CAPE PENINSULA UNIVERSITY OF TECHNOLOGY

DEPARTMENT OF CHEMICAL ENGINEERING

SUBJECT: CHEMICAL ENGINEERING PLANT 3B (CPL301S)

COOLING SYSTEMS

Lecturer: Mr Wighens Ngoie Ilunga

Cooling Systems

Introduction to Psychometric
Charts
Definition - graphical representation of gas-vapour (moistair) systems physical and thermodynamic properties at
constant pressure

Why study

- We will be dealing with industrial systems

involving moist air e.g. cooling systems, these can be used

to determine other properties if given a status point ( a
state of a given atmosphere)

Cooling Systems

Learning Objectives
1. Define

the

properties

that

are

obtained

from

the

psychometric chart
2. Determine the system variables from the charts given some
of the variables

3. Represent the changes in the atmospheric conditions

(psychometric processes)

Cooling Systems

Humidity
1. Absolute humidity (AH) - is the vapor content of air, given in
grams of water vapour per kg of air (g/kg)

2. Humidity ratio is the ratio of AH to moisture content

3. Saturation humidity (SH) The maximum amount of moisture

that air can support at a given temperature and pressure

4. Relative humidity (RH) - Is the moisture content of a given

atmosphere as a percentage of the saturation humidity at the
same temperature. As a result this can be expressed as follows:

AH
RH
100%
SH
Cooling Systems

..Continued
Plotting

the

saturation

humidity

against

the

dry

bulb

temperature (DBT) gives the saturation humidity line

RH lines are plotted by halving each SH ordinate to obtain the 50%
curve, and further proportionate subdivision gives any intermediated RH
curve

Cooling Systems

Wet bulb Temperature (WBT)

Measured using a hygrometer.
Consists of two thermometers , one measuring the DBT and the other
having a wick around it

The difference in the two bulb readings gives the wet bulb depression
As water evaporates from the wet wick, it lowers the WBT and this
shows the moisture carrying capacity of the air at the given
temperature
When the air is saturated the WBT and DBT readings are identical and
the status point' is determined at the intersection of the vertical DBT
line and the sloping WBT line of the psychometric chart.

Cooling Systems

. Continued

Cooling Systems

Specific Volume
Is the reciprocal of density (m3/kg).
Indicated by slightly more sloping lines and is useful in the conversion
of volumetric air flow quantities into mass flow quantities

Cooling Systems

Enthalpy (H)
It is the heat content of unit mass of the atmosphere (kg/kJ), relative
to the heat content of dry air at 0C
In order to avoid confusion with the WBT lines , the H scale is at the
perimeter of the chart
E.g. for air condition at P the enthalpy is read at point A. The sensible
heat component can be read at point B, corresponding to the enthalpy
of dry air at the same temperature. The remainder, ie, A - B, is the latent
heat content.

Cooling Systems

Cooling Systems

Cooling Systems

Heating/ Cooling
During heating or cooling, without any change in moisture content
(AH), resulting in the change in DBT . The status point moves
horizontally. Left - cooling and right - heating
Though AH is constant, the RH changes that is it increases if the
temperature is lowered and vice versa

Cooling Systems

Dehumidification by cooling
During cooling, the status point reaches the saturation line and some
condensation begins, and the DBT corresponding to this point is the
Dew point temperature of the original atmosphere
Further cooling, results in more condensation and the vertical gives
the moisture precipitated out.

NB: This reduces the AH

Cooling Systems

Adiabatic dehumidification
by sorbents
During this some moisture is removed and the latent heat of
evaporation is released

There is an increase in sensible heat content, the status point will

move down towards the right along the H line

Cooling Systems

Adiabatic humidification by
evaporative cooling
Adiabatic is the removal of moisture into an air volume without
adding or removing heat
Latent heat of evaporation is from the atmosphere

DBT is reduced but latent heat content increases

The status point moves up along the WBT line to the left

NB: This increase the RH and this can only increase till it coincides with
the saturation line. This explains why during hot and humid months,
evaporative cooling is ineffective

