Galaxy Surfactants Ltd.

Summer Internship 2013

Summer Internship 2013

Date: 11th May, 2013

Under the guidance of Shrivardhan Nuwal Sub mitted by Jogender Dhayal IIT Kanpur

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Galaxy Surfactants Ltd. Summer Internship 2013

Problem Statement 1 Cooling Tower

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INDEX ACKNOWLEDGMENT Page no.

1. Theory.5 1.1. Introduction..5 1.2. Cooling Tower Performance Parameters...7 1.3. Cooling Tower Internals8 2. Analysis of Existing System11 2.1 Cooling Tower Specifications11 2.2 Existing Network12 2.3 Analysis of Cooling Tower Water12 3. Inefficiencies in the Present System ...14 4. Viable Solution..15 5. Calculations16 6. Cost Analysis.16 7. Energy Saving Opportunities.17 8. Latest Trends.18 8.1. Chemical treatment programs.18 8.2. Zero Blow Down Technology..19 8.3. Side Stream Filters.19 8.4. Fan Control strategies...21 8.5. Pump Control Strategies..21 8.6. Special Fills.21 8.7. Variable Flow Nozzle..22 9. Proposed Modification.23 9.1 Types of Fills23 9.2 Evaluation of Alternatives..24 10. References.27

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ACKNOWLEDGEMENT

My heartfelt thanks to Mahendra Yadav for formulating interesting and intriguing problem statements which deepened my liking for some aspects of Chemical Engineering. I sincerely thank Shrivardhan Nuwal for his guidance throughout the project. I also thank Jami Shrinu, Siddhart, Vivek, Sachin, Himanshu, Santosh and Vikrant Raut for providing valuable inputs during various stages. Ravichandran, Rupali Raut, and Bhoosan Thakur of QA lab for rigorous analysis of various samples. Jagdish Boir, Vishal Raut, Vishal Rahul, Vishal Mahatre, Ramchandra Enamdar and other operators and maintenance staff for providing with the specific information on reactors, cooling towers and chemicals.

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Galaxy Surfactants Ltd. Summer Internship 2013 PROBLEM STATEMENT Study the cooling tower at N-46, evaluate its performance and compare with the actual data. Optimize the system for energy savings.

1.1. Introduction
The machines and industrial processes generate tremendous amounts of heat which must be continuously dissipated if those machines and processes to operate efficiently. Cooling tower is a heat removal device that uses water as the medium to remove heat.

1.1.1. Working Principle: When warm water is brought into contact with unsaturated air, part of liquid vaporizes and liquid temperature drops. The cooling takes place by the transfer of sensible heat & by evaporative cooling. The driving forces for mass and heat transfer are predicted using a quality called wet bulb temperature. Ideally the wet bulb temperature is the lowest theoretical temperature to which the air can be cooled. Wet bulb temperature is defined as "the steady state, non-equilibrium temperature reached by a small mass of liquid exposed under adiabatic conditions to a continuous stream of gas. Water evaporating from the moistened wick on the wet-bulb thermometer bulb cools the thermometer bulb and lowers the temperature reading. The reduction in water temperature in the cooling tower comes from evaporation, although when the air temperature is low, there is some sensible heat transfer to the air. Types of Cooling Towers:

1.1.2.

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1) Mechanical draft is in turn classified into Induced draft and Forced draft based on the location of the fans. a) Forced draft: In the forced-draft tower the fan is mounted at the base, and it forces air into the tower, creating high entering and low exiting air velocities. The low exiting velocity is much more susceptible to recirculation.

b) Induced draft: The fan is located at the top of the tower, induces hot moist air out the discharge.

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2) Natural Draft: Utilizes buoyancy via a tall chimney, usually used in thermal power plants.

Counter Flow Vs Cross Flow

Criteria Principle

Counter Flow The air is vertically upwards, with the hot water falling downwards. The coldest water comes in contact with the coolest and most dry air,

Cross Flow The air flows horizontally and the water falling downwards meets the air at different temperatures. Therefore the heat
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Area

optimizing the heat transfer and obtaining the maximum performance The tower area required is comparatively much smaller. Since the air-water contact time is higher, the quantity of air required is lesser The distribution is done through channel with lateral pipes, fitted with splash cum spray nozzles. Air intake is at the bottom of the tower and the discharge is at a much higher level. The problem of recirculation is less. The fan Power consumption is low as the required air quantities comparatively lower. Distribution nozzles difficult to inspect and clean.

transfer is optimized

not

always

Air Flow Distributio n System Recirculati on

Fan Power

Maintenan ce

Larger area due to features like the arrangement and material of the pack. Since the air-water contact time is lesser, more air is required The distribution is done by open trough systems on the fan deck, fitted with nozzles. Since the air intake area extends from the bottom to the deck level, it creates the effect of recirculation. The fan power consumption is higher as the airflow required is higher. Easy maintenance access to distribution nozzles

1.2.Cooling Tower Performance Parameters Range = difference between the cooling tower water inlet and outlet temperature. Approach = difference between the cooling tower outlet cold water temperature and ambient wet bulb temperature.

