کولینگ تاور کراس فلو

برج خنک کننده جریان متقاطع یا ابارا

برج خنک کننده جریان‌ متقاطع یا برج‌خنک‌کن کراس‌فلو (Cross Flow Cooling Tower) نوعی سیستم مدارباز جهت خنک نمودن آب محسوب می‌شود. برج خنک‌کن جریان متقاطع برای اولین بار توسط شرکت ابارا در ژاپن برای خنک‌کردن آب در مناطق شرجی ارائه گردید و به همین دلیل در صنایع برودتی تحت عنوان برج خنک کننده ابارا نیز شناخته می‌شود. در برج خنک کننده جریان متقاطع جریان آب از بالای برج به سمت پایین پاشیده شده و هوا از قسمت پایین توسط یک فن یا پروانه در جهت عمود بر جریان آب دهش یا مکش‌شده و در این ارتباط جریان آب در سطح عرضی کولینگ تاور خنک می‌گردد. نوع ساختار برج خنک کننده کراس فلو به شکل هندسی مستطیل می‌باشد و جریان هوا از دو طرف توسط لوور یا دریچه های ورودی سرتاسری به داخل کشیده می‌شود.

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چرا برج خنک کننده جریان متقاطع؟

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برج خنک کننده وظیفه دفع گرمای حاصل از تجهیزات‌صنعتی گرمازا را به عهده دارد و از آنجا که خود نوعی مولد سرمایش تبخیری محسوب می‌شود سبب افزایش رطوبت محیط می‌گردد و درنتیجه با افزایش رطوبت هوا ظرفیت‌برودتی کولینگ تاور نیز کاهش می‌یابد. باتوجه به مطالب ذکرشده، برج‌خنک‌کننده مخالف دستگاه مناسبی برای خنک‌کاری آب در مناطق مرطوب به حساب نمی‌آید. در این طور مناطق از چیلرها جهت خنک‌سازی آب در یک سیکل تراکمی یا جذبی استفاده می‌شد. به دلیل مشکلات متعدد از جمله هزینه‌بالای خرید چیلر و تعمیر و نگهداری سخت این تجهیز شرکت ابارا تصمیم به طراحی برج‌خنک‌کننده ابارا یا کراس فلو با سیستم گردش‌هوا به صورت متقاطع شد.

پس از تکمیل این طراحی در واقع هوای محیط‌های مرطوب که دارای رطوبت زیادی بودند در تمامی لایه‌ها به صورت یکنواخت در تماس با آب قرار می‌گرفت و راندمان برج‌های خنک‌کن با تغییر نوع گردش هوای ورودی بسیار افزایش پیدا کرد. به بیانی علمی‌تر و واضح‌تر برج‌خنک‌کننده جریان‌متقاطع سبب تماس هوای‌تازه در تمامی سطوح و لایه‌های پکینگ با جریان‌آب می‌شود و دیگر همانند برج‌خنک‌کننده جریان‌مخالف هوا خاصیت رطوبت‌گیری خود را در لایه‌های بالاتر از دست نخواهد داد.

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نحوه کارکرد برج خنک کننده جریان متقاطع یا کراس‌فلو

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برج‌خنک‌کننده کراس‌فلو همانطور که از نام آن مشخص است با ورود جریان هوا به صورت عرضی در سراسر سطوح خنک‌کننده(پکینگ ها) سبب برخورد هوا و آب به صورت عمودی و درنتیجه کاهش دمای آب می‌شود. به دلیل ورود هوا به صورت عرضی در تمامی لایه‌های پکینگ‌مدیا هوای‌تازه در ارتباط با آب قرار خواهدگرفت و از این رو اگر هوای‌تازه ورودی به برج‌خنک‌کن دارای رطوبت بالایی باشد قابلیت خوبی است که برج‌خنک‌کننده جریان‌متقاطع از هوای تازه بهترین استفاده را می‌نماید. درواقع به دلیل همین عملکرد ورودی جریان هوا از برج‌خنک‌کننده جریان‌متقاطع بیشتر در مناطق با اقلیم رطوبتی و مرطوب (شرجی) استفاده می‌شود. ورودی هوا در برج‌خنک‌کننده جریان‌متقاطع از دو طرف این دستگاه طراحی‌شده و به دلیل نحوه چگونگی ورود هوا این لوورهای مکش هوا به صورت سرتاسری در دو طرف برج‌خنک‌کاری تعبیه می‌گردد.

