Applied Thermal Engineering 35 (2012) 233e239

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Applied Thermal Engineering

journal homepage: www.elsevier.com/locate/apthermeng

Experimental and computational analysis of thermal performance of the oval tube

closed wet cooling tower
Wei-Ye Zheng a, *, Dong-Sheng Zhu a, Jin Song a, Li-Ding Zeng a, Hong-jian Zhou b
a

Key Laboratory of Pressure System and Safety(MOE), School of Mechanical and Power Engineering, East China University of Science and Technology, Shanghai 200237,
Peoples Republic of China
b
Shanghai Baofeng Machinery Manufacturing Co. Ltd, Shanghai 2004444, Peoples Republic of China

a r t i c l e i n f o

a b s t r a c t

Article history:
Received 10 May 2011
Accepted 23 October 2011
Available online 30 October 2011

Closed wet cooling towers (CWCTs) characterize by smaller investment and exploitation cost as well as
fewer materials and less space. It can be regarded as a cooling tower with the packing replaced by a bank
of tubes. However, heat and mass transfer in an oval tube closed wet cooling tower (CWCT) have been
little investigated under different operating conditions. The thermal performance characteristics of an
oval tube CWCT were conducted. From the experimental results, correlations for the water-lm heat
transfer coefcient and airewater mass transfer coefcient are obtained. Experimental tests show the
water-lm heat transfer coefcient is a function of deluge-water temperature, deluge-water mass
velocity and air mass velocity, which is different from that in the public literatures. The airewater mass
transfer coefcient is a function of air mass velocity. In addition, a mathematical model with three
ordinary differential functions is presented to predict the outlet process water temperature. The model is
solved by a sectional method. The results show the analytical outlet temperature compares well with the
experimental data. The method is suitable for evaluating the performance of an oval tube CWCT.
2011 Elsevier Ltd. All rights reserved.

Keywords:
Thermal performance
Oval tube
Closed wet cooling tower
Heat and mass transfer
Sectional method

1. Introduction
The energy saving and emission reduction are important for high
efcient cooling systems in China. As an environmental-friendly
cooling system, cooling towers are widely used to reject heat, cool
buildings and reduce the temperature of water circulated through
various heat rejection equipments. In comparison with the shelland-tube heat exchangers and cooling tower systems, CWCTs
characterize by smaller investment and exploitation cost as well as
fewer materials and less space. The closed wet cooling tower can be
regarded as a cooling tower with the packing replaced by a bank of
tubes. The process uid, such as water to be cooled, ows inside the
tubes. The deluge water is sprayed downward over the tube bundles
and then is pumped up to circulate in a closed circuit. The air ows
up through the bank of tubes. In this way, the energy is transferred
from the process uid through the tube wall to the deluge water and
then into the air due to convection and evaporation.
Many researchers have investigated the heat and mass transfer
processes in plain-tube CWCTs. Merkel [1] and Nottage [2]
described the fundamentals of the physical phenomena taking
place in cooling towers. The rst practical design procedure for the
* Corresponding author. Tel./fax: 86 02164253708.
E-mail addresses: zheng_weiye@163.com (W.-Y. Zheng), cedshzhu@ecust.edu.cn
(D.-S. Zhu).
1359-4311/$ e see front matter 2011 Elsevier Ltd. All rights reserved.
doi:10.1016/j.applthermaleng.2011.10.047