Cooling tower effectiveness = It is the ratio of range, to the ideal range, i.e., Range / (Range + Approach). Cooling capacity = It is the heat rejected in kCal/hr. or TR, given as product of mass flow rate of water, specific heat and temperature difference.
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Galaxy Surfactants Ltd. Summer Internship 2013 Evaporation loss = It is the water quantity evaporated for cooling duty and, theoretically, for every 10, 00,000 kCal heat rejected, evaporation quantity works out to 1.8 m3. An empirical relation used often is: Evaporation Loss (m3/hr) = 0.00085 x 1.8 x circulation rate (m3/hr) x (T1-T2) T1-T2 = Temperature difference between inlet and outlet water. Cycles of concentration (C.O.C) = It is the ratio of dissolved solids in circulating water to the dissolved solids in makeup water. Blow down losses = It depends upon cycles of concentration and the evaporation losses and is given by relation: Blow Down = Evaporation Loss / (C.O.C. 1)

1.3.Cooling Tower Internals 1) Basin- The cooled water is stored in the basin. Basin can be made from FRP or RCC. Basins can be of various capacities. It is divided into two parts a) Basin Sump- Lowest portion of the basin to which cold circulating water flows: usually the point of circulating pumps suction connection. b) Basin curb-The top level of the retaining wall of the cold water basin; usually the datum point from which tower elevation points are measured. A Float valve is used to avoid overflow and to maintain automated makeup water flow. 2) Cell - Cooling towers with circulation rate of more than 100 m 3/hr are usually subdivided into different parts with a common basin. The cell is the smallest tower subdivision which can function as an independent unit with regard to air and water flow; it is bounded by exterior walls or partitions. 3) Fills Fills are installed in cooling tower to increase the surface area of water exposed to air. Basic types of fills are splash fills and film fills. a) Splash fills

b) Film fills

4) Nozzle-A device for controlled distribution of water in a cooling tower. Nozzles are designed to deliver water in a spray pattern.

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5) Louvers-Members installed horizontally in a tower wall to provide openings through which the air enters the tower while also containing the falling water within the tower.

6) Drift eliminators -An assembly constructed of wood, plastic, or other material that serves to remove entrained moisture from the discharged air. Drift eliminators remove entrained particles from air stream with minimum pressure drop. This helps in reducing the fan power requirement when the air passes through them.

Drift Eliminators can solve some of the most common problems associated with drift loss: Corrosion problems on surrounding piping, equipment, and electrical components.

Short circuiting resulting in failure of electrical systems especially fans. Emission of chemicals to the atmosphere.

7) Fan- A device for moving air in a mechanical draft tower. The fan design may be either an axial flow propeller or centrifugal blower. Fan pitch is the angle that a fan blade makes with the plane of rotation.
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Galaxy Surfactants Ltd. Summer Internship 2013 Fan guard is the protective screen installed either at the inlet of a forced draft fan or at the exit of an induced draft fan. 8) Side stream filter The cascading water in a cooling tower continuously "scrubs" airborne contaminants from the atmosphere. These contaminants, in conjunction with particulate in makeup water, find their way into the cooling tower sump and ultimately can flow downstream into the system, where they accumulate in heat exchangers, condenser tubes and other critical water-cooled process equipment. In conjunction with corrosion, particles contribute to the following problems: Reduced operating efficiency. Increased downtime for cleaning and repair. Increased cost of water treatment. Shortened equipment lifespan. Side-stream filtration, although popular, does not provide complete protection, but it can be effective. With side-stream filtration, a portion of the water is filtered continuously. This method works on the principle that continuous particle removal will keep the system clean. For high flow systems, this method is cost-effective.

2. EXISTING SYSTEM
2.1.Cooling Tower Details:

Type Capacity Fills Basin Dimensions Basin Water

Counter flow 150 TR Film fills (PVC) 2.5 m X 2.5 m x 0.48 m 2.5 m X 2.5 m x 0.48 m
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Capacity
Pump:

Make Type Sr.no. Model Rpm Frequency Q P2 Pmax Tmax Hmax

GRUNDFOS CR-64-2 A-F-A-E-HQQE 0003 A96123530P11019 2924 50 HZ 64 m3/hr. 11.0 KW 16 BAR 120 c 60.9m
Fan motor: GRUNDFOS

MAKE Type SR no. Voltage FREQUENCY KW/HP Rpm Bearing DE Bearing NDE TAmb Net Weight Grease

3~MOT-M6160MB242FF300-F1 1569 415 V 50 Hz 11/15 2940 7309 BE 6309 C4 40 C 89 kg IOC Servoplex LC3/Equivalent LI Complex
0

2.2.Existing Network:

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2.3.Water Analysis: Cost savings can result even from one additional cycle if we start at low levels of "Cycles of concentration". The greater the number of cycles, the lesser will be the cost of water and chemicals. As cycles increase beyond a certain point, however, the savings become less and less significant. The amount of bleed off and of the make up to replace it declines rapidly at about 4 cycles and almost levels out at above 6 cycles, resulting in very little further reduction in water or chemical consumption. The TRADE OFF - possibility of increased deposition and greater potential for corrosion. 2.3.1. Tests: Most commonly, chloride tests are used since chlorides are highly soluble, remain in solution, and are easy to measure at low levels. Conductivity readings were used in the QA Lab to calculate TDS in water samples.

