Mass Transfer 2

CPB 20104

Experiment 1
COOLING TOWER
______________________________________________________________________________________

INTRODUCTION
When warm liquid is brought into contact with saturated gas or air, part of the
liquid evaporates and the liquid temperature drops. This principle is used in the
operations of cooling towers. In the cooling towers the temperature of the re-circulated
water used for condensers and heat exchangers in chemical plants, is brought down by
cooling using air humidification process. Cooling towers are the cheapest way to cool
large quantities of water. In the cooling tower when the water is distributed over a
packing of a certain height through which the air passes up wards causing evaporation
and hence cooling of the water stream. This packing would be able to make the surface
of air or water contact area as large as possible. Hot water sprayed onto the top of the
tower trickles down through packing or wooden slats, evaporating as it goes. Air is
passed through the packing by forced-draft or induced draft fans or it is drawn by
natural convection.
The reduction in water temperature in the cooling tower comes mainly from
evaporation, although when the air temperature is low, there is also some sensible heat
transfer to the air. However, even when the air is warmer than the water, water can be
cooled by evaporation if the wet bulb temperature is below that of the water. In practice,
the discharge temperature of the water is 3 to 8 degree C above the wet bulb
temperature. The water temperature from inlet to exit is generally 6 to 17 degree C.
The Bench Top Cooling Tower (Model HE 152) has been designed for students
demonstration and to give them an understanding of the construction, design and
operational characteristics of a modern cooling system. The unit resembles very much
like a full size forced draught cooling tower and it is actually an open system through
which two streams of fluid (in this case air and water) pass and in which there is a
mass transfer from one stream to the another. The unit is self-contained supplied with
a heating load and a circulating pump. Once energy and mass balances are done,
students will then be able to determine the effects on the performance of the cooling
tower by the following parameters:
1)
2)
3)
4)

Temperature and flow rate of water

Temperature and flow rate of air
Cooling load
Packing density

Packing characteristics column is designed to facilitate study of water and air

conditions at three additional sections (I, II, III) within the column. This enables driving
force diagrams to be constructed and the determination of the characteristic equation
for the tower.

FG/Exp1/Jan2015

Mass Transfer 2

CPB 20104

EXPERIMENTAL PROCEDURES
General Start-up:
1.
2.

3.
4.
5.
6.
7.

8.

9.
10.

Check to ensure that valves V1 to V6 are closed and valve V7 is partially

opened.
Fill the load tank with distilled water or deionised water. It is done by first
removing the make-up tank and then pouring the water through the opening
at the top of load tank. Replace the make-up tank onto the load tank and
lightly tighten the nuts. Fill the tank with distilled water or deionised water
up to zero mark on the scale.
Add distilled water or deionised water to the wet bulb sensor reservoir to the
fullest.
Connect all appropriate tubing to the differential pressure sensor.
Install the appropriate cooling tower packing for the experiment.
Set the temperature set point of temperature controller to 50C. Switch on
the 1.0 kW water heater and heat up the water until approximately 40C.
Switch on the pump and slowly open the control valve V1 and set the water
flow rate to 2.0 LPM. Obtain a steady state operation where the water is
distributed and flowing uniformly through the packing.
Fully open the fan damper and then switch on the fan. Check that the
differential pressure sensor is giving reading when the valve manifold is
switched to measure the orifice differential pressure.
Let the unit run for about 20 minutes for the float valve to correctly adjust
the level in the load tank. Refill the make-up tank as required.
Now, the unit is ready to use.

Note:
i)

ii)

iii)
iv)
v)

It is strongly recommended that only distilled water or deionised water be

used in this unit. The impurities existing in tap water may cause the
depositing in cover tower.
Check that the pressure tubing for differential pressure measurement are
connected correctly :
a. orifice pressure tapping point to V4
b. Columns lower pressure tapping point to V6
c. Columns higher pressure tapping point to V3
d. V5 leave to atmosphere
To measure the differential pressure across the orifice, open valve (V4 and
V5), closed valve (V3 and V6).
To measured the differential pressure across the column, open valve (V3 and
V6), closed valve (V4 and V5).
Always make sure that no water is in the pressure tubing for accurate
differential pressure measurement.

FG/Exp1/Jan2015

Mass Transfer 2

CPB 20104

Experiment A
Investigation of the effect of air velocity on wet bulb approach and pressure drop through
the packing

Objectives:
To investigate the effect of air velocity on:
a. wet bulb approach
b. pressure drop through the packing

Procedures:
1.
2.

3.

4.

5.