evaluation of counter-ow cooling towers was given by Parker and

Treybal [3]. They developed the relationship between the heat and
mass transfer coefcient at the airewater interface by using the
Lewis factor. This method was based on the following assumptions:
(1) The Lewis factor relating heat and mass transfer was equal to 1.
(2) The enthalpy of saturated moist air was a linear function of
temperature over the whole range of bulk water and airewater
interface temperature in the unit. (3) The recirculation water ow
rate was so large that the corresponding changes due to evaporation could be neglected. Mizushina et al. [4] presented two
methods of heat calculation for coolers: one assumed constant
deluge-water temperature and the other took into account the
variation of the deluge-water temperature through the tube
bundle. They determined applicable heat and mass transfer coefcients by tting test data to empirical log mean differences that
used average water and tube wall temperature. Niitsu et al. [5]
tested banks of plain and nned tubes, and the plain tubes had
an outside diameter of 16 mm in a staggered arrangement. They
studied the lm heat transfer coefcient and airewater mass
transfer coefcient, as well as the air-side pressure drop over the
tube bundle. Faco et al. [6] tested a new closed wet cooling tower
for use with chilled ceilings and obtained experimental correlations
for mass and heat transfer coefcients to predict well thermal
performance. Gan and Riffat [7] conducted a CFD method to predict
the performance of CWCT according to the cooling capacity and the

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W.-Y. Zheng et al. / Applied Thermal Engineering 35 (2012) 233e239

Nomenclature
A
cp
d
G
h
hd
i
k
m
Q
T

Tp
Tw
K
w

Area, m2
specic heat constant pressure, J/kgK
Diameter, m
mass velocity, kg/sm2
heat transfer coefcient, W/m2K
mass transfer coefcient, kg/m2s
Enthalpy, J/kg
thermal conductivity, W/mK
mass ow rate, kg/s
heat transfer rate, W
Temperature, K

process water temperature, K

spray water temperature, K
overall heat transfer coefcient, W/m2K
humidity ratio, kg water vapor/kg dry air

Subscripts
a
air, or based on air-side area
i
inlet, or inside
o
outlet, or outside
p
constant pressure or process water
w
water or wall
wb
wet-bulb

pressure drop. The predicted thermal performance was validated

by experimental data. Hasan and Siren [8] made a comparison
between plain and oval tube coolers based on similar operating
conditions. The results showed that oval tube had a better
combined thermal-hydraulic performance. The heat-mass analogy
revealed lower values for the mass transfer coefcient estimated
from dry heat transfer correlations when compared with wet
measurements. Experimental study was also carried out on hybrid
CWCT which had a rated capacity of 136kW by Sarker et al. [9].
More recently, Heyns and Krger [10] investigated the thermalow performance characteristics. They presented and discussed
the derivation of the Poppe [11] and Merkel [1] analysis. They
developed correlations for the water-lm heat transfer coefcient
and airewater mass transfer coefcient, which compared well with
the correlations given by Mizushina et al. [4].
As mentioned above, the performance of a CWCT depends on
the size and arrangement of tubes. It is also found that the uniform
distribution and effectiveness of the water and air across the tube

Fan

bundle have great inuence on the thermal performance. However,

there is no valid and accurate method for predicting the performance of the oval tube CWCT. It is necessary to evaluate the
thermal-ow performance characteristics experimentally. The
objective of this study is to analyze the performance and obtain
a practical design procedure for evaluating the oval tube CWCT.
2. Assumptions and governing equations
The assumptions are as follows:
(1) It is a steady state.
(2) The radiation between the cooling tower and the surroundings
is neglected.
(3) The tube surfaces are uniformly wetted, and the air ow and
deluge water are uniformly distributed throughout the cooling
tower.
(4) The Lewis factor is equal to 1 [12].

Outlet air:
Ambient drybulb temperature, Ta
Ambient relative humidity

Drift eliminator
Spray frame
Inlet process water
temperature, Tpi

Deluge water
temperature
entering the
spray frame, Tw
Heat exchanger
(tube bundle
with 8 passes)
Deluge water
temperature
through the tube
bundle, Twm

Process water
mass flow rate,
mp
Outlet process
water
temperature, T po

L=1.14m

Inlet air:
Ambient drybulb temperature, Ta
Ambient wetbulb temperature, Twb

Deluge water
mass flow rate,
mw

Deluge water
temperature in the sump,
Tw
Fig. 1. Sketch of experimental setup [10].

W.-Y. Zheng et al. / Applied Thermal Engineering 35 (2012) 233e239

235

Fig. 3. Heat balance of experimental apparatus.