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Conductivity Meter in the QA lab, probes for TDS and Temperature measurement 2.3.2. Terms used: 1. Bleed Off or Blow Down (BD) (m3/h) 2. Evaporation Rate (ER) in (m3/h). Includes "windage" and "drift". 3. Makeup (MU) in (m3/h). 4. Circulation Rate (CR) in (m3/h). 5. Delta T (T) in C. Differential between incoming water and outgoing water. 6. Cycles of Concentration (C) 7. TDS - Total Dissolved Solids (in ppm) 2.3.3. Calculations: Cooling Tower 150 TR

Make Up TDS* 93.6

Blow Down TDS* 1112

Cycles of Concentration 11.88

*All the measurements for hardness, TDS and pH were done in the QA lab.

Treatment/Operating procedure being followed:

Chemical MAX Treat 2521 MAX Treat 606 Amount 500ml Effect Controls precipitation of Calcium phosphate, carbonate, sulfate. Control build-up of biological slimes formed by algae and bacteria Biocide / Slimicide for bacterial and fungal Slime control Cleaning Action For higher Efficiency Frequency Daily Cost per kg (Rs) 151

300ml

Alternate Weeks

214

MAX Treat 608

300ml

Alternate Weeks

214

MAX Treat 2001

300ml

Weekly

337

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3. INEFFICIENCIES IN THE PRESENT SYSTEM

Some pressing issues: 1. Blow Down done on arbitrary basis rather than analyzing the outlet water samples and required cycles of concentration. 2. No arrangement is made to measure blow down water quantity. 3. No flow measuring equipments near the outlets of the tower and at the main header. Proper estimate of overall TR required cannot be calculated. 4. Continuous operation of the towers despite very low heat load, no controls implemented over the CT pump. 5. Insufficient basin cleaning. Huge amounts of algae formation. All these situations lead to the inter related cooling tower problems.

What Causes Poor Performance? The performance of a cooling tower degrades when the efficiency of the heat transfer process declines. Some of the common causes of this degradation include: Scale Deposits When water evaporates from the cooling tower, it leaves scale deposits on the surface of the fill from the minerals that were dissolved in the water. Scale build-up acts as a barrier to heat transfer from the water to the air. Clogged Spray Controllers Algae and sediment that collect in the water basin as well as excessive solids get into the cooling water and can clog the spray nozzles. This causes uneven water distribution over the fill, resulting in uneven air flow through the fill and reduced heat transfer surface area. Poor Air Flow Poor air flow through the tower reduces the amount of heat transfer from the water to the air. Some causes of poor air flow are buildings or walls adjacent to the tower , heating equipments like compressors located nearby, poor motor and fan alignment, improper fan pitch, damage to fan blades, or excessive vibration. Reduced air flow due to poor fan performance can ultimately lead to motor or fan failure.
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Extreme cases of clogging in fills and Scale deposit in pipes

4. VIABLE SOLUTION
The principal objective of a good cooling water treatment programme is to: Prevent corrosion to extend equipment life, Inhibit scale and deposit build up and Control the growth of micro-organisms which can both-corrode and foul the system. Proposed Scheme of Audit: The intent of cooling water treatment audit is three fold: Measure the Effectiveness Improve upon the practices Standardize Improvements and Practices In order to carry out the audit the following procedure is suggested: A. Review the current conditions and service standards This is the starting point and forms the baseline data. The following data should be collected: Details of the treatment programme currently used. Overall treatment performance currently achieved and history. History of critical equipment and parameters. Critical process data relevant to water treatment. B. Gather records, data and statistics The data for screening should include: Daily log sheets at operating levels Daily water analysis data Monitoring data and records Data on microbial analysis Data on corrosion rates measured Consumption of chemicals Specific observations - Nearby equipments, Leaks, etc Seasonal variations
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C. Evaluate performance The performance evaluation is based on: Corrosion control Microbial control Scaling & deposition control General water chemistry D. Measure costs: Actual Vs. capability This data will allow for optimization of the feed rates of various chemicals and fine tune their frequency of addition to bring in direct benefits to the plant. Variations in the regular maintenance level can be reduced and the chemicals can be maintained in a narrower band of operation to avoid wide fluctuations and overfeed of chemicals. E. Overall review Once all the information is collated a detailed study of the data is necessary to suggest any improvements with regard to the system, and to bring in value addition and cost benefit.

