How to Save Money When Buying cooling tower fill

1. What are Cooling Towers?

Cooling towers are heat rejection devices that remove waste heat from the atmosphere through the cooling of a water stream to a lower temperature. They are used in industries such as power plants, chemical plants, and factories to cool down the hot water produced by industrial processes

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2. The Science Behind Cooling Towers

Cooling towers operate on the principle of evaporative cooling. The hot water that is to be cooled is pumped to the tower and distributed over the fill (a material designed to increase the surface area and air-water contact). As the water trickles down the fill, it comes in contact with air that is drawn through the tower. This causes a small amount of the water to evaporate, reducing the temperature of the water.

Illustrations:

3. Types of Cooling Towers
1. Cross Flow Cooling Towers:

In a cross flow cooling tower, air flows horizontally across the falling water stream.

Water enters the tower from the top and flows downward over the fill surfaces while air is drawn horizontally through the fill by a fan located at one end of the tower.

Heat transfer occurs as a result of the contact between the air and the falling water, causing some of the water to evaporate and thus dissipating heat from the system.

The cooled water collects at the bottom of the tower and is recirculated back into the process.

Cross flow towers are often characterized by their rectangular shape and are suitable for moderate cooling requirements.

2. Counter Flow Cooling Towers:

In a counter flow cooling tower, air flows vertically upwards against the falling water stream.

Water is sprayed or distributed from the top of the tower and flows downward over the fill surfaces while air is drawn upwards through the fill by a fan located at the base of the tower.

Heat transfer occurs as a result of the counter direction of the air and water flow, maximizing the cooling efficiency.

Similar to cross flow towers, some of the water evaporates, carrying away heat from the system.

Cooled water collects at the bottom and is recirculated back into the process.

Counter flow towers are often more efficient than cross flow towers due to the better utilization of the temperature difference between the inlet air and the warm water.

4. Benefits of Cooling Towers

Cooling towers make industries more efficient by reusing water, which is a precious resource. They also help to maintain the working efficiency of the plant by cooling down the machinery and preventing overheating. Furthermore, they can enhance energy production in power plants by providing cool water that can be used to condense steam after it has powered the steam turbines.

5. The Future of Cooling Towers

With the increasing scrutiny on water use globally and the need for energy efficiency, the future of cooling towers lies in the development of designs that minimize water loss and maximize cooling. New technologies like hybrid cooling towers, which combine the features of wet and dry cooling towers, are being developed to meet these challenges.

1. Determine Your Cooling Needs:

The first step in selecting a cooling tower is to determine your cooling needs. This involves understanding the heat load that your operations generate, the ambient temperature, as well as the required temperature of the cooled water. These factors will dictate the size and type of the cooling tower needed.

2. Type of Cooling Tower:

Cooling towers come in two main types: evaporative (wet) and dry. Evaporative towers provide cooling via the evaporation of water, which provides efficient cooling but consumes more water. Dry cooling towers, on the other hand, do not require water for cooling but may be less efficient. Your choice will depend on the availability of water, environmental considerations, and operational requirements.

3. Energy Efficiency:

Energy efficiency should be another critical consideration. Look for cooling towers that have energy-saving features, such as variable-speed fans, high-efficiency fill materials, or heat exchangers. Although these features might increase the upfront cost, they can save you money in the long run through reduced energy costs.

4. Material of Construction:

Cooling towers are typically made from materials like galvanized steel, stainless steel, fibreglass, or plastic. The choice of material will depend on the environmental conditions, the type of water used, and budgetary constraints. For instance, stainless steel towers are more expensive but can withstand harsh conditions and have a longer lifespan.

