Saving Energy with Cooling Tower

Cooling towers are now being designed to fit a wide gamut of input requirements even as the thermal designs get more efficient.
  A cooling tower is a machine that works to re-circulate water in process cooling circuit loop. Every manufacturing process involves heat and subsequent cooling. The process cooling is often provided by cold water which in turn then transfers the heat onto itself. This hot water is driven back into the cooling tower which is a machine designed to exchange the water’s heat with the ambient cooler air.
Cooling tower is a key component in the power plant that conserves resources. The primary task of a cooling tower is to reject heat into the atmosphere. Not only does it add efficiency to the generation process but also does that while conserving the water intake needed by the plant.
Cooling tower in its simplest form may be an atmospheric cooling tower that does not utilise a fan to create airflow and hence may be power efficient. However these small atmospheric cooling towers have limited use. On the other hand of the spectrum are natural draft cooling towers, again fan-less, that are typically used in the largest cooling tower applications such as power generation. The most commonly used and visible cooling towers however are the induced draft cooling towers that involve aerodynamically designed fans to draw air through the tower. Forced draft cooling towers also use fans but these fans are located in the ambient air stream entering the tower.Beyond the source of the air, cooling towers are defined by the nature in which the air and water interact. Counter flow towers involve the movement of air and water in counter directions while as the name suggests, they move perpendicular in each other in cross flow towers.
Speaking about the technology and trends Harsh Bhargava, Director, Cool Deck Industries Pvt Ltd says, “Cooling towers are getting efficient every year with the use of better designed components such as the fans, fills, drift eliminators and the distribution system. Better materials used in the construction of these components also give a longer life to cooling towers thereby giving years of uninterrupted service to the user.”
Aerodynamically designed axial flow hollow bladed FRP fans such as the ones manufactured by Cool Deck can provide up to 30 per cent power saving over conventional aluminium fan blades, the company claims. By insisting on the right grade of FRP resin and fail proof moulding techniques these fans can offer 10 to 15 years of service lifetime.
Both fill design and material also go a long way in determining the efficiency of the cooling tower. The most efficient fill media is the film fill but is also the most susceptible to fouling on account of untreated make up water. Towers based on film fill designs such as COOLFill CD-19 and COOLFill CD-12 can be designed to be of small footprints to treat large amounts of water thereby reducing construction as well as running costs. For water sources where they may be limited amount of suspended particles Cool Deck low clog fill media is a solution. However, with the limited sources of clean water and the cost of treatment many users are now opting for splash fill media for their cooling towers. There are available in the form of splash bars or splash grids, both of which are extremely forgiving to dirty water conditions.
A good drift eliminator system not only minimises the quantum of makeup water regularly needed by the cooling tower but also keeps the environment around the cooling tower cleaner and safer. A proper distribution system with the right choice of nozzles also goes a long way in running an efficient cooling tower.
In summary, due to the awareness from the industry and innovation by cooling tower companies, cooling towers are now being designed to fit a wide gamut of input requirements even as the thermal designs get more efficient.
National Cooling Tower’s FRP, timber, RCC induced draft type cooling towers utilise fans to suck the air through circulated water. The water falls downward over fills surfaces which help improve the contact time between the water and air. This helps maximise heat transfer between the two. Cooling roles of induced draft counter flow depend upon their diameter and speed of operation.
Induced draft counter flow cooling tower:In the counter flow induced draft design hot water entered the cooling tower inlet, while the air is introduced at the bottom and exit at the top. In the FRP induced draft counter flow cooling tower available in the factory. Briefing about product range Prabhakar Acharya, Sales and Marketing Manager, National Cooling Tower says, “Our product range is Model No NCT-45 to NCT-15000 in single cell. We have design in multi-cell type cooling tower as per customers’ requirement.”
National Cooling Tower offers three types of cooling tower namely FRP induced draft counterflow, Timber induced draft, and RCC induced draft. The company also offers chilling plants in air cooled type, water cooled type, as well as brine type.
Major components of cooling tower in FRP, timber and RCCThe basic components of evaporative towers are frame, casing, fills, motor, fan and support for honeycomb fills, S.S. grid, drift eliminator support, louvers, and nozzles. Structural frame that support the exterior casing. Motor, fans, motor stand, FRP domb, FRP canopy, high pressure ABS nozzles.