Cooling Systems

Mixing
If two streams are mixed, having:
- mass flow rates m1 and m2,
- DBT t1 and t2,
-Enthalpy H1 and H2
The result will be
m1t1 = m2t2 = (m1 + m2) t3
Therefore :
t3 = (m1t1 + m2t2)/m1 + m2
H3 = (m1H1 + m2H2) / m1 + m2
Connecting the two status points by a straight line in the chart will
establish the value of t3 and H3. Divide this in inverse proportions of m1
and m2, if the mass flow rate m1 is greater, the resulting point P will
represent the state of the combined air streams.
Cooling Systems

Tutorial
1. A dry-bulb thermometer reads 25C and a wet-bulb thermometer reads 18C.
What is the relative humidity?
2. What is the dew point temperature of the air in problem 1?.
3. What is the humidity ratio (absolute moisture content of the air in problem
1?
4. If the air in problem 1 is passed through a 100% efficient evaporative cooler,
what will be its temperature after it leaves the cooler?
5. When air represented by point A (db= 25C, wb=18C) enters a storage room
with a temperature of 0C and a relative humidity of 95%, will it add
moisture to the storage room or dry it out?
6. If air leaves a wet-coil evaporator at 0C and 100% relative humidity and is
heated 2C by the circulation fan before it reaches a stored product, what
is the relative humidity of the air to which the product is exposed?
Cooling Systems

Cooling Systems - Glossary

Corrosion - damage/wearing out of equipment especially
metals caused by the presence of oxygen and water

Blowdown

- continuous removal of water from the

circulating system in order to prevent scaling due to dissolved

solids build up

Makeup water Water added to the circulating system to

make up for the lost water through evaporation

Purge - loss of water to relieve the system

Windage loss loss due to liquid entrainment

Cooling Systems

.........Continued
Corrosion - damage/wearing out of equipment especially
metals caused by the presence of oxygen and water

Scaling/fouling - When suspended/or precipitated particles

from solution are deposited on equipment surfaces (Sohnel
and Garside, 1992)

Cooling Systems

Learning Objectives
1. Describe the purpose of cooling systems

2. Define the terms associated with cooling systems

3. Explain the different cooling systems
4. Identify and explain the purpose of the important
components that make up the cooling system
5. Explain how the cooling occurs and the factors that can be
manipulated to ensure optimum operation/performance
6. Basic calculations of the systems
7. Identify the most likely problems encountered in cooling

systems. Explain the factors that affect scaling and how

scaling can be minimised.

Cooling Systems

Purpose and Types of Cooling

Systems
Introduction
Remove heat from process streams through coolant
circulation

Three systems normally implemented are as follows:

1). Once through
2). Open evaporative recirculating
3). Closed non-evaporative recirculating

Cooling Systems

Once Through Systems

Cooling water passes through the heat exchanger once. Once
through systems can be used when plenty of cheap cool water is
available and adequate facilities for disposal of warm water exist.

Pump
Discharge

Intake
Heat
exchanger

Cooling Systems

.......... Continued
Advantages:
No cooling tower system;
No water treating

Disadvantages:
Corrosion
Fouling
Waste of water
Thermal pollution of river

Cooling Systems

Open Evaporative
Recirculating System
Cooling water evaporates about 1% water. Water is needed for

make up.

Cooling
tower

Heat
exchanger

Makeup
Pump

Blowdown

Cooling Systems

.......... Continued
Advantages:
Less water required
Enhanced corrosion control feasible

Disadvantages:
Higher capital cost than once through;
Large cooling towers may be unacceptable;

System purge may pose environmental problems

Cooling Systems

Closed Non-Evaporative
Recirculating System
Cooling water is cooled in a secondary (air) heat exchanger. No
evaporate, no makeup.

Water cooling
equipment
Pump

Cooling Systems

Heat
exchanger

.......... Continued
Advantages:
Water remains clear
Cooling water temperature above 100oC is possible

Disadvantages:
High capital cost
Limited by air temperature

Open evaporative systems are usually used.

Cooling Systems

Cooling System Variables

Tower design

Water alkalinity

Pumps and fans air flow

Humidity, temperature

Corrosion and Scaling

Cooling Systems

Basic Calculations for Evaporative

Recirculating System
Make up (M)
M = E + W + P = E + W + B + IL
Where E is the Evaporative rate
W is Windage loss
P is the Purge
IL loss due to leaks

Evaporative rate:

F T
E
700
Cooling Systems

m3/hr

....................Continued
Where T is temperature difference between feed and return
water (C)
F is circulation rate (m3/hr)
Windage loss, W:
-normally specified by tower manufacturer
0.01% of circulation for modern units and 0.2% for old units
Total Purge , P
Water loss other than by windage loss

P B IL

Where B is the bow down

IL is the loss by leaks
Cooling Systems

....................Continued
Concentration factor (CF)
-During evaporation the concentration of solid increases in the

circulation water.
CF = %X in circulating water) (%X in make up)
Typically, "markers" for "X" are magnesium or chlorine ions.

