The cooling tower is nothing but a device used to reduce the heat and increase production efficiency. In simple words, it is used to cool industrial hot water. Its size ranges from tiny to massive towers based on the requirement.
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A cooling tower’s main function is to remove heat from water by evaporating a little amount of it. The mixture of warm and cooler water leads to latent heat evaporation causing the water to cool. A commercial cooling tower has an average life expectancy of 15-20 years.
Several industries use a cooling tower, such as chemical manufacturing plants, primary metals processing plants, petroleum refineries, rubber products manufacturing plants, tobacco manufacturing plants, glass manufacturing plants, and textile manufacturing plants.
The cooling tower provides high cooling efficiency, needs less maintenance, consists of reliability and sustainability, and can be operated for a longer duration. Now, let us have a look at a few questions that will help you get clear with the idea behind cooling towers.
1. What is a cooling tower?
A cooling tower is nothing but a heat exchanger. It extracts waste heat to the atmosphere by cooling the water stream to a lower temperature. Water begins to cool when it comes into contact with air. In this way, the same amount of water is evaporated and thereby cool down the hot water.
2. What are the different types of cooling towers?
There are two types of cooling towers:
3. What is an Evaporative cooling tower?
Cooling is provided via an evaporative cooling tower based on a design wet-bulb temperature. This cooling tower can cool water to 85 degrees Fahrenheit. It is the most economical option for cooling a large amount of water.
4. What is entering wet-bulb temperature (EWBT)?
EWBT is nothing but a device that measures the level of humidity in the air entering the cooling tower. The higher the temperature of the wet bulb, the more moisture exists in the air. The cooling tower needs to be larger with a high wet-bulb temperature compared to a lower wet-bulb temperature.
5. What is the difference between ‘counterflow’ and ‘cross flow’ cooling towers?
In a counterflow cooling tower, air travels vertically upwards through the fill and makes intimate contact with water. Hence, both air and water are in opposite directions. In a crossflow tower, air passes through the fill horizontally, crossing the downwards water flow.
6. Why choose the FRP cooling tower?
FRP (fibreglass reinforced polyester) is mixed with a gel coating that protects the cooling tower from direct UV rays. Additionally, it also provides a higher resistance to rot and decay to all FRP portions. Hence, FRP cooling tower manufacture is considered in extreme climate conditions.
7. How do Cooling Towers Operate in Cold and Sub-zero Weather?
In cold weather, the cooling tower is operated with a heat load. The operating water flow is directly bypassed to the cold-water basin to prevent icing if the heat load drops too low. The water flow is maintained over the cooling tower.
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8. What is the difference between a ‘Force Draft’ and ‘Induced Draft’ cooling tower?
A Force-draft cooling tower imparts an agitation system that forces air into the tower, and fans are positioned on the side of the cooling water. Meanwhile, induced draft tower works by pulling air from the building and fans are located on the top of the cooling tower.
9. How is Water Loss Calculated in Cooling Tower?
There are three types of water loss in the cooling tower: drift, evaporation, and blowdown. Drift loss is while circulating water for the natural draft tower. Evaporation loss is simple as it sounds, water loss due to evaporation. Blowdown loss is during circulating water that lowers the concentration of solids.
10. What is Cooling Tower Drift?
Drift is undesirable loss of water to the environment through tiny, unevaporated droplets in the existing cooling tower stream. These water droplets carry minerals, microorganisms, debris, and chemicals from the circulating water. Hence, it potentially impacts the environment.
11. What is the regulating organization for cooling tower technology, and where can you learn more about the cooling tower industry?
There’s a worldwide industry named Cooling Technology Institute (CTI) authorized on cooling tower technology. In this institute, there are manufactures, owners/operators, and supplies providing facilities for the cooling tower. Moreover, you can get more information on CTI guidelines and specifications on the CTI site.
12. How to clean Air Inlet Louvers of Cooling Tower?
The best method to remove the minerals from the air inlet louvres is to remove the louvre equipment and let them soak in the cold-water basin of the unit. The chemicals present in the water treatment unit will neutralize and dissolve the minerals buildup. The time depends on the severity of the buildup.
1) COILS AND COUNTER-FLOW
The first thing to remember about coils and counter-flow is that chilled water coils are always built to be piped in counter-flow. This means that the air flows in the opposite direction as the water. For example, with counter-flow, the air flows through rows 1-8, while the water runs through rows 8-1. Water always travels through the coil in the opposite direction of the air; hence the term “counter-flow.”
Direct Expansion Coils (Evaporator Coils) are also piped in the same manner.
With that said, what happens when you do not pipe cooling coils counter-flow? Almost all coil selection programs you will see or use will be based on counter-flow conditions. If you opt to not counter-flow a chilled water coil, you’ll have to reduce the coil’s overall performance by a certain percentage. That percentage reduction varies based on each coil’s unique dimensions, but a reliable estimate is a loss of 8-12%. Simply piping the coils in the correct manner from the beginning would seem to be the easiest and most cost-effective solution.
Did you recently turn on your DX systems only to find your Condenser Coils are not working? Simple fix right? Unfortunately, no. If you get lucky, you can send us the model number of the unit, and there’s a great chance we’ve already built it. In the case that we do not have that model number on file, you have two options. You can go back to the OEM and wait two months for an OEM part while paying through the roof. Or you can call Capital Coil, and we’ll walk you through the engineering it takes to replace a condenser coil.
Very rarely do condenser coils ever freeze so the first thing you’re going to want to know is if your coil died of corrosion, old age, or possibly vibration. Old age is obviously preferable because with a few easy dimensions, we’ll have enough to price up your duplicate coil. Condenser coils are usually outside and are easily accessible for measurements and digital pictures. With just the size, the rows, and fins/inch, you can get a price. And digital pictures of the headers and return bends will give us a good idea of the circuiting and sub-cooler circuits.
If the coil has been eaten away by corrosion, it was an improper design to begin with. Most people don’t know that salt in the air will ruin aluminum fins within a year or two. There are two ways to combat this.
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