5. CALCULATIONS
S. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Properties Dry-Bulb Temperature Wet-Bulb Temperature Cold water outlet Temperature Hot water Inlet Temperature Range Approach Effectiveness Cooling Tower TR Circulation water flow rate Head Loss Pump power Fills cross-section area Fills height C.O.C. Evaporation and drift losses Blow down losses Total water losses Theoretic al 35C 29C 32C 42C 10C 3C 0.76 144 58 m3/hr. 52 m 10.88 kW 6.49 m2 2.93 m 11.88 0.98 m3/hr. 0.08 m3/hr. 1.06 m3/hr. Actual 35C 29C 32C 42C 10C 3C 0.76 150 64 m3/hr. 60 m 11kW 6.25 m2 2m 11.88 0.5 m3/hr. 0.009 m3/hr. 0.51 m3/hr.

6. COST ANALYSIS
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Galaxy Surfactants Ltd. Summer Internship 2013 Pump running cost: Volt Current Power consumed Cost of electricity Total cost of operation Fan running cost: Volt Current Power consumed Cost of electricity Total cost of operation

420 V 17.6 Amp.

12.54 KW

Rs7.5/kWh Rs2954/day

420 V 9.3 Amp. 6.6 kW Rs7.5/kWh Rs696/day

Chemical cost: Chemical Amou nt MAX Treat 500ml 2521 MAX Treat 606 300ml MAX Treat 608 MAX Treat 2001 300ml 300ml

Frequency Daily Alternate Weeks Alternate Weeks Weekly

Cost per kg (Rs) 151 214 214 337

Cost per month 2265 128.4 128.4 404.4

Total Chemical cost per month = Rs2926.2 Total Chemical cost per day = Rs97.54 Make up water cost: Water consumed per 25.85 m3 day Water cost Rs15/m3 Water cost per day Rs387 Maintenance and labor cost = Rs600/month = Rs20/day Total cost per day = Rs3460 Cost of per m3 cooling water = Rs2.5

7. ENERGY SAVING OPORTUNITIES

i. ii. Follow manufacturer's recommended clearances around cooling towers and relocate or modify structures that interfere with the air intake or exhaust. Optimize cooling tower fan blade angle on a seasonal and/or load basis.
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Galaxy Surfactants Ltd. Summer Internship 2013 iii. iv. v. vi. vii. viii. ix. Correct excessive and/or uneven fan blade tip clearance and poor fan balance. Automatic adjustable pitch fans and variable-speed fans can provide closer control of tower cold water temperature than the on/off control strategy. On old counter-flow cooling towers, replace old spray type nozzles with new square spray, variable flow, and practically non-clogging nozzles. Periodically clean plugged cooling tower distribution nozzles. Optimize blow down flow rate, as per COC limit. Replace slat type drift eliminators with low pressure drop, self-extinguishing PVC cellular units. Monitor L/G ratio, CW flow rates w.r.t. design as well as seasonal variations. It would help to increase water load during summer and times when approach is high and increase air flow during monsoon times and when approach is narrow. Monitor approach, effectiveness and cooling capacity for continuous optimization efforts, as per seasonal variations as well as load side variations. Consider energy efficient FRP blade adoption for fan energy savings. Control cooling tower fans based on leaving water temperatures especially in case of small units. Use of side stream filters for continuous filtration of circulating water. This will increase the C.O.C and thus decrease Blow Down.

x. xi. xii. xiii.

8. LATEST TRENDS
8.1.Chemical Treatment Programs: The most commonly adopted methods include zinc and orthophosphate as the main corrosion inhibitors along with organo-phosphonates and polymers for scale and deposit control. Microbial control is done by addition of specific biodispersants. Corrosion Inhibition:

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With aromatic azoles it is possible to operate cooling water system at alkaline pH (8-9) with all organic water treatment formulations. It becomes especially useful in preventing the usage of base for the control of pH. At higher pH the corrosion potential is lower and the all organic composition provides adequate corrosion protection without the fear of deposition usually faced with inorganic salts used. The most widely used polymers are low molecular weight (2000 to 20,000) and usually use acrylic acid as one of the monomers. Polymers are designed for specific functions like: Calcium carbonate inhibition Metal ion and their foulant control Suspended matter dispersion Microbial Control: It is important to control the formation of Biofilm very efficiently because they can cause the: Reduction in plant performance by the growth of Biofilm. Reduction in plant integrity due to microbial corrosion Reduction in plant safety due to the growth of legionella. Biodispersants preferably should be non foaming or low foaming

