Computer controlled forced draft cooling tower by using heat exchanger with help of auto-controlling fan.

Project Title

Computer controlled forced draft cooling tower by using heat exchanger with help of auto-controlling fan.

Project Area of Specialization Mechatronics EngineeringProject Summary

A cooling tower is a specialized heat exchanger in which air and water are brought into direct contact with each other in order to reduce the water's temperature. As this occurs, a small volume of water is evaporated and resulted in reducing the temperature of the water being circulated through the tower. The Computer Controlled forced draft cooling tower, includes a pump that impels hot water from a tank (with level indicator and heating element) to the manifolds located at the top of the cooling tower. Water flow can be adjusted by a flow control sensor. A temperature sensor measures the temperature of the water just before entering the tower. Water cools down as it falls through the manifolds of the tower, and finally falls into the tank where its temperature is measured again. A fan propels atmospheric air with an accurate control of the air flow introduced in the tower. The air passes through wet bulb and dry bulb sensors before entering the column. As air flows through the column, its temperature and humidity rise and for measuring this rise and fall in humidity we will use Hygrometer. On the other hand, water temperature falls. In order to determine leaving dry bulb and wet bulb temperature sensors. This Computer Controlled Unit includes: The unit itself + a Control Interface Box + a Data Acquisition Board + Computer Control and Data Management Software Packages, for controlling the process and all parameters involved in the process. Four actuators and 8 Sensors are used to control process occurring from any computer and working simultaneously. The cooling tower environment almost demands stud mounted sensors. The alarm levels will depend on the fault frequency being measured, and the configuration of the cooling tower. In the air to air heat exchanger, warm-wet air out of the tower is cooled by relatively drier and cooler ambient air. By using of auxiliary fan, the minimum dry bulb temperature difference between ambient air and warm-wet air for evaporated water recovery was reduced to 4-6 °C. As the warm-wet air from the tower is cooled by an auxiliary fan, water condenses out and is collected. The result showed that in a laboratory model, water saving could be expected to about 35% of evaporation loss, depending on ambient air conditions. The results show that, the quality of this water is very higher than recirculation water. The condensate conductivity ranged from 5 to 13% of the recirculating water. Better condensate quality is achieved by more water vapor recovery.

A cooling tower is a specialized heat exchanger in which air and water are brought into direct contact with each other in order to reduce the water's temperature. As this occurs, a small volume of water is evaporated and resulted in reducing the temperature of the water being circulated through the tower. The Computer Controlled forced draft cooling tower, includes a pump that impels hot water from a tank (with level indicator and heating element) to the manifolds located at the top of the cooling tower. Water flow can be adjusted by a flow control sensor. A temperature sensor measures the temperature of the water just before entering the tower. Water cools down as it falls through the manifolds of the tower, and finally falls into the tank where its temperature is measured again. A fan propels atmospheric air with an accurate control of the air flow introduced in the tower. The air passes through wet bulb and dry bulb sensors before entering the column. As air flows through the column, its temperature and humidity rise and for measuring this rise and fall in humidity we will use Hygrometer. On the other hand, water temperature falls. In order to determine leaving dry bulb and wet bulb temperature sensors. This Computer Controlled Unit includes: The unit itself + a Control Interface Box + a Data Acquisition Board + Computer Control and Data Management Software Packages, for controlling the process and all parameters involved in the process. Four actuators and 8 Sensors are used to control process occurring from any computer and working simultaneously. The cooling tower environment almost demands stud mounted sensors. The alarm levels will depend on the fault frequency being measured, and the configuration of the cooling tower. In the air to air heat exchanger, warm-wet air out of the tower is cooled by relatively drier and cooler ambient air. By using of auxiliary fan, the minimum dry bulb temperature difference between ambient air and warm-wet air for evaporated water recovery was reduced to 4-6 °C. As the warm-wet air from the tower is cooled by an auxiliary fan, water condenses out and is collected. The result showed that in a laboratory model, water saving could be expected to about 35% of evaporation loss, depending on ambient air conditions. The results show that, the quality of this water is very higher than recirculation water. The condensate conductivity ranged from 5 to 13% of the recirculating water. Better condensate quality is achieved by more water vapor recovery.

Project Objectives

This project having following number of objectives.

Data Collection

Designing of Colling Tower by using specific software tool.

Development of model by suitable material (Acrylic Sheets, SS Material)

Energy Analysis of Cooling Tower

Testing of Unit Based on different film media and flow patterns.

Reduction of water withdrawal and consumption are the key requirement in the power plant cooling system. Generally, cooling water is lost in three ways: Drift, Blowdown, and Evaporation. According to the recent research, there are frequently two ways to reduce water consumption in a cooling tower: 1)Reduction in blowdown with increasing of concentration cycles and 2) Using air to air heat exchanger on the cooling tower. As Technology Revolution is coming and water crises will be at critical level in Pakistan by 2025 so Industries and Powerplants are moving toward modernization of cooling towers to decrease the use of make-up water as well as modernization of controlling of water flow through sensors. As Cooling Towers are the largest consumer of water in the power plants. In this paper, a laboratory model of Forced Draft Wet Cooling Tower with air to air heat exchanger is used to study reduction of water consumption. The experimental study is performed in order to design and simulate flow conditions in the cooling tower. The air to air heat exchanger makes contact of warm-wet air out of the cooling tower with relatively drier and cooler ambient air. As the warm-wet air from the tower is cooled through the exchanger by an auxiliary fan, water condenses out and is collected. The condensate conductivity has been in the range of 5 to 13% of the recirculating water. The result showed that in a laboratory model, water saving could be expected to about 35% of evaporation, depending on ambient air conditions.

Project Implementation Method

Easily implemented in industries, Powerplants, Gas Stations, HVAC Systems. Most of Multinational Firms in Pakistan are now moving towards this modernization of Cooling towers. It is just an addition in already fitted cooling tower but more efficient innovation in cooling tower is being considered.

Easily implemented in industries, Powerplants, Gas Stations, HVAC Systems. Most of Multinational Firms in Pakistan are now moving towards this modernization of Cooling towers. It is just an addition in already fitted cooling tower but more efficient innovation in cooling tower is being considered.

Benefits of the Project

35% Make-up water will be less used as compare to other types of cooling tower that are being used in industries.

By using acrylic sheets whole process occurring inside cooling tower can be understood easily. Most of Evaporative Water will again recirculated by heat exchanger with fan to make it condensed to fill make-up water

Technical Details of Final Deliverable

Electronic (software) control of water recirculation, air flow and heater power.

Electronic sensors measure flow of air and water, temperature of air and water and humidity entering and leaving the packing.

Modern electronic humidity sensors utilized, eliminating the need for high maintenance wet and dry bulb thermometers.

Water loss due to evaporation measured electronically.

User supplied material can easily be fitted into the tower for project work.

Uses true industrial packing material for more representative demonstrations.

Whole process will be visible and can be seen clearly with human eye.

Can be operated as a simple spray tower with no packing installed.

Improved distribution of water onto the packing using an array of spray nozzles.

Three different heights of packings can be compared.

Fuji Electric Solution( For Cooling Tower Fan Control)

Final Deliverable of the Project Hardware SystemCore Industry Energy Other Industries Others Core Technology Clean TechOther TechnologiesSustainable Development Goals Decent Work and Economic GrowthRequired Resources

Easily implemented in industries, Powerplants, Gas Stations, HVAC Systems. Most of Multinational Firms in Pakistan are now moving towards this modernization of Cooling towers. It is just an addition in already fitted cooling tower but more efficient innovation in cooling tower is being considered.