FRP bodyWith some smaller designs such as some glass fibre units. The body of the tower made of tough fibre glass reinforced plastic. It has sufficient structure strength to withstand high industrial vibrations and velocity.
Special motors IP-55Continuous rating shock proof totally enclosed type as per IP-55 and weather proof ranging long shaft flange mounting direct motor and big size of cooling tower will reduce motor. Front is directly driven and axial flow type. The blades of cast aluminium LM-6 casted fan or FRP fans.
Cold water basinThe cold water basin located at or near the bottom of the tower. Receives the cooled water that flows the basin usually has point for the cold water discharge connection.
RCC and timberStructure will be RCC and timber, timber patti, cement, sand, steel, aggregate fills, bottom fills, support I beam, support type channel, ABS nozzles. Drift eliminator type and drift eliminator supports, water distributor’s header pipe and branch, gear boxes, drive shafts, motor supports.
Fans both axial and centrifugal fans are used in towers. Generally propeller fans are used in induced draft towers. Both propeller and centrifugal fans are found in draft towers. Depending upon their size. Propeller fans can either be fixed or variation pitches. A fan having no automated adjustable pitch blades permits the same fan to be used for wide range of kW with the adjusted to deliver the desired airflow at the lowest power consumption. Automatic variable pitch blades can be varying air flow.
The heat load imposed on cooling tower determined by the process being served. The degree of cooling tower controlled by the desired operating temperature level of the process in most case, a low operating temperature is desirable to immerse process efficiency or to improve the quality or quantity of the product.   Process heat loads may vary considerably depending upon the process involve of accurate process heat loads can become very complex but prefer consideration of accurate process satisfactory results. On the other hand air conditioning and evaporative heat loads can be determined with greater accuracy.
ConclusionDue to massive urbanisation and industrialisation, cooling tower market scope is widening up in India. There are around 40 cooling tower companies in India ranging from small, medium and large capacity cooling tower manufacturers. With energy being a scarce resource, there is a tendency towards energy savings and this will drive the cooling tower industry strongly.

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Saving Energy with Cooling Tower

Cooling towers are now being designed to fit a wide gamut of input requirements even as the thermal designs get more efficient.
  A cooling tower is a machine that works to re-circulate water in process cooling circuit loop. Every manufacturing process involves heat and subsequent cooling. The process cooling is often provided by cold water which in turn then transfers the heat onto itself. This hot water is driven back into the cooling tower which is a machine designed to exchange the water’s heat with the ambient cooler air.
Cooling tower is a key component in the power plant that conserves resources. The primary task of a cooling tower is to reject heat into the atmosphere. Not only does it add efficiency to the generation process but also does that while conserving the water intake needed by the plant.
Cooling tower in its simplest form may be an atmospheric cooling tower that does not utilise a fan to create airflow and hence may be power efficient. However these small atmospheric cooling towers have limited use. On the other hand of the spectrum are natural draft cooling towers, again fan-less, that are typically used in the largest cooling tower applications such as power generation. The most commonly used and visible cooling towers however are the induced draft cooling towers that involve aerodynamically designed fans to draw air through the tower. Forced draft cooling towers also use fans but these fans are located in the ambient air stream entering the tower.Beyond the source of the air, cooling towers are defined by the nature in which the air and water interact. Counter flow towers involve the movement of air and water in counter directions while as the name suggests, they move perpendicular in each other in cross flow towers.
Speaking about the technology and trends Harsh Bhargava, Director, Cool Deck Industries Pvt Ltd says, “Cooling towers are getting efficient every year with the use of better designed components such as the fans, fills, drift eliminators and the distribution system. Better materials used in the construction of these components also give a longer life to cooling towers thereby giving years of uninterrupted service to the user.”
Aerodynamically designed axial flow hollow bladed FRP fans such as the ones manufactured by Cool Deck can provide up to 30 per cent power saving over conventional aluminium fan blades, the company claims. By insisting on the right grade of FRP resin and fail proof moulding techniques these fans can offer 10 to 15 years of service lifetime.