Comparisons of construction material for cooling towers

# Criteria Timber FRP RCC 1 Quality Available Timber of low grade. Consistent and High quality. Depends on specifications. 2 Installation & Operating Cost. Low installation cost & high operation cost. Slightly high installation costs but low operation costs. High cost for a small tower 3 Operation & Maintenance. High. Low. High for corrosive environment. 4 Length of Members. Small. Tailor make (as per requirement). As per design. 5 Bio Decay Decays due to Fungus, Algae and bacteria. No such decay. Algae formation. 6 Repair & Replacement Very frequent. Very less. Very less. 7 Life 5 Years 15-20 Years 20 Years 8 Environmental Impact. Wood logging & treatment of wood plays havoc with the environment. No such direct impact. No such direct impact.
5. Consider the Installation and Operating Costs:

The cost of a cooling tower includes not only the initial purchase price but also the costs of installation, operation, and maintenance. Higher-efficiency towers may have a higher upfront cost but can save money in the long run through reduced energy use. Additionally, consider the longevity and durability of the tower, as a longer lifespan can offset higher initial costs.

6. Maintenance and Lifespan:

Regular maintenance of cooling towers is crucial for their optimal operation. Choose towers that are easy to maintain, with accessible parts and a design that facilitates cleaning and inspection. In terms of lifespan, towers with durable materials and robust construction are likely to last longer.

7. Review the Tower's Water Treatment System:

A proper water treatment system is vital for maintaining the efficiency and longevity of your cooling tower. Look for towers with systems that effectively prevent scale, corrosion, and biological growth. Additionally, consider the ease and cost of maintaining the water treatment system

8. Manufacturer Reputation:

Finally, consider the reputation of the cooling tower manufacturer. Look for manufacturers known for their quality, reliability, and excellent customer service. Read reviews, ask for references, and speak to past customers if possible.

Conclusion:

Selecting the right cooling tower is a critical decision that requires careful consideration of various factors. By understanding the types of towers, determining your cooling needs, considering costs, evaluating materials, and reviewing water treatment systems, you can make an informed decision that will provide reliable and efficient cooling for your operations. Remember, a well-chosen cooling tower not only ensures the smooth running of your business operations but can also save you significant time, resources, and money in the long run.

In the last three articles (March, May, Sept. ), we introduced the problem of wasted energy in cooling-water systems and presented two types of solutions—minimizing “parasitic” heat gains and raising water temperatures to minimize demand. Now let’s examine what can be done on the supply side to save energy and money. We’ll look at three system components: cooling towers, chillers, and air-blast cooling.

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RUN COOLING TOWERS EFFICIENTLY

Cooling towers are one of the simplest cooling mechanisms known and are economical to use and run. Most towers used in plastics processing are the mechanical draft type (forced or induced draft). These use evaporative cooling in a semi-closed circuit to cool water to slightly above the ambient wet-bulb temperature.

Evaporation is fundamental to cooling-tower performance and can occur only at the surface of the water, so cooling towers should maximize the water surface presented to the air flow.

•Ensure that the water is evenly distributed over the tower fill and that the fill is correctly stacked and undamaged.

•The fill should be free of obstructions and cleaned periodically to give good air and water distribution.

•Air access to the tower should be unobstructed. Do not stack or build anything in front of the air inlets that will obstruct access.

•Evaporation inevitably leaves behind any solids (salts) in the water. These can build up on cooling surfaces and both decrease their heat-transfer effectiveness and increase energy consumption. Regular and effective water treatment is necessary to prevent build-up of solids. The amount of  cooling from a tower can be controlled by varying the fan speed according to the required flow temperature. The simplest method is to manually turn fans off during cold weather, but automatic controls are far better. You can use a simple thermostat, controlled with a signal from the water sump. But the best method is to use a variable-speed drive (VSD) for the fan motor using the sump temperature as the control signal. This reduces energy use and also improves control of the water flow temperature.

If you can operate the cooling tower in “cascade” mode during winter—i.e., with the fans turned off—then installation of temperature controls for the fans provides a real cost-saving opportunity. This should be possible in temperate climates if the tower system is correctly sized for the load.

When using any type of temperature control, the thermostat should be checked regularly for correct operation.