Prepare and start the cooling tower with according to general start-up
procedures.
Set the system under the following conditions and allow stabilizing for about
15 minutes.
Water flow rate
: 2.0 LPM
Air flow rate
: Maximum
Cooling load
: 1.0 kW
Column Installed
: Column A (110 m2/m3)
Dimension of Column
: 15 cm (w) x 15 cm (d) x 60 cm (h)
After the system stabilizes, record a few sets of measurements and then
obtain the mean value for calculation and analysis.
Temperature (T1-T6)
Orifice differential pressure (DP1)
Water flow rate (FT1)
Heater power (Q1)
Pressure drop across packing (DP2)
Repeat the test with three different sets of orifice pressure drop values (75% ,
50% and 25% of the maximum value) without changing the water flow rate
and cooling loads.
Finally, measure the cross sectional area of the column.

RESULTS AND DISCUSSION:

Discuss all your results. The questions below only serve as a guideline. Your discussion
should not only limited to these questions.
1.
2.
3.
4.

Calculate the nominal velocity of air and find the wet bulb approach.
Plot a graph to show that the relationship between wet bulb approach and
packing pressure drops versus nominal air velocity in the same graph.
Discuss the effect of nominal air velocity on the approach to wet bulb and
pressure drop through packing.
Discuss the relationship between the approach to wet bulb and pressure
drop through packing.

FG/Exp1/Jan2015

Mass Transfer 2

CPB 20104

Table of Results:
Table A
Description

unit

Packing density

m-1

Air inlet dry bulb, T1

Air inlet wet bulb, T2

Air outlet dry bulb, T3

Air outlet wet bulb, T4

Water inlet temperature, T5

Water outlet temperature, T6

Orifice differential, DP1

Pa

100%
110

Water flow rate, FT1

LPM

Heater power, Q1

Watt

Pressure drop across packing, DP2

Air Flow
75%
50%
110
110

25%
110

Pa

Table B
Description

Air Flow
75%

100%

50%

25%

Nominal velocity of air (m/s)

Approach to web bulb (K)
Pressure (mm H2O)

FG/Exp1/Jan2015

Mass Transfer 2

CPB 20104

Useful Information:
In order to plot the graph, it is necessary to follow the steps of calculation.
1. Calculate approach to wet bulb.
Approach to wet bulb = Outlet water temperature (T6) Inlet air wet bulb
temperature (T2)
2. Check the value of specific volume of air at outlet in the humidity chart (plotting
air outlet dry buld and air outlet wet bulb on psychometric chart)
o

3. Calculate the air mass flowrate,

o

m 0.0137

m (kg/s)

h : orifice differential in mm H2O

: specific volume of air (m3/kg)
o

4. Calculate air volumetric flowrate,

o

(m3/s)

m
5. Calculate nominal air velocity, (m/s)
o

A
A : packing area (m2)

FG/Exp1/Jan2015

Mass Transfer 2

CPB 20104

Experiment B
Investigation of the relationship between cooling load and cooling range

Objective:
To investigate the relationship between cooling load and cooling range

Procedures:
1.
2.

3.

4.
5.

Prepare and start the cooling tower with according to general start-up
procedures.
Set the system under the following conditions and allow stabilizing for about
15 minutes.
Water flow rate
:
2.0 LPM
Air flow rate
:
Maximum
Cooling load
:
0.0 kW
Column Installed
:
Column A (110 m2/m3)
After the system stabilizes, record a few sets of measurements and then
obtain the mean value for calculation and analysis.
Temperature (T1-T6)
Orifice differential pressure (DP1)
Water flow rate (FT1)
Heater power (Q1)
Without changes in the conditions, increase the cooling load to 0.5 kW.
When the system stabilized record all the data.
Similarly, repeat the experiment at 1.0 kW and 1.5 kW.

RESULTS AND DISCUSSION:

Discuss all your results. The questions below only serve as a guideline. Your discussion
should not only limited to these questions.
1.
2.
3.

What is cooling range?

Plot the graphs between water inlet temperature and water outlet
temperature as a function of cooling load in the same graph.
Based on your result, discuss the relationship between the cooling range and
cooling load.

General Shut down:

1.
2.
3.
4.
5.

Switch off heaters and let the water to circulate through the cooling tower
system for 3-5 minutes until the water cooled down.
Switch off the fan and fully closed the fan damper.
Switch off the pump and power supply.
Retain the water in reservoir tank for the following experiment.
Completely drain off the water from the unit if it is not in used.

REFERENCES
1.

Perry, R.H., Green, D.W. and Maloney, J.O., Perrys Chemical Engineering
Handbook. 6th edition, McGraw Hill, 1984.

FG/Exp1/Jan2015

Mass Transfer 2

CPB 20104

Table of Results:
Table A
Description

unit

Packing density

m-1

Air inlet dry bulb, T1

Air inlet wet bulb, T2

Air outlet dry bulb, T3

Air outlet wet bulb, T4

Water inlet temperature, T5

Water outlet temperature, T6

Orifice differential, DP1

Pa

Water flow rate, FT1

LPM

Heater power, Q1

Watt

0.5kW
110

Cooling Load
1.0kW
110

1.5kW
110

FG/Exp1/Jan2015