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مقایسه بین برج خنک کننده جریان متقاطع و جریان مخالف

• دارای ارتفاع کمتری در مقایسه با انواع کولینگ‌تاور جریان‌مخالف می‌باشد.

• نیازمند مساحت بیشتری جهت خنک‌سازی می‌باشد و آب در برج‌خنک‌کن جریان‌متقاطع در یک جریان سطحی خنک می‌شود تا در ریزش در لایه‌های مختلف(ارتفاع).

• نوع پکینگ یا سطوح خنک‌کن در برج خنک‌کننده جریان‌متقاطع از نوع شانه تخم‌مرغی می‌باشد ولی نوع پکینگ‌مدیا در برج خنک کننده جریان‌مخالف از نوع فیلمی یا آبشاری می‌باشد.

• افت فشار کمتری دارد(به دلیل ارتفاع کمتر) و این موضوع سبب کاهش توان مصرفی پمپ سیرکولاتور نسبت به انواع برج‌خنک‌کن جریان‌مخالف می‌شود.

• امکان ارسال در ظرفیت‌های بالا به صورت غیرترافیکی و مونتاژ درب کارخانه (به دلیل تولید به صورت مستطیلی)

• نوع نازلهای بکاررفته در برج‌خنک‌کننده جریان‌متقاطع از نوع پروانه‌ای می‌باشد و درحالی که در کولینگ‌تاور کانترفلو از انواع نازلهای دایره‌پاش و نازل مربع‌پاش جهت پاشش آب استفاده می‌شود.

• ورودی آب از قسمت‌های بالا در دو طرف و تشتک‌های سوراخ داری صورت می‌پذیرد و همانند برج‌های مدور و مکعبی دارای فلنچ ورودی و خروجی آب نمی‌باشد.

• دارای درب منهول(یا دریچه ورودی) در بخش پنل مرکزی به منظور عبور و مرور اپراتور در زمان‌های انجام امور بازدید، تعمیر و نگهداری می‌باشد.

• ارتفاع چیدمان سطوح خنک‌کننده یا پکینگ‌مدیا در کولینگ‌تاور جریان‌متقاطع خیلی بیشتر از جریان‌مخالف می‌باشد چرا که در طراحی این مدل برج‌خنک‌کاری حتی تا 5 لایه پکینگ با ارتفاع هر لایه 50 سانتی‌متر نیز استفاده می‌شود.

• برج‌خنک‌کننده جریان‌متقاطع بیشتر در مناطقی با نسبت رطوبت بالا (هوای نزدیک به حالت اشباع) یا خیلی مرطوب مورد استفاده قرار می‌گیرد و برج‌خنک‌کن جریان‌مخالف بیشتر در مناطق خشک مورد کاربری واقع می‌شود.

• چیدمان پکینگ‌ها در برج‌خنک‌کن جریان‌متقاطع در نزدیکی دهانه‌ی لوورها یا دریچه‌های ورود هوا می‌باشد در صورتی که در برج‌های خنک‌کننده جریان‌مخالف این سطوح تبادل حرارت در مرکز برج قرار می‌گیرد.

• جریان ورودی هوا در برج‌خنک‌کننده جریان‌متقاطع از دو طرف وارد دستگاه می‌شود در صورتی که در کولینگ‌تاورهای مکعبی و مخروطی با جریان ناهمسو هوا از چهارطرف به داخل مکش می‌گردد.

