Abstract

This report presents a comprehensive study on the performance of cooling towers,

integrating theoretical concepts, experimental analysis, and computational modeling.

The research explores the influence of varying water and air flow rates on the thermal

efficiency and heat transfer mechanisms within the cooling tower. Key findings

demonstrate that evaporative cooling dominates under specific environmental

conditions, while the developed computational model aligns well with experimental

data, validating its reliability for predictive analysis. The study concludes with

recommendations for optimizing operational parameters and enhancing measurement

accuracy for improved cooling tower performance.

Content

I. List of Figure ............................................................................................. III

II. List of Tables.......................................................................................... IV

.III Table of Symbols and Units .................................................................... V

1. Introduction .............................................................................................. 1

1.1. Importance of Cooling Towers .............................................................. 1

1.2. How Cooling Towers Work.................................................................... 1

1.3. Cooling Tower Classifications ............................................................... 1

.1.3.1 Classification Based on Heat Transfer Mechanism ....................... 2
1.3.2. Classification Based on Airflow Mechanism ................................. 2
1.3.3. Classification Based on Water Flow Arrangement ........................ 3

.2 Experimental Test Rig (Cooling Tower Setup( ..................................... 6

2.1. Components of the Cooling Tower ........................................................ 7

2.1.1. Water Circuit .................................................................................. 8
2.1.2. Air Circuit ...................................................................................... 8
2.1.3. Additional Component – Cooling Column Type 5 (WL 320.04) .. 9

2.2. Working Principle of the Test Rig .......................................................... 9

.2.3 Instrumentation and Measurement ................................................... 11

........................................................................................................................ 11

.3 Experimental Procedure........................................................................ 12

3.1. Filling / draining the water tanks ......................................................... 13

3.1.1. Filling: .......................................................................................... 13
.3.1.2 Draining: ...................................................................................... 13
3.1.3. Assembling a cooling column ...................................................... 14
3.1.4. Pressure loss measurement .......................................................... 14
3.1.5. Regulating the volumetric water flow.......................................... 14

I
 4. Cooling Tower Experimental Results ................................................... 15

.4.1 Calculations...................................................................................... 15

4.2. EES code .............................................................................................. 16

4.3. Discussion ............................................................................................ 18

4.3.1. Cooling Capacity (QL) and water Heat Load (QW) with Changing
Flowrate……..…………………………………………………………………..18
4.3.2. Effect of Flow Rate on Wet Bulb Approach (a). .......................... 19
4.3.3. Effect of Flow Rate on Heat Transfer Mechanisms. .................... 19
4.3.4. Effect of Flow Rate on Heat Exchanger Effectiveness ................ 20

5. Computational Model Development .................................................... 21

5.1. Relationship Between Experimental Data and the Computational

Model……………………………………………………………………………...21

5.2. Assumptions and Governing Equations ............................................... 22

5.3. Model Validation .................................................................................. 23

5.3.1. Heat Transfer Rate (Q) ................................................................. 23
5.3.2. Cooling Tower Effectiveness (η) & Outlet Air Humidity (φ) ...... 26

5.4. Studying New Cases ............................................................................ 28

5.4.1. Airflow rate (mL) ......................................................................... 28
5.4.2. Air inlet temperature (T1)............................................................. 30
5.4.3. Air inlet relative humidity (φ1). ................................................... 35

Conclusion ......................................................................................................... 38