(5) The deluge-water ow rate is so large that changes in it due to

evaporation are negligible.
(6) The airewater boundary offers a negligible resistance to heat
transfer [13], therefore the boundary air enthalpy can be
considered equal to the saturated air enthalpy at the delugewater temperature.
The governing equations of the heat and mass transfer in the
cooling tower are stated as follows.
The heat transfer rate in the closed wet cooling tower can be
calculated from the equation below:

(1)

where the subscripts p and a refer to the heat transfer rate of the
process water and air-side respectively.
The overall heat transfer coefcient (K) between the process
water inside the oval tubes and the deluge water on the outside can
be written as

1
1
do lndo =di
do

di hi
K
hw
2kt

(3)

iao imasw  imasw  iai ehd Aa =ma

(4)

where Twm is the mean deluge-water temperature, Aa is the airewater interface area, and hw can be determined by Eqs. (2) and (3).
The outlet air enthalpy is measured or determined by Eq. (1). Thus
hd can be obtained by the above equations.

Fig. 2. Photograph of the oval tube closed circuit cooling tower.

Qp mp Cpp Tpi  Tpo

Qa ma iao  iai

Tpo Twm Tpi  Twm eUA=mp cpp

3. Experimental apparatus
3.1. Test apparatus
A test facility was assembled in Shanghai to test the cooling
tower, the schematic of which was shown in Fig. 1. The process water
was heated by stream vapor and stored in a constant temperature
water tank. The inlet temperature of the process water was
measured as it entered the cooling tower. The outlet water
temperature was measured by the calibrated PT100 at the bottom of
the tube bundle. The PT100 used could measure the temperature in
a wide range from 80 to 400  C keeping the possible error 0.1  C.
The volumetric ow rates of the process water and deluge water
were measured by two electromagnetic ow-meters with 0.5%
accuracy. The process water and deluge-water ow rates could be

(2)

Krger [14] suggested the use of simplied Merkel-type analysis. Heyns [10] found the following equations to evaluate the
water-lm heat transfer coefcient and airewater mass transfer
coefcient by assuming a constant mean deluge-water temperature
through the cooling tower.

Table 1
Experimental conditions.
Process water
Volume
ow rate
(m3/h)
20e37

Inlet
temperature
( C)
13.7e36

Deluge water Ambient air

Volume
ow rate
(m3/h)
10e22

Inlet
velocity
(m/s)
2.5e5

Dry-bulb
temperature
( C)
4e15

Wet-bulb
temperature
( C)
2.1e9.6

Fig. 4. Experimental results of deluge-water lm heat transfer coefcient.

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W.-Y. Zheng et al. / Applied Thermal Engineering 35 (2012) 233e239

tube bundle consists of 8 rows of externally galvanized steel oval

tubes. The major axis of the tube is 31.8 mm, and minor axis 21.6 mm
with tube wall thickness 1.5 mm. The oval tubes are 1.2 m long and
arranged in a stagger pattern at a transversal pitch of 44 mm and at
a longitudinal pitch of 64 mm. There are 37 oval tubes per tube row.
The experiment was conducted with variations of the process
water ow rate, process water inlet temperature, deluge-water
ow rate, wet-bulb temperature and inlet air velocity. Table 1
gave the experimental conditions.
4. Results and discussion

Fig. 5. Experimental results of airewater mass transfer coefcient.

changed manually through buttery valves. Deluge-water

temperatures downward the tube bundle were measured with
seven platinum resistance thermometers (PT100) placed after each
tube row. The mean deluge-water temperature was taken as the
average of these thermometer readings [10].
The inlet dry-bulb and wet-bulb temperature were recorded by
Testo 625 while Testo 625 and EE21 were applied to test the dry-bulb
temperature and relative humidity at the outlet of the apparatus. The
air pressure was measured by YM3 aneroid barograph with accuracy
of 2 hPa. The air ow rate was controlled by means of a frequency
controller changing fan speed and measured with one vane
anemometer-Testo 417. The Testo 417 was located by hand in different
points of tower inlet section, thus an average air velocity was adopted.
The data acquisition system used a data logger-HP 34970 A.
3.2. Test sample
An innovative oval tube closed wet cooling tower was manufactured by Shanghai Baofeng Machinery Manufacturing Co. Ltd., as
shown in Fig. 2. It is an induced-draught closed wet cooling tower
and has an external dimension of 1.420 m  1.140 m  3.398 m. The

