Parameters of the Atmospheric Air in the Dimensioning of Industrial Cooling Tower

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1 17 th Symposium on Thermal Science and Engineering of Serbia Sokobanja, Serbia, October 20 23, 2015 Society of Thermal Engineers of Serbia Faculty of Mechanical Engineering in Niš Parameters of the Atmospheric Air in the Dimensioning of Industrial Cooling Tower Laković Mirjana a, Laković Slobodan a and Jović Milica a a Faculty of mechanical engineering, University of Niš, Serbia, lmirjana@masfak.ni.ac.rs Abstract: For the purpose of cooling in the adhesive factory ''Chemise doo '' in Aleksinac, 350 kw mechanical draught wet cooling tower was designed and built. Dimensioning of the cooling tower was done according to parameters of the atmospheric air higher than the standard recommendations given in the literature. This was done to ensure the smooth functioning of the cooling process, and therefore adhesive production in the examined plant during the hottest periods of the year. In this paper, the reasons for the deviation from the recommendations and analysis of operation of the cooling tower in the summer and winter season is given. Keywords: cooling tower, parameters of the atmospheric air, cooling water 1. Introduction Cooling towers are a very important part of many chemical plants. They represent a relatively inexpensive and dependable means of removing low grade heat from cooling water. Cooling towers are heat exchangers that are used to dissipate large heat loads to the atmosphere. All cooling towers that are used to remove heat from an industrial process or chemical reaction are referred to as industrial process cooling towers [1]. Applying recirculation cooling system up to 98% savings in water consumption can be achieved. Payback period depends on the capacity of the plant, the cost of equipment, automation etc. [2] Figure 1. Closed Loop Cooling System In general, the design solution of cooling systems with wet cooling towers depends on the power and type of plant, thermodynamic parameters, techno-economic conditions, cost of equipment and other. The required tower size will be a function of: cooling range, approach to wet bulb temperature, mass flow rate of water, wet bulb temperature, air velocity through tower or individual tower cell and tower (fill pack) height. 695

2 2. Cooling tower theory and calculation The cooling of the water is carried out in direct contact with atmospheric air due to convection and evaporation of water in the moist air. Since a cooling tower is based on evaporative cooling the maximum cooling tower efficiency is limited by the wet bulb temperature of the cooling air. In practice, the actual temperature of water cooling is higher than wet bulb temperature for (5-10) K. Heat is transferred from water drops to the surrounding air by the transfer of sensible and latent heat. The cooling characteristic of the cooling tower is represented by the Merkel Equation [4]: (1) The Merkel Equation primarily says that at any point in the tower, heat and water vapor are transferred into the air due (approximately) to the difference in the enthalpy of the air at the surface of the water and the main stream of the air. Thus, the driving force at any point is the vertical distance between the two operating lines. And therefore, the performance demanded from the cooling tower is the inverse of this difference. For technical calculations can be considered with sufficient accuracy that unsaturated moist air obeys the laws of a mixture of ideal gases. The absolute air humidity (ω) can be calculated as: The relative humidity (φ) of an air-water mixture can be calculated as: The enthalpy of moist and humid air includes the enthalpy of the dry air - the sensible heat and the enthalpy of the evaporated water - the latent heat. Specific enthalpy of moist air on the tower inlet can be expressed as: where: h - specific enthalpy of moist air (kj/kg) ha - specific enthalpy of dry air (kj/kg) x - humidity ratio (kg/kg) hw - specific enthalpy of water vapor (kj/kg) t - dry bulb air temperature (ºC) The saturated vapor pressure can be calculated by different methods. In this paper, the IAPWS-97 method is used [5, 6]. Determination of the volumetric heat and mass transfer coefficients is done for the cooling devices in which water is sprayed through nozzles (Fig. 3) or in the form of drops is flowing on the grid. Size of surface (2) (3) (4) 696

