1. A refinery uses 25 barrels of water per barrel of crude processed, 80 to 90 % of which is used for
cooling purposes. So reuse of water is necessary to fulfill this bulk requirement.
2. Heat is transferred by Conduction, Convection and Radiation.
Conduction is heat transfer mode where due to molecular interaction heat transfers from
higher to lower point.
Convection is transfer of heat which involves physical movement of substance.
Radiation is transfer of heat due to radiant energy.
Terminologies:
3. Major Cooling is done by evaporation. As entering air is cool as compared to hot water so minor
cooling is also due to conduction, convection and radiation too.
4. Higher humidity in air, higher atmospheric pressure and low air to water contact will resist
evaporation and hence decreases cooling rate.
5. Open Spray pond is the simplest example of cooling water system.
Construction of Tower
Drift Eliminators:
They are installed at the top to minimize water loss by drifting phenomena. They are also
used to control air flow rate.
Louvers:
They are installed at the side of the tower in the form of sheets, which provide direction
to entering air and restrict showering water from coming outside of tower by splash. Adjustable louvers
also control amount of entering air.
They are installed in the tower in the form of wire mesh sheets and break water into
small drops and increases contact area.
Here draft is maintained by mechanical power of motor. On the basis of push and pull there are two
further types. Which are,
Fan is located at the top of the tower and pulls air through the whole column. Here, chance of re-
entrance of wet air is low as compared to forced draft tower. But they produce noise.
Fan is located at the bottom of the tower and it pushes air through the tower. They produce less noise
but recirculation of wet air is possible.
Material of Construction:
1. Corrosion take place when iron based material is exposed to water and air, as both are present
in cooling tower so iron related material is not used in towers.
2. Copper and brass coated materials, synthetic fibers and wood based structures are used
because of corrosion resistant properties. To reduce swelling and contraction/expansion of
wood in water, they are treated with certain chemicals.
Water Losses:
Wind Speed:
Higher wind speed is required for good evaporation but if it is too much it will increase drift losses.
Humidity:
Humidity in air reduces rate of evaporation so more humid the season less efficient will be cooling tower
as compared to dry air.
Temperature of Air:
If temperature of air is low than it will provide cooling by conduction, convection and radiation too, so
lower air temperatures are favorable.
Difference of wet and dry bulb temperatures indicates relative humidity of air which shows how much
water air can be taken by air? Higher difference will favors evaporation and hence cooling rate.
Cooling tower perform best when entering air is dry and cool