Biodispersants are specific surfactants that target microbiological slime and biofilm and dislodge them from metal surfaces. Once brought into circulation, regular biocides (oxidizing or non-oxidizing) can then control these organisms by killing them. Some of the future trends in microbial control that are being worked on are: Enzyme control of Biofilm Ultrasound control of biofouling
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Galaxy Surfactants Ltd. Summer Internship 2013 Surface-catalyzed disinfection 8.2.Zero Blow-Down Technology: Zero Blow Down Technology - Newer technology. Works on the principle that blow down can be avoided by equating the wind age drift losses to the blow down hence allowing operation of cooling tower at very high COC. The companies ProchemTech or Leed Technologies provide with the filter and required chemicals for this patented procedure 8.3.Side Stream Filters: Side stream filtration systems continuously filter a portion of the cooling water to remove debris and particles and return filtered to the cooling tower basin (called the sump). These systems remove suspended solids, organics, and silt particles for a portion of the water system on a continuous basis, reducing the likelihood of fouling and biogrowth, which helps to control other issues in the system such as scaling and corrosion. This improves system efficiency and often reduces the amount of water blown down. There are a variety of filter types, which generally fall into four basic categories: screen filters, centrifugal filters, sand filters, and multi-media filters.

Side stream filtration increases water and energy efficiency and reduces cost, as described below: Reduction in water consumption: Demand for makeup water in cooling towers is decreased with an increase in the systems cycles of concentration. Essentially, higher cycles of concentration mean that water is being recirculated through the system longer before blowdown is required. Less blowdown reduces the amount of makeup water required in the system, resulting in water savings. Reduction in energy consumption: Side stream filtration reduces the likelihood of scale and fouling on the heat exchangers Reduction in chemical use: Chemicals are used to bind suspended particles in the water stream and prevent scaling and corrosion. Dirty water requires more chemicals
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Galaxy Surfactants Ltd. Summer Internship 2013 than clean water because a buildup of solid contaminants provides a buffer that reduces the effects of treatment chemicals. A side stream filtration system can remove suspended particles, reducing the need for additional chemical treatments such as dispersants and biocides. Lower maintenance cost: Traditionally, cooling towers are cleaned by draining the tower and having the sediment removed mechanically or manually from the sump. Costs associated with the cleaning process include downtime, labor, lost water, and additional chemicals. Cooling systems that are cleaned via side stream filtration routinely provide longer periods of continuous operation before being taken off-line for required maintenance. Improvement in productivity and reduction in downtime : When a cooling system is fouled or has scale buildup, production may be slowed due to inefficient heat exchange equipment. In some cases, the cooling system and heat exchange equipment may need to be taken offline for repairs, decreasing production. Control of biological growth: Biological growth control and reduction can mitigate potential health problems, such as those caused by Legionella. ASHRAE Guideline 122000 has basic treatment recommendations for control and prevention, stating that the key to success is system cleanliness. Legionella thrives where there are nutrients to aid its growth and surfaces on which to live. Use of side stream filtration can minimize habitat surfaces and nutrients by maintaining lower particle levels in the water stream.

8.4.Fan Control Strategies: Control of tower air flow can be done by varying methods: starting and stopping (On-off) of fans, use of two- or three-speed fan motors, use of automatically adjustable pitch fans, and use of variable speed fans. On-off fan operation of single speed fans provides the least effective control. Two-speed fans provide better control with further improvement shown with three speed fans. Automatic adjustable pitch fans and variable-speed fans can provide even closer control of tower cold water temperature. In multi-cell towers, fans in adjacent cells may be running at different speeds or some may be on and others off depending upon the tower load and required water temperature. Depending upon the method of air volume control selected, control strategies can be determined to minimize fan energy while achieving the desired control of the Cold water temperature. 8.5.Pump Control Strategies: Typically, the water pump is connected to the different processes with a system of pipe work. Instead of running at constant speed, the speed of the pump is adjusted by Variable Speed Drive (VSD) according to the temperature of process water leaving temperature could be good indicator for the adequacy of condensing water flow rate.

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8.6.Special Fills

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From these data we can say that C6 is the best fill. 8.7.Variable Flow Nozzles: Cooling tower do not always have a constant heat load, so depending upon the load pump needs to change its flow rate accordingly for energy saving. But Cooling Tower manufacturer do not allow reducing water flow rate below 80% because fills may get dry and becomes more prone to scaling. But now with the variable flow nozzles you can vary the water flow rate to save pump energy. Following are the advantages of variable flow nozzle: The Variable Flow nozzle has variable flow capability with an 8 to 1 turn down ratio, allowing pumps to be cycle off during cool climatic conditions or when loads demands are down. The Variable Flow nozzle produces a square water distribution pattern, which will increase thermal performance by 10% to 12%. The Variable Flow nozzle operates only 3 above the fill media reducing structural height requirements in new tower construction. Also this feature reduces tower pump head by approximately (2) ft. The Variable Flow nozzle operates at a sweet spot of only (1) lb of pressure as compared to 2lbs or more for other nozzles.