II
I. List of Figure
Figure 1:Types of Cooling Towers – (a) Wet, (b) Dry, (c) Hybrid ...................... 2
Figure 2 Types of cooling towers (a) natural draft (b) induced draft .................. 3
Figure 3:Types of cooling towers (a)Crossflow (b) Counterflow ..................... 5
Figure 4 cooling tower laboratory device ........................................................... 6
Figure 5:Components of the Cooling Tower ....................................................... 7
Figure 6 : sensor arrangement ........................................................................... 11
Figure 7:filling ................................................................................................... 13
Figure 8:draining ............................................................................................... 13
Figure 9 Assembling a cooling .......................................................................... 14
Figure 10 Pressure loss ...................................................................................... 14
Figure 11:Regulating ......................................................................................... 14
Figure 12 Relationship Between Heat Transfer and Flow Rate ................... 18
Figure 13: Relationship Between Wet Bulb Approach and Flow Rate ........... 19
Figure 14 : Heat Transfer Mechanisms ............................................................. 19
Figure 15: Effect of Flow Rate on Heat Exchanger Effectiveness .................... 20
Figure 16: Heat Transfer Rates (Experimental Result) ..................................... 23
Figure 17: Heat Transfer Rates (Model Result) ................................................ 24
Figure 18: Cooling Tower Effectiveness (η) & Outlet Air Humidity (φ)
(Experimental Result) .................................................................................................. 26
Figure 19 : Cooling Tower Effectiveness (η) & Outlet Air Humidity (φ) (Model
Result) .......................................................................................................................... 26
Figure 20: Airflow Rate with Heat Transfer rates ............................................ 28
Figure 21: Effect of Airflow Rate (mL) on Effectiveness (η) ............................ 29
Figure 22: Effect of Inlet air Temperature on Heat Transfer ........................... 30
Figure 23 :Effect of Inlet Air Temperature on Effectiveness ............................ 31
Figure 24: Effect of Inlet air Temperature on Heat Transfer ........................... 32
Figure 25: Effect of Inlet Water Temperature on Effectiveness ........................ 34
Figure 26: Effect of Inlet RH on Heat Transfer................................................. 35
Figure 27: Effect of Inlet RH on Effectiveness ................................................. 37

III
II. List of Tables
Table 1: experimental values from device screen .............................................. 15
Table 2:Heat Transfer Rates Maximum Percentage Errors (%) ........................ 25
Table 3 :Maximum Errors Recorded of RH and Effectiveness ......................... 27

IV
III. Table of Abbreviations and Symbols

Symbol Description & Unit

𝑄𝐿̇ Cooling capacity (W)

𝑉𝐿̇ Volumetric airflow rate (m³/s)

𝑄𝑤̇ Heat load (W)

𝑚𝑤
̇ Water mass flow rate (kg/s)

Cpw Specific heat capacity of water (J/kg·K)

T4 Water inlet temperature (°C)

T5 Water outlet temperature (°C)

𝑚𝑤𝑣
̇ Water loss rate (kg/s)

X1 Absolute humidity at inlet (kgwater/kgdry air)

X2 Absolute humidity at outlet (kgwater/kgdry air)

𝑄𝑣̇ Cooling capacity due to evaporation (W)

r Latent heat of evaporation (J/kg)

𝑄𝑘̇ Cooling capacity due to convection (W)

Cpl Specific heat capacity of air (J/kg·K)

T1 Air inlet temperature (°C)

T2 Outlet temperature (°C)

η Cooling coefficient (Dimensionless)

a Wet bulb approach (K)

z Cooling range (K)

𝑚̇ 𝑙 Air mass flow rate (kg/s)

ΔP Pressure difference (Pa)

V
South Valley University Cooling Tower Experiment Faculty of Engineering -Mechanical
Power Dept.

1. Introduction

1.1. Importance of Cooling Towers

towers are vital components in many industrial and commercial systems. They
serve as heat rejection devices, lowering the temperature of a fluid typically water by
extracting waste heat and releasing it into the atmosphere. Their role is essential in
maintaining thermal efficiency and operational stability in industries such as:
• Power generation
• Oil refining
• Chemical manufacturing
• HVAC applications
By efficiently dissipating excess heat, cooling towers prevent overheating,
ensuring the smooth operation of various industrial processes.

1.2. How Cooling Towers Work

A cooling tower operates by transferring heat from water to the surrounding air,
primarily through evaporation or heat exchange.
Different types of cooling towers exist, categorized based on:
• Heat transfer mechanism
• Airflow system
• Water flow arrangement
The selection of a cooling tower depends on specific application needs,
environmental conditions, and operational constraints.

1.3. Cooling Tower Classifications

Cooling towers can be classified into different categories based on three main
factors:
• Heat Transfer Mechanism
• Airflow Mechanism
• Water Flow Arrangement

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1.3.1. Classification Based on Heat Transfer Mechanism

• Wet Cooling Towers (Open-Circuit or Evaporative Cooling Towers)

These towers operate on the evaporative cooling principle, where the
working fluid (usually water) is exposed directly to air. Heat is
removed as a portion of the water evaporates, effectively reducing the
temperature of the remaining water.
• Dry Cooling Towers (Closed-Circuit Cooling Towers):
Unlike wet cooling towers, dry cooling towers do not rely on
evaporation. Instead, they operate using a heat exchanger, separating
the working coolant from ambient air. This is like a radiator, utilizing
convective heat transfer.
• Hybrid Cooling Towers (Wet-Dry Cooling Towers):
Hybrid cooling towers can switch between wet, dry, and adiabatic
cooling modes, optimizing water and energy savings based on climate
conditions. These towers can achieve thermal efficiencies of up to
92%, making them a preferred choice in regions with varying weather
conditions.

a b c
Figure 1:Types of Cooling Towers – (a) Wet, (b) Dry, (c) Hybrid

1.3.2. Classification Based on Airflow Mechanism

Cooling towers can also be categorized based on how air moves through
the system, affecting efficiency and performance.