Cooling Systems

Mass balance around the marker

Mm Xin = (P + W)Xout = (Mm - E)Xout

X out
X out
Hence M m E
, sin ce CF

X in
X out X in
CF
E
Therefore Mm E
E
CF 1
C F 1
B M m E W IL
E
B
W I L
CF 1
Therefore, higher CF gives lower Mm and B.
Cooling Systems

Example

Given that the circulation rate = 1000 m3/hr, Tw to tower = 30oC, Tw

from tower = 20oC. Calculate the makeup rates for the concentration
factors listed in the table below for this system?
CF
1.2
Mm (m3/hr) 85.8

1.5
42.9

2.0
28.6

Cooling Systems

3.0
21.5

4.0
19.1

Most likely problems encountered

in cooling systems
Two problems in cooling water systems:
1). Fouling due to the following
a)Scaling
- Precipitation of insoluble salts may occur, e.g. CaCO3

b)Sedimentation or silting
- This is caused by the particles in the source water e.g. sand

c)Biological growth
- This is promoted by the presence of heat, oxygen, phosphates

promote biological growth

Cooling Systems

--------Continued
2) Corrosion
- This is promoted by the presence of oxygen, water, material
roughness.
NB: Scaling in the system impairs heat transfer efficiency and may
increase pumping cost. With stainless steel, scaling may promote

stress corrosion cracking.

Cooling Systems

Factors affecting scaling

Concentration factor
- The alkalinity is most likely to increase in the circulating water in
evaporative systems promoting scale formation e.g. CaCO3 scales.
pH value
- High pH changes CO2 speciation in water i.e. the CO2 : HCO3- : CO32- ratio,
in favour of carbonate promoting CaCO3 precipitate formation
Temperature
The dissociation of HCO3- to CO32-, the amount of CO2 and H2O is greater at
higher temperature whilst the solubility of CaCO3 decreases with
temperature thereby promoting scaling

Cooling Systems

Factors affecting scaling

continued
Bacteria slime
This provides sites for scale growth, e.g. on cooling tower timbers.
Corrosion

Rough surfaces tend to promote scaling

Flow velocity
low flow velocities promotes sedimentation of solid particles thereby

promoting scaling.
Retention time/circulating rate
- long half lives gives longer time for the following equilibrium to be achieved
Ca(HCO3)2 CaCO3 + CO2 + H2O
-also with faster circulation there is more CO2 stripping in cooling tower. Hence
both factors reinforce scaling tendency.
Cooling Systems

Scale Prevention
- Higher system purge used to reduce CF at the expense of higher
water/chemical costs.

- Soften makeup water

- Acid treatment to reduce CO32- Use scale inhibitors

Cooling Systems

Environmental considerations
- The problems of fouling and corrosion can be can be minimized by
cooling water treatment
-However, there is need to adhere to the environmental regulations
when disposing the waste waters from the treatment plants.
-Hence, the choice of treatment chemicals needs stringent
considerations and as such inlet water quality must first be known
e.g. the pH, total dissolved solids, suspended solids, alkalinity

Cooling Systems

Tutorial
1. Once through, Open evaporative and closed non-evaporative are three
types of water-cooling systems in common use.
Which one of these would be most suitable for cooling water at a city power
station? Explain.
[3]
2. Draw a labeled sketch of an open evaporative cooling system
[5]
Write an overall mass balance equation around this system.
[1]
Explain clearly the meaning of each term in your mass balance equation. [5]
How is the value of each term estimated?
[3]
Use the mass balance equation to derive an expression that shows the
. variation of blow down rate with concentration factor CF.

Explain how the following factors affect the rate of scaling in pipe-work in a
cooling system:
Concentration factor.
[2]
pH
[2]
Temperature
[2]
Explain how each of the three factors above can be modified to reduce the
rate of scaling.
[6]
Cooling Systems