 2=2319.71 h s 1=2297.7
kg kg

5. Enthalpy of water leaving 6. Enthalpy of water entering

h w1 =C p water × T w 1 h w2 =C p water × T w 2
h w1 =4.178 ×31 h w2 =4.179 ×39.5
kJ kJ
h w1 =129.52 h w2 =165.07
kg kg

7. Overall energy balance

( ma 2 ha 2−ma 1 ha 1 ) + ( ms 2 hs 2−ms 1 h s 1) + g ( l2 ( ma 2 ha 2 )−l1 ( ma 1 h a 1) )=( mw2 hw 2−mw 1 hw 1 ) + g ¿

Run 1 Run 2

RHS(water)= 2741.12 kj/h RHS(water)= 3461.5 kj/h

9
3.5 Discussion

During the experiment it can clearly be seen that a there is a drop in water level, in this case both
water levels dropped by the same amount. This is in conclusive as the water level meter measures in
millimetres which leaves a lot of room for error. If the water were to be weighed it would have
served for much more accurate results.

Concerning the mass balance it was seen that with an increase in air flow rate a increase in
evaporation can be seen where in run 1 the flowrate of air was 13l/s with a total of 0.736 kg water
evaporated per hour . In run 2 the the air flow rate was set to 26l/s and the total amount of water
evaporated was 0.88 kg per hour. With this facts it can be seen with double the air flow rate there is
a increase in water evaporated per hour but a lower outlet temperature of the water, so by
increasing air flow rate, rate of evaporation and rate of cooling increases. Decreasing air flow rate,
decreases evaporation and rate of cooling.

In the energy balance it can be seen that the energy supplied by the hot water,2741.12 kj/h, in run 1
is not equal to the energy removed by the air ,2223.6 kj/h. It can also be seen that the difference in
energy is more in run2 than run 1 which is possible due to the increase in air flow rate. The missing
energy can be contributed to many various aspects such as heat losses through the chamber, pipes
or tank. To reduce the energy losses one can insulate the column and pipes entering, but that would
defeat the purpose of a cooling tower which is to lose energy and heat

3.6 Conclusions

The experiment was successfully carried out and the calculations were made for Mass and energy
It was seen that mass and energy is lost when using a cooling tower.

Given al the results collectively it can be seen that many variables play a role when using a cooling
tower in the industry.

The value of cooling towers within the industry is understood and the efficiency is good that is why
they are so widely used in the industry

10
3.7 References

 Coulson , J.M and Richardson , F.1999. Chemical Engineering “ vol 1 , 3rd edition:
BUTTERWORTH HEINEMANN .
 Gerald Bowen Hill, E. J. Pring, Peter David Osborn, William Stanford. (1990).
Cooling towers: principles and practice. Technology & Engineering: Butterworth-
Heinemann.
 Perry, R. 1997.Perry’s Chemical Engineers’ Handbook, 6th ed. Mc Graw Hill.
 "Chemical Engineering Practical manual",Dep. of Chemical engineering.

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