The inuence of the air mass ow rate, deluge-water temperature and the deluge-water ow rate on the deluge-water lm heat
transfer coefcient and the airewater mass transfer coefcient is
investigated by the experiment. Based on Eqs. (1)e(4), lm heat
transfer coefcient hw and airewater mass transfer coefcient hd
can be determined with the measured or known values, and the
tube outer area is used as reference area.
The heat transfer rate of the air-side and process water has been
presented in Fig. 3. It can be seen that the heat balance data those
inhered within 10%. It implies that the heat balance of the
apparatus could be claimed to be satisfactory.
From the present experimental study, it is found that a delugewater mass velocity of 1.2 kg/m2s is needed for the uniform wetting
of all oval tubes in the tube bundle. An increase in deluge-water
ow rate above 1.2 kg/m2s does not signicantly improve cooling
capacity which is consistent with the results given by Faco [6] and
Peterson [15]. Thus, an optimum spray rate can be found through
experimental measures.
Fig. 4 shows the deluge-water lm heat transfer coefcient with
respect to the mean deluge-water temperature, which is a little
different from the correlations given by Mizushina et al. [4], Niitsu
et al. [5], Parker and Treybal [3] and Heyns [10]. Mizushina et al. [4]
and Niitsu et al. [5] describe the lm heat transfer coefcient as
a function of only deluge-water mass velocity. Parker and Treybal
[3] extend their correlation to include the effect of deluge-water
temperature. Heyns and Krger [10] state the lm heat transfer
coefcient is a function of deluge-water mass velocity, delugewater temperature and air mass velocity. The present experimental results show that the deluge-water lm heat transfer
coefcient is a function of air mass velocity, deluge-water mass

Deluge water

a
(1,1)

(1,2)

b
(1,n-1)

(1,n)

Process water

ma
ima+dima

mw
Tw

(2i-1,1)
(2i,1)

(2i-1,2)

(2i-1,n-1)

(2i,2)

(2i,n-1)

(2i-1,n)

mp
Tp

(2i,n)

Tube inside

mw
Tw+dTw

(N,1)

(N,2)

(N,n-1)

mp
Tp+dTp

dL

ma
ima

(N,n)

Air

tube coil with N tube rows and n elements per tube row
Fig. 6. Flowchart of the calculating process.

control volume

W.-Y. Zheng et al. / Applied Thermal Engineering 35 (2012) 233e239

237

Start
Input inlet operating condition: mp, Tp,
ma, Ta, Twb, mw
Guess value Tw,in=Twb
Guess air outlet enthalpy
ima,out=ima,in

ima,out=ima,in+(imasw,Tw-ima,in)/1000

i=1:N/2
tube row (2i-1) element j=1 to n

Tw=Tw,in+0.05

Solve for hi(2i-1,j), hw(2i-1,j), K(2i-1,j)

Solve for Tp(2i-1,j+1), ima(2i,j), Tw(2i,j)
tube row (2i) element j=n to 2
Solve for hi(2i,j), hw(2i,j-1), K(2i,j)
Solve for Tp(2i,j+1), ima(2i+1,j-1), Tw(2i+1,j-1)
Next element
NO

|sum(ima(2N,1:n))/n/ima,in-1|<0.005
YES
|sum(Tw(2N,1:n))/n-Tw,in|<0.1

NO

YES
Outlet results: Tp, ima, Tw
End
Fig. 7. Flowchart diagram for the prediction of outlet process temperature.