Both fill design and material also go a long way in determining the efficiency of the cooling tower. The most efficient fill media is the film fill but is also the most susceptible to fouling on account of untreated make up water. Towers based on film fill designs such as COOLFill CD-19 and COOLFill CD-12 can be designed to be of small footprints to treat large amounts of water thereby reducing construction as well as running costs. For water sources where they may be limited amount of suspended particles Cool Deck low clog fill media is a solution. However, with the limited sources of clean water and the cost of treatment many users are now opting for splash fill media for their cooling towers. There are available in the form of splash bars or splash grids, both of which are extremely forgiving to dirty water conditions.
A good drift eliminator system not only minimises the quantum of makeup water regularly needed by the cooling tower but also keeps the environment around the cooling tower cleaner and safer. A proper distribution system with the right choice of nozzles also goes a long way in running an efficient cooling tower.
In summary, due to the awareness from the industry and innovation by cooling tower companies, cooling towers are now being designed to fit a wide gamut of input requirements even as the thermal designs get more efficient.
National Cooling Tower’s FRP, timber, RCC induced draft type cooling towers utilise fans to suck the air through circulated water. The water falls downward over fills surfaces which help improve the contact time between the water and air. This helps maximise heat transfer between the two. Cooling roles of induced draft counter flow depend upon their diameter and speed of operation.
Induced draft counter flow cooling tower:In the counter flow induced draft design hot water entered the cooling tower inlet, while the air is introduced at the bottom and exit at the top. In the FRP induced draft counter flow cooling tower available in the factory. Briefing about product range Prabhakar Acharya, Sales and Marketing Manager, National Cooling Tower says, “Our product range is Model No NCT-45 to NCT-15000 in single cell. We have design in multi-cell type cooling tower as per customers’ requirement.”
National Cooling Tower offers three types of cooling tower namely FRP induced draft counterflow, Timber induced draft, and RCC induced draft. The company also offers chilling plants in air cooled type, water cooled type, as well as brine type.
Major components of cooling tower in FRP, timber and RCCThe basic components of evaporative towers are frame, casing, fills, motor, fan and support for honeycomb fills, S.S. grid, drift eliminator support, louvers, and nozzles. Structural frame that support the exterior casing. Motor, fans, motor stand, FRP domb, FRP canopy, high pressure ABS nozzles.
FRP bodyWith some smaller designs such as some glass fibre units. The body of the tower made of tough fibre glass reinforced plastic. It has sufficient structure strength to withstand high industrial vibrations and velocity.
Special motors IP-55Continuous rating shock proof totally enclosed type as per IP-55 and weather proof ranging long shaft flange mounting direct motor and big size of cooling tower will reduce motor. Front is directly driven and axial flow type. The blades of cast aluminium LM-6 casted fan or FRP fans.
Cold water basinThe cold water basin located at or near the bottom of the tower. Receives the cooled water that flows the basin usually has point for the cold water discharge connection.
RCC and timberStructure will be RCC and timber, timber patti, cement, sand, steel, aggregate fills, bottom fills, support I beam, support type channel, ABS nozzles. Drift eliminator type and drift eliminator supports, water distributor’s header pipe and branch, gear boxes, drive shafts, motor supports.
Fans both axial and centrifugal fans are used in towers. Generally propeller fans are used in induced draft towers. Both propeller and centrifugal fans are found in draft towers. Depending upon their size. Propeller fans can either be fixed or variation pitches. A fan having no automated adjustable pitch blades permits the same fan to be used for wide range of kW with the adjusted to deliver the desired airflow at the lowest power consumption. Automatic variable pitch blades can be varying air flow.
The heat load imposed on cooling tower determined by the process being served. The degree of cooling tower controlled by the desired operating temperature level of the process in most case, a low operating temperature is desirable to immerse process efficiency or to improve the quality or quantity of the product.   Process heat loads may vary considerably depending upon the process involve of accurate process heat loads can become very complex but prefer consideration of accurate process satisfactory results. On the other hand air conditioning and evaporative heat loads can be determined with greater accuracy.
ConclusionDue to massive urbanisation and industrialisation, cooling tower market scope is widening up in India. There are around 40 cooling tower companies in India ranging from small, medium and large capacity cooling tower manufacturers. With energy being a scarce resource, there is a tendency towards energy savings and this will drive the cooling tower industry strongly.

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