3 cooling, which refers to the active volume unit is changed in this case, depending on the amount of water entering the cooler and air speed, which is reflected in the value of the heat and mass transfer coefficients. Criteria equations do not include changing the surface of liquid, so in the absence of exact methods it is common use of the purely empirical formulation. In [4] empirical formula is given as m n 3 ( wρ) q,[ kg / m h( kg / )] β xv = A 1 kg (5) Where q 1 - specific mass flow rate [kg/ m 2 s], w air velocity A, m, n are constants and value of this constants are: A = 1050, m = 0.53 and n = 0.39 For the analytical solution of this integral, it is necessary to find appropriate dependence of specific enthalpy of saturated air and temperature. The parabolic dependence is chosen: '' 2 h t t = ,[kJ/kg] (6) Solving the Merkel integral, the following equation can be written: Gcw t 3 Gcw t V = HF cs = [ m ] or H = [ m] β h β hf where xw m xw m cs 1 '' hm = ( h1+ h2) δ hm 2 h + h 2h h = h h h = h h h = 4 '' '' '' '' '' '' 1 1 2, 2 2 1, δ m 1 2 m '' h 1,2,m - specific enthalpy of saturated air at inlet, outlet and mean temperature h1,2 - specific enthalpy of saturated air at inlet and outlet temperature Fan power consumption dp V P =, η (7) 2 ξ H ρ w dp = (8) 1.4 Thermal analysis should be done as a control in the case of determining the temperature of cold water, depending on various atmospheric conditions. In that case, the following equation can be written, as a result of Merkel integral solution [7]: 2 cw Gc w 0.045tw, out tw, in tw, out + 2λ V βxv (9) 2 cw Gc w tw, out tw, in + hin + 40 = 0 2λ V β xv Solution of this equation is temperature of the water on the outlet of the cooling tower, as function of atmospheric air parameters, inlet water temperature, flow rate of the water and air flow rate. This dependence gives an opportunity for overall consideration of the influence of different parameters on the outlet water temperature. 697

4 3. The choice of the atmospheric air parameters For thermal calculation of the cooling tower, the folowing atmospheric air parameters are necessary: Dry bulb temperature, t a [ C] Relative humidity, ϕ [%] or Wet bulb temperature, t wb [ C]. Mostly used recommendation for value of the air temperature for designing of cooling towers is mean air temperature for three hottest months (June, July, August in our climate zone). The explanation for this recommendation is that very high wet bulb temperatures (24-26ºC) appear in a very short time ( %) [8]. Some other authors recommend cooling towers design according to the "worst case scenario" - highest geographic wet bulb temperatures. This temperature will dictate the minimum performance available by the tower. As the wet bulb temperature decreases, so will the available cooling water temperature [9]. In our opinion, both recommendations are not appropriate solutions. In the first case, in the hot summer months, the cooling capacity will decrease and due to lack of appropriate cooling the whole process in the industrial plant could be threatened. In the other case, the investments and operating costs will be too high. We have decided to find a solution that will be appropriate for both, performances and costs point of view. A first criterion is to ensure a continuous production process i.e. adequate cooling under all atmospheric conditions. The second criterion is to ensure energy efficient operation during the less harsh atmospheric conditions. In order to meet these two criteria, the climatic parameters for the specific geographic area are considered. The temperature regime of the region in which the factory is located shows all the characteristics of continental climate. Mean monthly and mean annual air temperature, extreme values of air temperature and mean number of days with characteristic values of air temperature, for the period from 2005 to 2012, is shown in Table 1, [11]. The mean relative humidity, absolute minimum and the number of days when the relative humidity was 30%, 50% and 80% are shown in Table 2. Most of the values show that the relative humidity decreases from winter to summer months and then rises again from the summer to winter. A small increase in relative humidity was recorded in May and June because they are the months with the highest rainfall. Monthly relative humidity ranges from 62% (July and August) to 85% (December), while the average annual value is 71%. Table 1. Average monthly and yearly air temperature, air temperature extremes, and average number of days within specified values of air temperature 698

5 Table 2. Average monthly and yearly relative humidity, absolute minimum of relative humidity, average number of days within specified values of relative humidity The most important data in the selection of design parameters of atmospheric air are values for summer months (June, July, and August) The average dry bulb temperature, relative humidity and wet bulb temperature statistic for summer period is given in Table 3. Table 3. Average values Month June July August Dry bulb temperature [ºC] Mean 21 Relative humidity [%] Mean 64 Wet bulb temperature [ºC] Mean 16.7 The average maximum dry bulb temperature, relative humidity and wet bulb temperature statistic for summer is given in Table 4. Table 4. Average maximum values Month June July August Dry bulb temperature [ºC] Mean 28.3 Relative humidity, mean [%] 64 Wet bulb temperature [ºC] Mean 23 According to this climate statistics, the dry bulb temperature 29ºC and relative humidity 64% i.e. wet bulb temperature 23 ºC was adopted as designed atmospheric air parameters. 4. Analysis of the cooling tower performances For the cooling towers of this type and capacity and the cooling zone width (i.e. the water temperature difference on inlet and outlet of the tower), the recommended values of air speed amounts to 2-5 m/s. These recommendations by the standards meet the requirements of stability in work and efficiency of the cooling process in the tower. Fill pack material is TYPE MBV-312 from manufacturers and characteristics of this type of material are: 699

