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Cooling Tower Info
Cooling Tower Info
1 01/16/06
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 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
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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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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Tr (10F
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Psychrometric diagram
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Pre-cooling effect
h * tower airflow (lbs/h) = cooling tower capacity (Btu/h) h
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
Pre-cooling effect
h * tower airflow (lbs/h) = cooling tower capacity (Btu/h) h
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
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
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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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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
hp
Approach=4F
hp = Pre-cooling Load
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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
0.037 gpm/ton
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
0.037 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
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
0.027 gpm/ton
2-Stage Design
73.4 tons heat re-gain
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
0.027 gpm/ton
Note that these values are fairly easily derived, but dont show the whole picture.
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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
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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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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
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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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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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
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 ?
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 ?
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 ?
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 ?
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 ?
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
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
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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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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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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 Calculations-Step 2
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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Qact C Hot
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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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
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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
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-NTU method:
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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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Coil Calculations-Step 3
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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-NTU method:
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-NTU method:
THot , out
THot ,in
Q act CHot
68.2 = 83
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 Calculations-Step 4
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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-NTU method:
C 2 = c 22 = 1.0
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-NTU method:
THot , out
THot ,in
Q act CHot
65.1 = 67
TCold, out
TCold,in +
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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.
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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)
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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 =
$600,000
$400,000
$300,000
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
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$600,000
$400,000
$300,000
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
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Questions
?
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Psychrometric diagram
WET
Back to cooling tower principles
DRY
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Psychrometric diagram
COLD
HOT
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Psychrometric diagram
Flo rid a
Back to cooling tower principles
San Francisco
Las Vegas
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Psychrometric diagram
90
70 50
Temperature
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Absolute Humidity
Psychrometric diagram
Temperature
Absolute Humidity
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Psychrometric diagram
90% RH
FOG
50% RH
20% RH
Temperature
Absolute Humidity
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Psychrometric diagram
FOG
90% RH
50% RH
20% RH
Temperature
Absolute Humidity
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For the same moisture content, warmer air has a lower relative humidity or a lower saturation rate because hot air can absorb more moisture
Psychrometric diagram
87 wb
90/90%
68 wb 90/33%
Temperature
Absolute Humidity
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