velocity and mean deluge-water temperature, and it is plotted

versus experimental data in Fig. 4. From the experimental results
the following correlation for the deluge-water lm heat transfer
coefcient is derived.
1=3

hw 350:31 0:0169Tw G0:59

Gw
a

(5)

for 2.57 < Ga < 4.94 kg/m2s; 1.2 < Gw G/d < 3.176 kg/m2s;
11 < Twm < 28  C where Ga ma/[(W  Ntdo/2)L],
The correlations recommended by Mizushina et al. [4] and Heyns
and Krger [10] for airewater mass transfer coefcient are in terms of
air mass velocity and deluge-water temperature. Parker and Treybal
[3] and Niitsu et al. [5] describe the mass transfer coefcient only

W.-Y. Zheng et al. / Applied Thermal Engineering 35 (2012) 233e239

0.1

0.0

0
Discrepancy, %

Temperature difference, T, oC

238

-0.1
-0.2
-0.3
-0.4

6 8 10 12 14 16 18
Operating condition

-2
-4
-6
-8

6 8 10 12 14 16 18
Operating condition

Fig. 8. Temperature difference and discrepancy.

a function of air mass velocity. It is found that the airewater mass

transfer coefcient is largely independent of the deluge-water ow
rate, which agrees with the ndings of Parker and Treybal [3] and
Peterson [15]. The deluge-water ow rate only affects the coefcients
at low ow rates when the tubes are incompletely wetted. The
airewater mass transfer coefcient hd is plotted versus mass velocity
of air in Fig. 5. From the experimental results the following correlation for the airewater mass transfer coefcient is derived:

hd 0:034G0:977
;
a

2:57 < Ga < 4:94

(6)

The correlations developed for the water-lm heat transfer

coefcient and airewater mass transfer coefcient are valid for
a tube bundle consisting of 8 rows of externally galvanized steel oval
tubes. The oval tubes are arranged on a staggered pattern with major
axis 31.8 mm, minor axis 21.6 mm and tube wall thickness 1.5 mm.
5. Prediction and comparison
5.1. Prediction of outlet temperature
The tower is divided into elementary volumes, as shown in
Fig. 6a, b shows an elementary control volume about a tube. The
analysis of the energy and mass balance for the tube element will
dene the mathematical equations for the tower performance. The
following model simplies by making use of the assumptions of
a Merkel-type analysis: First, the evaporative loss is negligible and
second the Lewis factor is equal to unity.
The total energy balance for process water, deluge water and air
owing inside the element shown by Fig. 6b gives

mw cpw dTw ma dima mp cpp dTp 0

(7)

Since the temperature gradient between the process water

temperature and deluge-water temperature, heat transfer through
the tube wall to the deluge water is given by

dQp mp cpp dTp K Tp  Tw dA

(8)

Heat gained by air at the airewater interface due to enthalpy

potential difference can be represented by an overall process

dQa hd imasw  ima dA ma dima

(9)

As it is assumed insulated, the heat loss is negligible, the inlet

deluge-water temperature is equal to the outlet deluge-water
temperature.

Tw;in Tw;out

(10)

A mathematical model with three ordinary differential functions (Eqs. (7)e(9)) and a boundary condition (Eq. (10)) is presented. The outlet temperature of process water in oval tubes is
predicted by a sectional method [16]. The tower consisted of 8 tube
rows, each tube row is divided into several elements. The energy of