6 Dimension:1200x300x300mm The contact surface for heat exchange: 240 m 2 /m 3 Maximum capacity (hydraulic load of fill): 30t / m 2 h Figure 2 Fill pack MBV-312 and drift eliminator MBV-130 According to calculations, with air velocity of 3 m /s, dimensions of fill are 1.8 x 1.8 x 0.9 m. Designed cooling tower is built and put into operation in November The energy efficiency of the cooling system in the adhesive factory is tested during the winter and especially during the very hot summer in Required cooling water parameters, necessary for undisturbed production process are provided in any season, together with savings in energy demand during the seasons with lower ambient air temperature [10]. Figure 3. Cooling tower in factory "Chemis d.o.o" The cooling tower performances during the three month winter and three month summer period is analyzed, according to meteorological data obtained from republic Hydrometeorological Service of Serbia [9]. For the calculation of the cooling water outlet temperature, the mean daily atmospheric air dry bulb temperature in every 5 days and mean monthly relative humidity is used, as it is shown in Table 5 and Table

7 Table 5. The mean daily atmospheric air dry bulb temperature in every 5 days SUMMER I II III IV V VI June T [ºC] R.H. [%] July T [ºC] R.H. [%] August T [ºC] R.H. [%] Table 6. The mean monthly relative humidity WINTER I II III IV V V June T [ºC] R.H. [%] July T [ºC] R.H. [%] August T [ºC] R.H. [%] In Figure 4 and 5, the relevant climate characteristic of the site is given for the 2015 winter and summer, having on mind that this cooling tower is in operation until the end of Figure 4. Three month temperature for winter 2014/15 Figure 5. Three month temperature for summer

8 Using designed value of air flow i.e. air velocity and mean atmospheric air temperature and relative humidity, the change of cooled water temperature at the outlet of the cooling tower is obtained. The results are shown in Figure 6 and Figure 7, for the winter and summer period Cooled water temperature tw 2 [ o C ] 36, ,8 35,6 35,4 35, ,8 34,6 34,4 34,2 JUNE JULY AUGUST Figure 6 The change of cooled water temperature, summer 2015 Cooled water temperature tw 2 [ o C ] 35 34,8 34,6 34,4 34, ,8 33,6 33,4 33,2 33 DECEMBER '14 JANUARY '15 FEBRUARY '15 Figure 7. The change of cooled water temperature, winter 2014/15 As it can be seen, during the winter period, due to favorable atmospheric conditions, temperature of the cooling water is always under the limit of 35ºC. During the critical period of three hottest summer months, at the designed air velocity of 3 m/s, temperature of the cooled water was near to designed value, the highest value was 35.9 ºC. It means that, even in the season with atmospheric conditions above the average value for the specific geographic region, this cooling tower can provide continuous operation of the reference plant. Figure 8 shows a comparison of the results obtained in the winter and summer mode, with the required value of the cooling water temperature 35 ºC. Although deviations from the reference value is not large (less than 1 ºC), there is a possibility for improvement of cooling tower efficiency, by regulation of air flow rate and fan power. The objective of regulation is to achieve the required temperature of water and energy savings. 36 Cooled water temperature tw2 [oc ] 35, , , ,5 Winter 35 Summer Figure 8. Winter/summer mode and designed value comparison 702