• Natural Draft Cooling Towers: These towers rely on buoyancy

forces to move air naturally through a tall chimney. Warm, moist air

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rises because it is less dense than cooler, dry air, creating upward
airflow without the need for mechanical fans.
• Mechanical Draft Cooling Towers: These towers use powered fans
to either pull or push air through the system. They are further divided
into:
o Induced Draft Cooling Towers: In this design, a fan is located at
the top (air discharge), pulling air upwards. This setup reduces
recirculation, preventing discharged air from returning to the
intake. This fan arrangement is also called a draw-through system.
o Forced Draft Cooling Towers: Here, a blower-type fan is placed
at the air intake, pushing air into the tower. This design results in
high entering and low exiting air velocities, making it more
susceptible to recirculation.

Figure 2 Types of cooling towers (a) natural draft (b) induced draft

1.3.3. Classification Based on Water Flow Arrangement

Another important classification is how water and air interact within the
cooling tower.

Crossflow Cooling Towers: In crossflow cooling towers, air moves

perpendicularly to the direction of water flow. The airflow enters through one or

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more vertical faces of the tower and passes through the fill material, cooling the
descending water.

Advantages:

✓ Lower initial and long-term costs due to reduced pump

requirements.

✓ Simple gravity-fed water distribution system.

How It Works:

➢ Water flows downward through the fill material by gravity.

➢ Air moves horizontally across the water flow before exiting.

➢ A fan at the top expels the warm, moist air into the
atmosphere.

Counterflow Cooling Towers: In a counterflow design, air moves in the

opposite direction to water flow, which enhances heat transfer efficiency.

How It Works:

➢ Air first enters from an open space beneath the filled media.

➢ It is then drawn upwards through the filling material.

➢ Meanwhile, water is sprayed downward from pressurized

nozzles at the top.

Comparison: Crossflow vs. Counterflow

− Crossflow towers require less pumping power, making them

more cost-effective.

− Counterflow towers offer better thermal efficiency but require

higher pumping power due to the opposing air-water flow

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A b
Figure 3:Types of cooling towers (a)Crossflow (b) Counterflow

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2. Experimental Test Rig (Cooling Tower Setup (

Figure 4 cooling tower laboratory device

The test rig is based on the WL 320 wet cooling tower, a laboratory-scale system
designed to investigate the performance of wet cooling towers. In this system, heated
water is circulated from a water tank through a water circuit and sprayed onto a cooling
column. The water, delivered by a spray nozzle, is evenly distributed over the column’s
wet deck surfaces where it forms a thin film. Ambient air is drawn into the system from
the bottom by a radial fan and flows upward in counter-current to the water flow. As
the water trickles down, it loses heat through two mechanisms:

Evaporation: Part of the water evaporates, absorbing latent heat and thus cooling
the remaining water.

Convection: Direct heat transfer occurs between the water film and the upward-
moving air.

A PC-based data acquisition system continuously monitors key parameters such

as water and air temperatures, relative humidity, water flow, and differential pressure
across the cooling column. This setup allows the calculation of essential performance
metrics, including the air mass flow rate, cooling capacity, cooling range, wet-bulb
approach, water loss, and cooling coefficient under various operating conditions.
Moreover, the system accommodates different cooling column configurations; in our
experiments, we use the WL 320.04 Cooling Column Type 5.