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9. PROPOSED MODIFICATIONS
9.1.Type of Cooling Tower - Cross Flow and Counter Flow What is Common to both designs? 1. Both are induced flow arrangements. 2. The interaction of the air and water flow allows for evaporation of water. 3. Both are draw-thru arrangement where a fan induces hot moist air out the discharge. What is different in Cross-flow and Counter-flow designs? The comparative analysis is on the distinctive parameters: 1. Fill Media Counter-flow cooling towers utilize a plastic film fill heat exchange media and cross-flow towers typically utilize a splash-type heat exchange media. 2. Space and Size Constraints Counter flow towers are compact and have a smaller footprint, but these tend to be taller than cross flow models .Cross Flow Cooling Towers are large because of the cavity left between the fan and the fills. 3. Spray Pattern (Water Distribution) Counter flow towers use pressurized spray systems that are considered to be the most efficient method of water distribution in a cooling tower. No sprinkler distribution is possible in a cross flow cooling tower. 4. Operating Weight Counter flow towers have low operating weight and thus find greater acceptability at roof locations. Cross-flow operating weight is higher than the counter-flow tower. 5. Fill Arrangement For the counter flow tower, the wet deck (fill media) is encased on all four sides. The entire working system is guarded from the sun's rays and helps reduce algae growth. Air inlet louvers serve as screens to prevent debris from entering the system. Cross-flow wet deck (fill) is encased on two sides only. A cross-flow cooling tower where two opposed fill banks are served by a common air plenum is termed double flow arrangement. 6. Fill Support In counter flow design, the wet deck (fill) is supported from structural supports underneath. This prevents sagging and creates a working platform on top of the fill for service. In cross-flow design, the fill media is generally supported by rods. Wearing may deteriorate the fill making it sag, which may affect performance. 7. Operating Efficiency
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Galaxy Surfactants Ltd. Summer Internship 2013 Counter flow cooling towers are 25% more efficient than cross flow type. The reason being that as the air is being sucked from the lower part of the cooling tower, it rises upwards, gets warmer and when it reaches the top, it is hottest at that point. Since the water is flowing in the downward, it is the hottest at the top. Thus, the hottest of air meets the hottest of water and evaporation is more and thus the cooling is more. In the case of a cross-flow tower, air that passes the water is not capable of passing water at different temperatures. Thus the level of cooling in this case is less. 8. Maintenance Counter-flow towers are easy to maintain at cold-water basin level because they are open on all sides with no restrictions from the wet deck. Cross flow towers are difficult to clean at the cold water basin under the wet deck because of limited access. However while considering the cleaning of the nozzles, due to accessibility cross flow towers are easier to maintain. 9. Initial Cost Counter-flow towers are typically expensive to build and have higher initial cost v/s. cross flow towers as the cross flow towers usually use low cost fills. Conclusion Based on the above mentioned parameters, counter flow seems to address all the existing issues in the plant despite the higher initial cost. 9.2.Types of fills: There are two broad categories of fills - splash and film. Splash fills: The lower thermal performance is due to the splash fill's inability to equal the surface area of film fills coupled with the higher pressure drop of splash fills. The designs can be grouped into two categories. First category includes extruded "V" bars, flat bars, convex profiles and net shapes. Second category is grid packs

Splash Fills Film fills - Allow water to flow on film, thereby exposing more area to heat transfer. Cross-fluted fills for counter flow or cross flow towers. Vertical-offset fills for counter flow towers. Vertical-flow fills for counter flow towers.
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Cross-fluted designs Provide high thermal performance Have alternating fill sheets at 60 o angles to one other, creating redistribution of water at each sheet interface. They also offer improved water distribution in the direction of the fill pack. For optimum water distribution the fill installation be done in alternating layers, each at a 90o angle to the adjacent layer.

Vertical-offset fills are a newer design The majority of the water film travels in a vertical path. The larger flute openings and the higher water-film velocity makes the vertical-offset fills less prone to fouling.

Vertical-flow fills Address poor water-quality applications. The design directs the water in a vertical path, and microstructure and capillary features allow for water mixing and lateral water distribution. The higher water velocity through the fill reduces fouling potential.
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Conclusion: No single type of fill is absolutely better than the other hence combining a vertical-flow fill with a high performance fill such as cross-fluted or vertical-offset on the top 1' (0.30 m) will improve overall performance. The immediate layer of fill should be at 90 o to the top and bottom layer. This arrangement increases water mixing and helps ensure even distribution of air and water, optimizing tower performance. At present only cross fluted fills are being used. Material Thickness. The most commonly used material thickness is 0.010" (0.25 mm). For applications where there is excessive wear due to maintenance conditions or unique spray impingement, the material thickness of 0.015" (0.38 mm) should be considered Non-glued Fill. Consider using non-glued, mechanically assembled fill, which has two important advantages. First, if the fill packs are to be assembled at the site, the environmental and safety issues of gluing packs may prohibit field assembly. Second, unglued mechanically assembled systems address long-term environmental problems. ISO14001 directs the use of best available technology to protect the environment. Temperature - CTI Standard 136 specifies a heat-deflection temperature of 160 oF (71oC) for PVC, which is adequate for most applications.

