Many industries, including oil refineries, as well as chemical and steel mills, depend on cooling towers to remove heat from water in their industrial process. Cooling towers are essential as they allow smooth working and prevent industrial overheating. As technology advances, various types of cooling towers have emerged for different processes.
Understanding the working principle and mechanics is crucial for optimum operation. In this blog, we will discuss the proper working of cooling towers in various industries. Let’s discuss it more.
Table of Contents (How Cooling Towers Work?)
- Introduction
- Understanding Industrial Cooling Tower Systems
- Why Industries Rely on Cooling Towers?
3.1 Prevent Overheating
3.2 Water Conservation
3.3 Relatively Affordable - What Are The Cooling Tower Parts
4.1 Cooling Tower Fill Media
4.2 Cooling Tower Drift Eliminators
4.3 Industrial Cooling Tower Fan
4.4 Spray Nozzles
4.5 Coldwater Basin - How Does a Cooling Tower Work in Industries?
5.1 Heat Absorption
5.2 Evaporation
5.3 Cold Water Recirculation - Conclusion
Understanding Industrial Cooling Tower Systems
A well-equipped structure that captures heat from water, generated by manufacturing processes, and releases it into the atmosphere is called a cooling tower. Different sectors, such as power plants, food processing, and pharmaceutical industries, utilize these cooling systems. Cooling tower demand is increasing as the global population is rising.
Therefore, industries perform more in making the required items that ultimately generate more heat when machinery operates continually. The temperature must be cooled so that the machines function well. In this regard, cooling towers are the most effective and efficient solution for lowering the heat in industries. This system provides space for water and air to come in contact and exchange heat.
During this interaction, water circulates through the cooling tower and lowers its temperature through evaporation. After that, the cooled water goes back to the industrial processes for reuse. These cooling towers maintain industry operational efficiency by sustaining temperature and minimizing functional costs.
Why Industries Rely on Cooling Towers?
Many industries, buildings, and thermal power plants use large cooling towers for the cooling process. Their main goal is to remove excess heat from the industrial process and provide an ideal environment for efficient and smooth work without any interruption.
Would you like to stay in a building with poor ventilation and excessive heat during hot weather? I know your answer; it’s a clear No, right? That’s why cooling towers are used in all large buildings and industries.
Prevent Overheating
In industries, controlling heat is very critical because all the machinery works continuously, and there is a high chance of overheating. Additionally, overheating can also lead to equipment failures, reduced efficiency, and increased operating costs.
Cooling towers effectively remove excess heat and avoid any harmful situations. The hot water from industrial processes is pumped toward the cooling tower, bringing back cold water to lower the inside temperature.
Water Conservation
Nowadays, water scarcity has emerged as a critical global challenge, and even more concerning is how quickly water prices are soaring. Keeping this thing in mind, the latest evaporative cooling towers are designed to conserve water using different methods.
Water is effectively recycled in semi-closed or closed cooling tower systems. For example, hot water from industrial processes is cooled and reused several times, ultimately reducing the need for freshwater intake every time.
On the other hand, Cooling tower drift eliminators stop water droplets from fleeing the cooling tower as vapor. These droplets are captured and sent back into the system, reducing water loss and improving overall efficiency.
Relatively Affordable
When it comes to affordability and cost-effectiveness, cooling tower systems stand out. They use evaporative cooling, which is inherently energy-efficient. Unlike mechanical refrigeration systems that rely on compressors and consume significant electricity, cooling towers withdraw heat by natural processes involving water and air interaction.
They also have a lower carbon footprint, another advantage. This not only complies with environmental standards but also avoids any potential carbon taxes or penalties related to high-emission systems.
What Are The Main Cooling Tower Parts?
The cooling tower consists of different essential parts that work together to perform its function and cool the water. Every component has its specific role and requires regular maintenance for optimal working. The following are the main parts of a cooling system:
Cooling Tower Fill Media
The basic principle of this cooling is the evaporation process during air and water contact. The fill material provides maximized space for this interaction and increases the airflow to boost the evaporate rate. Different types of fill media are used in cooling towers, such as Polypropylene (PP), fiberglass, stainless steel, and wood. However, PVC is the most common and durable material because it is corrosion-resistant.