Operate towers only during production hours to avoid waste.

There are sometimes concerns that cooling towers can harbor Legionella bacteria (the cause of Legionnaire’s disease). But adequately treated water and regular testing can ensure safe operation of modern cooling towers.

CHILLERS ARE ENERGY HOGS

Water chillers are among the biggest energy users in a plant. For approximately 30 to 40 kW input of electricity for the chiller alone. Even a small plant can have a 200-kW output chiller. This will need 60 to 80 kW input and for 24/7 operation this will cost around $42,000 a year.

Chiller systems should be optimized for high partial load and winter efficiency. This is important where additional chillers have been added to the system to provide multi-chiller capacity.

New-technology chillers use efficient scroll and screw compressors and refrigerant gases. Replacement of older-technology chillers should be considered after evaluating plant cooling load and existing systems. When sizing a new compressor to match the cooling load, avoid the likelihood of running the compressor at low loads, where it is apt to be least efficient.

Where partial cooling loads are likely, then consider multicompressor chillers, which perform better under such conditions. Maintenance is a key to good chiller operation, and plants should carry out routine maintenance tasks such as these:

•Regular servicing, such as purging of condensers.

•Regular checks for gas tightness and refrigerant charge.

•Regular cleaning of evaporators and heat-exchanger surfaces.

•Regular checks on flow and return temperatures, and flow rates should be checked to keep them at the correct and optimum settings.

Finally, keep records of plant conditions to identify trends.

DON’T OVERLOOK‘FREE’ AIR COOLING

Standard chilled-water systems do not take advantage of cold weather conditions. In temperate or cold climates it is possible to use low ambient winter or overnight temperatures to pre-cool the return water from the process to reduce chiller energy use. During periods of low ambient  temperatures, air-blast cooling can considerably reduce energy costs (see Fig. 1).

Air-blast cooling is very suitable for plastics processing because the ambient and flow temperatures are similar and air-blast cooling can be used to its best advantage. This is particularly true for plants where the chillers are providing chilled water at around 60 F for molds and hydraulics. Air-blast coolers can be used as either for pre-cooling or for total cooling with chilled water or as direct replacements for cooling towers. The lowest temperature that can be achieved by air-blast cooling is related to the dry-bulb temperature and is therefore higher than the temperatures that can be achieved by a cooling tower. A typical installation diagram of an air-blast cooler for pre-cooling is shown in Fig. 2. If the ambient temperature falls sufficiently below the return water temperature, then air-blast cooling becomes effective and the return chilled water is diverted through the air-blast cooler section. This pre–cools the water, reducing the load on the main chiller and reduces the energy use and cost.

The lower the ambient temperature, the greater the air-blast cooling effectiveness, and when the ambient temperature is around 6o F below the return water temperature, the pre-cooling achieved is generally sufficient for total system demands. The air-blast cooler then provides the total cooling load and the cooling water does not enter the chiller at all but is diverted back to the process. The main chiller can then be switched off and the chiller load is reduced to zero. The only energy consumed at this stage is that used to drive the fan motors of the air-blast cooler.

This means that for flow temperatures of about 60 F, at ambient temperatures below about 54 F the main chillers become inactive. This is another reason for getting the flow temperatures as high as possible (see Sept. article). Air-blast cooling provides low-cost cooling; typical payback periods are less than 2 years and can be as little as 1 year. Air-blast cooling can be supplied as standard equipment with new chillers or can be retrofitted to existing chilled-water systems.

If lower temperatures are required, the air-blast cooler can be fitted with a water-mist system to give additional cooling.

Chillers with air blast cooling circuits have lower chiller running times, lower maintenance costs, and possibly extended chiller life.

The size of the overall chiller package should still be capable of providing the total cooling load to cope with the short periods when air-blast cooling is not feasible.

For retrofits, check that the existing chiller can run at partial load in order to achieve the full benefits of air-blast cooling.

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