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2.1. Components of the Cooling Tower

Figure 5:Components of the Cooling Tower

1 Radial fan V 16 Spray Nozzle

2 Air Chamber B1 17 Temperature/humidity sensors
3 Water tank B2 with heater 18 Temperature sensor for water
4 Drain valve for water tank 19 Hood
5 Pump P 20 Cooling column
6 Bypass with ball valve 21 Connection for temp./humidity sensor
7 Overflow pipe 22 Connection for temperature sensor
8 Drain valve for supply tank 24 Digital displays
9 Regulator valve 25 Switch for heater
10 Temperature sensor 26 Main switch
11 Flowmeter 27 Switch for fan
12 Supply tank B3 28 Switch for pump
13 Drain plug 29 Connection for pressure measurement
14 Connecting hose 30 Butterfly valve

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2.1.1. Water Circuit

• Heated Water Tank and Heater:

The water tank is equipped with an electrical heater that operates at selectable power
levels (0.5 kW, 1.0 kW, or 1.5 kW) to raise the water temperature, typically to
around 30°C, to generate a controlled heat load.

• Diaphragm Pump:

A diaphragm pump circulates the heated water from the tank through the system.

• Water Filter:

Positioned upstream of the flow meter, the filter removes impurities to prevent
clogging of the spray nozzle.

• Flow Meter:

A mini-turbine flow meter measures the volumetric water flow. Its non-contact
opto-electronic sensor converts the turbine’s rotation into a frequency signal
proportional to the flow rate.

• Spray Nozzle:

Mounted at the top of the cooling column, the nozzle produces a full cone spray
pattern, ensuring uniform water distribution over the wet deck surfaces.

• Water Collection Basin:

At the bottom of the column, a collection basin gathers the cooled water, which is
then recirculated back to the tank.

2.1.2. Air Circuit

• Radial Fan:
A radial fan draws ambient air into the cooling tower and forces it upward
through the cooling column.

• Air Chamber:
The air chamber distributes the incoming air evenly across the full cross-
section of the cooling column.

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• Butterfly Valve:
This valve allows for precise regulation of the volumetric air flow exiting the
fan, thereby controlling the cooling process.

• Moisture Eliminator:

Located at the top of the column, the moisture eliminator captures entrained
water droplets from the air stream and returns them to the column, minimizing
water loss.

• Differential Pressure Connections:

These connections are used to measure the pressure drop across the cooling
column, which is essential for calculating the airflow rate.

2.1.3. Additional Component – Cooling Column Type 5 (WL

320.04)

• Variable Wet Deck Surfaces:

The WL 320.04 column features adjustable wet deck surfaces. This design
allows the operator to vary the effective cooling surface area, directly
influencing the cooling capacity.

• Transparent Plastic Construction:

Made from transparent plastic, the column permits visual observation of water
distribution and flow over the surfaces.

• Integrated Temperature Sensor:

A sensor mounted on the column’s plates directly measures the water
temperature on the wet deck, providing accurate local thermal data.

• Plate Inserts:
The column includes three plates which modify the water’s flow path,
enhancing the contact time between water and air.

2.2. Working Principle of the Test Rig

The WL 320 test rig operates on the principle of counter-current heat and mass
transfer between water and air:

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• Water Distribution:
Heated water is pumped from the water tank and sprayed onto the top
of the cooling column by the spray nozzle. The fine spray forms a thin film as
it flows over the variable wet deck surfaces.
• Airflow and Heat Exchange:
A radial fan draws ambient air from the bottom of the tower, directing
it upward through the cooling column As the air passes through, it comes into
intimate contact with the water film:

o Evaporation: A portion of the water evaporates, absorbing latent

heat and thereby reducing the water temperature.

o Convection: Simultaneously, convective heat transfer occurs

between the water film and the air.

• Enhanced Contact Time:

The design of the cooling column (CC)with its angled stages and
adjustable wet deck surfaces—maximizes the residence time of the water
on the surfaces, optimizing the heat exchange process.
• Moisture Recovery:
The moisture eliminator collects water droplets entrained in the air
and channels them back into the column, reducing water loss and
improving overall efficiency.

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2.3. Instrumentation and Measurement

Figure 6 : sensor arrangement

• Temperature Sensors:
o Water Temperature Sensors: Installed at the inlet (Figure
6,ComponentT4) and outlet (Figure 6, Component T5) of the cooling
column.

o Air Temperature Sensors: Placed at the air inlet )Figure 6,Component

T1) and outlet (Figure 6, Component T2).

• Humidity Sensors:
Measure relative humidity at the inlet and outlet to assess air saturation levels.
(Figure 6, Component M1 and M2)

• Flow Meter:
Measures the volumetric water flow rate using a mini-turbine sensor (Figure 6,
Component F1).

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