There are two main types of filling: splash fill and film fill.
In splash fill, the bars are positioned sequentially over which water is distributed and converted into tiny droplets. These will come in contact with air through the open circuit and facilitate the heat transfer.
In the second type, film fill, the channels or small sheets are present that provide a large surface area for air and water contact and increase the heat exchange. In this, water forms a very thin film when it falls over the film-fill material.
Cooling Tower Drift Eliminators
It is another crucial part of the system as it conserves water by minimizing its loss. Drift is the term for tiny droplets that come out of the cooling system and are arrested in the air. Therefore, the drift eliminator is present in the device to reduce the loss of water by collecting the water droplets in the basin. It also lessens the environmental pollution.
Industrial Cooling Tower Fan
One of the most prominent components of the cooling tower is the fan. It performs the essential role by pulling the air towards the inside or water present in the atmosphere to exchange heat. When fans rotate, they produce airflow to aid in water evaporation and ultimately remove heat easily.
Spray Nozzles
These are used to distribute water to the fill material evenly over the entire material. They also convert the water into tiny droplets and increase the surface area to boost heat exchange. In this way, they also prevent fog formation, scaling, and fouling in the system and allow smooth working.
Coldwater Basin
It is the reservoir of the system and is present at the base or lowest point. It balances the water level and recirculates it in the cooling tower. The basin part also cleans the water, removes the dust and detritus from the water, and provides clear water. In this way, it settles down the clogs and other sediments. There is a sensor associated with the basin to monitor the quality of the water.
How Does a Cooling Tower Work in Industries?
How cooling towers work in industries depends only on their type. All types of cooling towers work differently, but their difference is minor. For example, the placement of the cooling tower fan or air movement direction could be different. But the basic mechanism is the same.
Heat Absorption
In evaporative cooling towers, the cooling process starts as quickly as hot water (from the industries ) is transferred to the cooling tower. With the help of spray nozzles, warm water is sprayed on the fill media. The tiny pores of the spray nozzles allow effective dispersal of water.
When water falls from the spray nozzles in the form of small droplets, the air flow absorbs the excess heat from the water, and the hot air leaves the cooling tower.
Water-air interaction will also take place in this step, which is the most crucial stage in cooling the tower because if there is no heat exchange, the final result will be poor.
Evaporation
Except for dry cooling towers, all other types of cooling towers, such as wet cooling towers or natural draft cooling towers, use evaporative cooling to remove waste heat from the water. When warm water and air interact, evaporation occurs, and water converts into vapours that leave the towers. These water vapours absorb a lot of heat before escaping and cooling the remaining water.
Let’s discuss and compare how evaporation takes place in different cooling towers!
Natural vs. Mechanical Draft Cooling Towers:
Natural draft cooling towers rely on buoyancy to move air, while the second one uses fans to circulate air inside the system.
Induced vs. Forced Draft Cooling Tower System:
Induced draft cooling towers pull air through the system, creating a stronger, upward airflow, whereas the other one pushes air through, creating a more directed flow.
Counter vs. Crossflow Cooling Tower:
Crossflow cooling towers move air horizontally across the water, although counterflow cooling towers move air vertically upward.
Cold Water Recirculation
The cooled water gathers in the cold tower basin and recirculates into the industrial process. This cycle is done multiple times to make sure that the industrial works run in the ideal environment and temperature.
Conclusion
Cooling towers are complex entities vital in large industries and commercial buildings. You should understand the basic parts, their working principles, and how to keep them in their optimal state. In this article, we discuss the proper functioning of an industrial cooling tower.
It is a very intricate process and demands experts’ involvement. Therefore, if you want any cooling tower repair, upgrading, or buying quality cooling tower spare parts, contact ICS.