9 In winter mode, the atmospheric air temperature is low enough to achieve adequate cooling capacity of the cooling tower. Since the lower the temperature of the cooling water is not needed for the production process, there is a possibility for energy saving. The reduction of air flow leads to an increase in cooled water temperature. Weather conditions during the cold period gives opportunity for lower air flow rate, thereby achieving satisfactory water temperature with a lower fan power consumption. Figure 9. shows cooled water temperature at different air flow rates. 36,2 35,7 5 kg/s 7 kg/s 10 kg/s 35,2 34,7 34,2 33,7 33,2 DECEMBER '14 JANUARY '15 FEBRUARY '15 Figure 9 Cooled water temperature at different air flow rates, winter 2014/15 In summer, the temperature increase of the atmospheric air aggravates the conditions of cooling in the cooling tower, which results in higher temperatures of the cooled water leaving the tower. Required water temperature of 35 ºC can be achieved by increasing the air flow rate. This increase was possible due to an increase in fan power consumption. With cooling tower dimensioning according to higher wet bulb temperature, this increasing in power consumption is relatively low - with 25% increase of power consumption compared to designed value, the required temperature of the cooling water is achieved, as it is shown in Figure 10. Cooled water temperature [ o C] 36, , , ,5 10 kg/s 12.5 kg/s 15 kg/s 33 JUNE '15 JULY '15 AUGUST'15 Figure 10. Cooled water temperature at different air flow rates, summer 2015 The flow is directly proportional to the speed, while the pressure is proportional to the square of the velocity. From the standpoint of energy savings, the most important is that the power consumed is proportional to the third gear. Thus, for example, 75% of the speed of products 75% of the flow, but it has only about 42% of the force, necessary for full flow. When the flow is reduced to 50%, power consumption is only 12.5%, [12]. Thus, regulation of air flow rate in winter mode generates energy savings, while in summer mode the desired temperature of the cooling water is achieved, regardless of the harsh atmospheric conditions. Figure 11. shows the power consumption in percent during the different period of the year, the referent value is power consumption for 15 kg/s air flow rate. 703

10 Power consumption [ % ] Dec '14 Jan '15 Feb '15 Mar '15 April '15 May '15 June '15 July '15 Aug '15 Sep '15 October Figure 11. Fan power consumption during the year, for 35 ºC cooling water temperature 5. Conclusion 350 kw industrial cooling tower was dimensioned according to atmospheric air parameters higher than standard recommendations, in order to ensure required cooling water temperature during the hottest period of the year. Designed cooling tower is built and put into operation in November The efficiency of the cooling system in the adhesive factory is tested during the winter and especially during the very hot summer in Required cooling water parameters, necessary for undisturbed production process are provided in any season, together with savings in energy demand during the seasons with lower ambient air temperature. By regulation of air flow rate in winter mode great energy savings are achieved, while in summer mode the desired temperature of the cooling water is achieved, regardless of the harsh atmospheric conditions. Nomenclature Latin symbols h Specific enthalpy of moist air [kjkg -1 ] h Specific enthalpy of saturated air[kjkg -1 ] G Water flow rate [kgs -1 ] q 1 Fill hydraulic load [kgm -2 s -1 ] H Fill height [m] V Fill volume [m 3 ] c Specific heat, [kjkg -1 K -1 ] p Pressure, [Pa] t Temperature, [ºC] Greek symbols λ air/water flow rate ratio [-] β xv the volumetric mass transfer coefficients [kg/m 3 h(kg/kg)] ρ Density, in [kg m 3 ]. Subscripts in Inlet out Outlet w Water a Air 704

11 References [1] H. John, Cooling Towers System Guidance for Energy Operations, Kelcroft E & M Limited, 1988, pp.1-6. [2] Laković Slobodan, Laković Mirjana, (2004) The recirculation cooling systems, 34th International Congress KGH, Belgrade 2004, pp [3] Zemanek, I.: Heat and Mass Transfer in Cooling Tower Packing, National Research Institute for Machine Design, Praha, [4] Berman, Evaporative Cooling of Circulating Water, 2nd edition, Henrych Stawistowshi, Pergamon Press, 1961 [5] Wagner W., Kruse A., Properties of Water and Steam, the industrial Standard IAPWS-IF97 for the Thermodynamic Properties and Supplementary Equations for Other Properties, Springer-Verlag, Berlin Heidelberg, [6] Laković Mirjana., et.al. Impact of the Cold End Operating Conditions on Energy Efficiency of the steam power plants, THERMAL SCIENCE: Year 2010, Vol. 14, Suppl., pp. S53-S66 [7] Laković Mirjana, Laković Slobodan, Banjac Miloš, Analysis of the evaporative towers cooling system of a coal-fired power plant, Thermal Science, Vol. 16 Suppl. 2, pp S375-S385, 2012 [8] D. Golubović, Jarmilo Jerković, MANAGEMENT AND REGULATION OF COOLING SISTEM OF SERVICE WATER, INFOTEH-JAHORINA, Vol. 2, Ref. C-8, p , March 2002 [9] [10] Laković Mirjana, Laković Slobodan, Jović Milica, Design and Performance Analysis of the Cooling Tower in the Adhesive Factory, The 3 rd International Conference Mechanical Engineering in XXI century, Proceedings, pp [11] [12] [13] Borislav Dugošija, FREKVENTNI REGULATORI-prednosti korišćenja, 705

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