Design and Fabrication of Cooling Tower

In the last few years, there has been a greater demand for consumption of energy which has led to the development of energy efficient policies aiming to reduce the emissions by carbon dioxide. Cooling towers are energy efficient devices operating at a low-level water temperature and are designed to

Project Title

Design and Fabrication of Cooling Tower

Project Area of Specialization

Mechanical Engineering

Project Summary

In the last few years, there has been a greater demand for consumption of energy which has led to the development of energy efficient policies aiming to reduce the emissions by carbon dioxide. Cooling towers are energy efficient devices operating at a low-level water temperature and are designed to ensure that maximum contact between water and air occurs. These devices lower the temperature of circulating water so that the water can be used in heat exchange equipment as well as condensers. Cooling towers are used in power plant and refineries sectors. The major applications of cooling tower are in Heat Ventilation and Air Conditioning (HVAC) systems. Cooling towers are installed in pharmaceutical companies, laboratories, chemical industries, power generation etc. they are divided into natural draft cooling towers(NDCT) and mechanical draft cooling towers(MDCT). The purpose of this project is to design and fabricate an induced draft tangential flow cooling tower ()and to determine the effect of the cooling tower (CT) ,  by using various parameters including wet bulb temperature, relative humidity and other important parameters. By using the fundamental experiment methods like Fluid Dynamics, Thermodynamics and some other methods, important parameters are determined. Moreover, by changing efficiency and effectiveness and with different inlet water temperature, factors such as range, approach and L/G ratio were also determined.

Project Objectives

• The main objective of a cooling tower is to lower the temperature of the hot water using the process of evaporative cooling.
• The use of lightweight materials in order to ease assembling and repairing/maintenance.
• To use materials having a minimum cost so that they present no harmful effects on the environment.
• To reduce the consumption of the water.
• Easy handling and flexible material assembly.
• To achieve a temperature difference of 5-10 degree centigrade of the hot water.
• Keeping air velocity inside the tower to approximately 185fpm and fill height 1.5 ft.
•  Electrical wirings in the system  will be insulated properly to prevent the risk of electrocution.
• Providing safety signs to ensure that no accidents occur.
• To control vibrations using foundation isolators.
• Ensuring safe distance from the fan/blades.

Project Implementation Method

This project is divided into four phases:

PHASE 1 : DATA COLLECTION AND RESEARCH 

Before starting any project,it is important to understand what the project actually is and without adequate research it is not possible to carry out furthur work.This phase is one of the most important and is the backbone of the project.

PHASE 2 : SELECTION OF DESIGN PARAMETERS AND DESIGN CALCULATIONS

For any project,design is the most important parameter before carrying out fabrication.This phase includes extensive research and selecting appropriate parameters which will later be used when performing calculations.AUTOCAD modelling is also being done here.

PHASE 3 : FABRICATION

Once design parameters and calculations are completed,the next phase is the fabrication of the cooling tower.Here, the fabrication parameters are listed down and any safety considerations in design is mentioned.

PHASE 4 : FUTURE WORKS 

After the project is completed,it is important to see whether the project performs its intended function or not.For this reason,testing phase will be carried out in which any remaining error will be checked for and eliminated so that the project is fully functional.Performance enhancement will also be carried out and it is intended that the project serves beneficial in the near future.

Benefits of the Project

This project serves benefical in many ways.

• Cooling Towers are required in commercial and industrial processes where there is a need to remove heat from water.
• For example,in tinned food production,water is used to cook food within the can.This process requires a great deal of water at a given temperature.Cooling Tower cools the water after use so that the process can be repeated again and again with limited evaporative loss.
• Cooling Towers provide a cost-effective and energy efficient operation of systems in need of cooling.
• Large facilities like powerplants,oil refineries and steel manufacturing plants make use of cooling tower while most other facilities have a cooling tower in their Heat Ventilation and Air Conditioning (HVAC) units.
• Since water is environmental friendly fluid,therefore can be used as a refrigerant in cooling systems.
• Dehumidifier in cooling towers help eliminate the pollutants and bacteria from the air which improves indoor air quality significantly.

Technical Details of Final Deliverable

• Cooling Tower Type: Counterflow 
• Cooling Tower Form factor: Circular
• Fills Type:Honeycomb rigid PVC
• Heat Load: 21.975kW
• Water Flow Rate: 140 lb per min
• Design Wet Bulb Temperature: 28 degree centigrade
• Cold Water Temperature: 32 degree centigrade
• Hot Water Temperature: 37 degree centigrade
• Water Quality(pH)=7.8
• Evaporation Loss = 16.08 kg/hr
• Drift Loss = 7.57 kg/hr
• Air Flow Rate = 2699 m cube /hr
• Number of blades =12
• Type of Fan = Axial
• Type of Coupling = Direct Drive 
• Motor Power (RPM)= 1500
• Motor enclosure= Aluminum/brass
• Class of Insulation = Class 'F'
• Frame Work = Mild Steel (MS)
• Casing /Basin = Galvanised Iron (GI)
• Fan Blades = Aluminium 
• Bolts,Nuts,Hardware = Stainless Steel

Final Deliverable of the Project

Hardware System

Core Industry

Energy

Other Industries

Core Technology

Clean Tech

Other Technologies

Sustainable Development Goals

Responsible Consumption and Production

Required Resources

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