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10. REFERENCE

Unit Operations McCabe and Smith Separation Process Principles Seader and Henley Mass Transfer Operations Robert E. Treybal http://www.energy.ca.gov/title24/2013standards/prerulemaking/documents/current/R eports/Nonresidential/HVAC/2013_CASE_WS4-CTWS_10.5.2011.pdf http://www.sanjoseca.gov/esd/PDFs/cooling.pdf http://www.waterworld.com/articles/iww/print/volume-10/issue-1/feature/-sidestreamfiltration.html https://en.wikipedia.org/wiki/Cooling_tower http://www.cti.org/whatis/coolingtowerdetail.shtml http://che.sharif.edu/~heatlab/Lab/Benefit%20Book%20&%20Journal/Benefit %20book/Cooling%20Tower%20Thermal%20Design%20Manual.pdf http://www.waterworld.com/articles/iww/print/volume-10/issue-1/feature/-sidestreamfiltration.html http://spxcooling.com/en/green/leed/water-usage-calculator http://www.cheresources.com http://www.starcoolingtowers.com http://www.oceaniccooling.com/Frp-Induced-Draft-Cooling-Towers.aspx http://wextech.co.in/cooling-water-systems-%E2%80%93-audit-and-future-trends/
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Galaxy Surfactants Ltd. Summer Internship 2013 http://www.curtistech.com/variable-flow-nozzle/ The most used link http://www.engineeringtoolbox.com

APPENDIX Sample calculation:

Organic solvent density 1000 Hvap 125 Cp 0.55 water properties density 995 Cp 0.9 Reactor properties Cp_steel 0.47 Density 7.9

1. Reactor details and heat load calculation:

properties kg/m3 kCal/kg kCal/kg*K

Kg/m3 kCal/kg*K

kCal/kg*K g/cm3

Heat load of:

SSR I3 reactor mass Product Reactor capacity Temperature_Ini tial Temperature_Fi nal Cooling Time Batch Mass Cp Total heat Condenser Rx OCN 6 kl 86 C 55 C 0.8 hr 5500 kg kCal/kg* 0.55 K 117218 .8 kCal/hr Time of operation mass collected Heat of vap. 48 hr 2800 kg 125 kCal/kg 11.141970 kCal/h 4 r Reactor body

7291.666 67 kCal/hr

11.141970 kCal/h 4 r
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Pipe length Valves Pipe Diameter Bends

Inlet 10 1 2" 6

Outlet 6 1 2" 6

Pipe length Valves Pipe Diameter Bends

Inlet 2 1 2" 3

Outlet 2 1 2" 3

Total heat load for SSR13 = 124521.5586 kCal/hr. Similarly, Total heat Total heat Total heat Total heat Total heat load load load load load for for for for for SSR12 = 124521.5586 kCal/hr. SSR10 = 162229.5 kCal/hr. oil vacuum pump = 5040 kCal/hr. dry vacuum pump = 44100 kCal/hr. Thin Film Evaporator = 10787.5 kCal/hr.

Therefore, total heat load on cooling tower = 471166.7 kCal/hr. Cooling Tower TR = 124.58 With 15% extra cooling tower TR will be = 144 Pump flow rate by energy balance: Total heat load = Cooling water flow rate*Cp*Range Range = 10C Therefore, Cooling water flow rate = 52.35 m3/hr With 10% extra pump flow rate will be = 58 m3/hr 2. Head loss calculation: Sample head loss calculation in pipes and fittings: Pipe losses = f*L*V2 D*2g Friction factor (f) can be calculated by calculating Reynolds number. Fluid velocity (V) in pipes can be calculated by corresponding flow rates. Fitting losses = K*V2/2g
Given Data Flow Rate (Q) Pipe Inside Diameter (D) Kinematic Viscosity () Specific Roughness () Pipe Length (L) Calculated Data Average Velocity - V (m/s) Reynolds Number Darcy Friction Factor m3/ hr mm cSt m m 0.062 15 1 1.50E06 3 0.10 1462 0.044 0.00002 m3/s 0.015 m 1.000E06 m2/s

TOTAL

0.01

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Galaxy Surfactants Ltd. Summer Internship 2013

HEAD LOSS, hf (m)

Head Loss - Pipe (m) Calculated Head Loss in Fittings, Valves, Entrances & Exits

0.00

Ball Valve, Full Port Butterfly Valve Elbow 90 Degrees, Long Radius Elbow 90 Degrees, Standard Gate Valve Globe Valve Pipe Entrance, Inward Projected Pipe Pipe Entrance, Sharp Edge Pipe Exit Tee, Standard, Flow Through Branch Tee, Standard, Flow Through Run Head Loss - Valves & Fittings (m)