each element is calculated. The data of the adjacent elements

depend on the directions of the ow: horizontally for the process
water temperature, vertically downward for the deluge-water
temperature and upward for air. The thermo-physical properties
(density, thermal conductivity, viscosity and heat capacity) of water
and air are based on the outlet temperature of the previous element
[17]. The deluge-water lm coefcient hw and mass transfer coefcient hd are specied by Eqs. (5) and (6) respectively. The equations must be solved by an iterative procedure. Successive
iterations are needed for the values of the outlet air enthalpy iao and
the inlet deluge-water temperature Tw to nd out the temperatures
for all the elements. The owchart diagram for the prediction of
outlet process temperature is shown in Fig. 7.
5.2. Comparison
Fig. 8 gives the comparison between analytical results and
experimental results. It can be seen that the analytical results are
consistent with the experimental results. The maximum deviation
in Fig. 8 is within 6% and the maximum temperature difference
is 0.29  C. The detail information is shown in appendix A. A good
agreement has been found between the model and the experimental results for the operation conditions.
6. Conclusions
The performance characteristics of a new oval tube closed wet
cooling tower have been investigated experimentally. Experimental
correlations for the water-lm heat transfer coefcient and airewater mass transfer coefcient are developed. The experimental
results show that the water-lm heat transfer coefcient (5) is
a function of deluge-water temperature, deluge-water mass
velocity and air mass velocity, while the airewater mass transfer
coefcient (6) was a function of air mass velocity. A mathematical
model has been used to predict the thermal performance of
a closed wet cooling tower. The predicted outlet process water
temperature by a sectional method is consistent with the experimental results. The simulation indicates that the sectional method
is a suitable tool for predicting the thermal performance of the
CWCT. The result obtained from this study is supposed to provide
basic relevant data for optimum design of the oval tube CWCT.
Acknowledgements
The authors wish to thank Dr. Guo-Yan Zhou for her helpful
discussion and valuable advice. The work was nancially supported
by Cultivation Fund for Interdisciplinary and Major Project (MOE)
(WG1013009). The authors also take the opportunity to express
sincere respect to the peer reviewers for the valuable comments
and suggestions.

W.-Y. Zheng et al. / Applied Thermal Engineering 35 (2012) 233e239

239

Appendix A

Comparison between the model and the experimental results for the operating conditions.
Operating
condition

Vp (m3/h)

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

27.66
28.47
28.47
27.24
27.54
28.10
27.47
28.28
28.31
26.91
27.29
27.94
27.31
28.11
28.22
26.66

Tin ( C)

33.16
22.91
22.54
39.22
36.03
20.91
33.21
22.93
22.56
39.27
33.48
20.92
33.26
22.99
22.61
39.36

Vd (m3/h)

15.21
15.07
15.32
15.25
12.48
12.59
15.11
15.09
15.24
15.19
12.23
12.32
14.97
15.08
15.22
15.13

Air
v (m/s)

Db ( C)

Wb ( C)

4.85
4.85
4.70
4.60
4.50
4.50
3.85
3.85
3.70
3.60
3.50
3.50
2.85
2.85
2.70
2.60

11.1
9.9
14.6
15.0
13.4
12.5
10.4
10.1
14.7
14.9
4.5
12.5
10.3
9.8
14.7
14.9

4.6
4.1
7.1
7.6
9.4
8.3
4.1
4.0
7.1
7.6
2.4
8.4
4.1
3.9
7.1
7.6

Tout by Exp

Tout by
Present
method

(Tin  Tout)
by Exp ( C)

(Tin  Tout)
by Pre ( C)

DT ( C)

Dp (%)

28.24
20.03
20.13
33.27
31.11
18.98
28.78
20.43
20.51
34.02
29.08
19.31
29.55
20.91
20.91
35.03

27.95
19.91
20.05
32.99
30.96
18.93
28.64
20.35
20.45
33.87
28.96
19.26
29.52
20.90
20.93
34.97

4.92
2.88
2.41
5.95
4.92
1.93
4.43
2.50
2.05
5.25
4.40
1.61
3.71
2.08
1.70
4.33

5.21
3.00
2.49
6.23
5.07
1.98
4.57
2.58
2.11
5.40
4.52
1.66
3.74
2.09
1.68
4.39

0.29
0.12
0.08
0.28
0.15
0.05
0.14
0.08
0.06
0.15
0.12
0.05
0.03
0.01
0.02
0.06

5.89
4.17
3.32
4.71
3.05
2.59
3.16
3.20
2.93
2.86
2.73
3.11
0.81
0.48
1.18
1.39

Dbedry-bulb temperature,  C; Wbewet-bulb temperature,  C; VpeVolumetric ow of process water, m3/h; VdeDeluge water volume ow rate (m3/h); veair velocity, m/s;
TineProcess water inlet temperature,  C; Touteoutlet temperature,  C; DT,  C; DpeDiscrepancy, %.

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