K 0.05 0.6 0.6 0.9 0.2 10 1 0.5 1 1.8 0.6

Qty 2 0 0 23 0 0 0 0 0 0 0

Sub Total K 0.1 0 0 20.7 0 0 0 0 0 0 0 20.8

0.01

Head loss in reactors, condensers, etc: Sample calculation: Reactor coil head loss: Length 104 m Diamete r 80 mm flow 18.607 m3/h 0.005168 rate 92 r 866 m3/s Velocity 2.06 m/s Head loss 5.3 m Total head loss = 9.57 m

Similarly for others also head loss is calculated. Resistance approach to head loss calculation: All components head loss is converted into corresponding resistance by following formula: R= hL/F(1.75)
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Resistance diagram:
R1+R2 R3 R4 R5 R6+R7 R8 R9 R10+R1 1 R12 R13 R14 R15 R16+R1 7 R18 R19 114522 .3 280806 7 362321 8 114045 7 5873.0 28 96043. 98 244246 4 59629. 75 94052. 13 946999 .3 289901 .2 145872 7 842.84 13 179286 .9 244246 4

Overall resistance Head loss with 15% extra,

hL

43431.16 34.67731 13 m 52.01596 695 m

3. Tower height calculation:

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Design flow rate Hot water temp. (T1) Cold water temp. (T2) Wet bulb temp. (Twb) Dry bulb temp. (Tdb) Range Approach 52355 Kg/hr 42 C 32 C 29 C 35 C 10 C 3 C 0.7692 31

Effectiveness Equilibrium line T 32 33 34 35 36 37 38 39 40 42.5 43.5 45 46.5 50

H 110 115 121 128 135 141 150 156 163 185 200 216 230 258

For minimum gas flow rate a tangent line is drawn to equilibrium line.
Minimum gas flow rate = 6.84184626 Kg/s Actual gas flow rate = 1.5*Minimum gas flow rate = 10.26 Kg/s H2 Enthalpy = 154333.3 J/Kg dry air For liquid rate = 2.7 Kg/m2.s = 5.386375

Tower cross section area m2

For gas flow rate = 1.58 Kg/m2.s Tower cross section area = 6.4954 24 m2 (This one is to be used.)
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TL 32 33 34 35 36 37 38 39 40 41 42

H* (eq.) 111000 118000 125000 130000 138000 145000 156000 159000 168000 178000 188000

H (op.) 95000 10100 0 10700 0 11300 0 11700 0 12300 0 13000 0 13700 0 14000 0 14800 0 15600 0

10^5/ (H*-H) 6.25 5.882352 94 5.555555 56 5.882352 94 4.761904 76 4.545454 55 3.846153 85 4.545454 55 3.571428 57 3.333333 33 3.125 2.7860 41

area*1 05 36397. 06 34313. 73 34313. 73 21288. 52 27922. 08 29370. 63 29370. 63 12175. 32 27619. 05 25833. 33 278604 .1

Area under the curve = Ky*a*Z/G = 2.786041

Kya = 1.5

Therefore, Z = 2.93 m
NtOG = HtOG = 2.7860 41 1.0533 33

4. Water analysis and losses:

Cooling Tower 150 TR Make up water TDS 93.6 Blow COC down water TDS 1112 11.880 34

Evaporation losses = 0.00153*Range*Circulation = 0.88 m3/hr. Drift losses = 0.2% of circulation rate
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Galaxy Surfactants Ltd. Summer Internship 2013 = 0.115 m3/hr. Blow down losses = Evaporation loss/ (COC 1) = 0.1 m3/hr Total water loss = 1.08 m3/hr 5. Pump power calculation: Hydraulic power = Flow rate**g*hL/(3.6*106) Shaft power = Hydraulic power/
Flow rate density g head efficiency Hydraulic power Shaft power 57.59 m^3/ 112 hr 1000 Kg/m ^3 9.81 m/s^2 52.015 m 97 0.75 8.1631 kW 68 10.884 kW 22

6. Cost analysis:
Pump and Fan Operating cost: Pump 1 Pump 2* Actual amp. 17.6 8.4 Power 12547.25 Operation time 24 Cost per day 2258.50 Total electricity cost/day = Rs *Only one pump is used at Make up water cost: MW per 25.855473 day 3 Cost of MW 15 Total water cost per day = Rs Chemical cost: Chemical 5988.46 (optional)

Fan 9.3 6630.0 8 14 696.15

2954.66 a time.

m^3 /m^3 387.8321 001

Amoun t 500ml

Frequen cy Daily

MAX Treat 2521

Cost per kg (Rs) 151

Cost per mont h 2265

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MAX Treat 606 MAX Treat 608 MAX Treat 2001 300ml 300ml 300ml Alternate Weeks Alternate Weeks Weekly 214 214 337 128.4 128.4 404.4

Total chemical cost per month = Rs2926.2 Total Chemical cost per day = Rs97.54 Maintenance and labor cost per day = Rs20 Total cost per day = Rs3460 Total cost per hr = Rs144 Cooling water flow rate = 57.59m3/hr Cost of water per m3 = Rs2.5

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