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مهمترین مزایای برج خنک کننده جریان متقاطع

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• راندمان بالا در مناطق رطوبتی و کاهش دمای آب در تا دماهای پایین

• امکان تولید به صورت چندسلولی و کنترل مصرف انرژی(خاموش نمودن یک یا چندموتور در زمان بار کم)

• کاهش هزینه‌های حمل(هزینه‌های بارترافیکی و بزرگ) به دلیل ابعاد مستطیلی در ظرفیت‌های بالا

• امکان تولید به صورت یکپارچه در ظرفیت‌های بالا به دلیل استراکچر مستطیلی

• اشغال فضای کمتر نسبت به مدل مخروطی و اشغال ارتفاع کمتر نسبت به مدل مکعبی

• کاهش هزینه مونتاژ در محل در ظرفیت‌های بالا به دلیل امکان تولید به صورت مونتاژ درب کارخانه

• تعمیر و نگهداری آسان و دسترسی راحت به تمامی اجزای داخلی برج‌خنک‌کننده

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اساسی ترین معایب برج خنک کننده جریان متقاطع

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• راندمان بسیار ضعیف در مناطق خشک و گرم

• توزیع آب نامناسب در نازل‌های پاشش آب

• اشغال فضای زیاد و جانمایی سخت و دشوار

• ایجاد افت فشار زیاد در هوا و افزایش توان مصرفی موتور

• رسوب و گرفتگی بیشتر نسب به برج‌خنک‌کن جریان‌مخالف

•  یخ‌زدگی مدارآب چرخشی در زمستان

• پرتاب قطرات آب به سمت فن و تخریب سیستم هوادهی و هوارسانی در برج‌خنک‌کننده

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روش‌های کنترل دمای آب در برج خنک کننده جریان متقاطع

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روش اول) برای کنترل دمای آب خروجی از برج‌خنک‌کن کراس‌فلو راه‌های گوناگونی وجود دارد که ساده‌ترین آن استفاده از سنسور دما به علاوه ترموستات و درنتیجه روشن و خاموش‌کردن فن های کولینگ تاور می باشد. در این روش حسگر ترموستات دمای آب خروجی برج خنک کننده را سنجیده و در صورت کمتر بودن دمای آب سرد از دمای ایده آل مورد انتظار فرمان خاموش شدن فن یا پروانه را صادر می کند.

روش دوم) در برج های خنک کننده ای  که دارای یک فن جریان محوری بزرگ هستند می توان با استفاده از یک کنترل‌کننده فرکانس (اینورتر) دور فن را کاهش یا افزایش دهیم و یا حتی می توان آن را خاموش یا روشن نمود. به منظور کنترل بهتر دمای خروجی آب در برج خنک کننده جریان متقاطع می توان از یک درایو دور متغیر یعنی اینورتر در مدارتابلوکنترل استفاده نمود که با کاهش فرکانس و دور خروجی موتور سبب کاهش دور فن یا پروانه و کاهش میزان هوادهی گردد. در این روش موتور دیگر به تعداد زیاد خاموش و روشن نمی گردد و با کاهش دور فن و موتور هم مصرف انرژی به شدت کاهش پیدا می کند و همچنین استهلاک قطعاتی همچون پروانه و موتور نیز به شدت کمتر خواهد شد.

نکته مهم و اساسی در بکارگیری سیستم کنترل دمای آب در برج خنک کننده جریان متقاطع

در برجهای خنک کننده جریان متقاطع با ظرفیت بالا که در طراحی آن ها از یک یا چند فن بزرگ استفاده می شود کنترل دمای آب از طریق خاموش روشن کردن موتور و فن می تواند مشکلاتنی را همچون افزایش سریع دمای آب و لزوم آغاز به کار فن در مدت زمان کوتاه است در این صورت مدت خاموشی فن کاهش یافته و دفعات راه اندازی آن بیشتر می شود. در این طور مواقع راه حل دوم یعنی استفاده از اینورتر جهت کنترل دور فن در برج خنک کن جریان متقاطع پیشنهاد می شود.

روش سوم) کنترل دبی آب با استفاده از شیر سه راهی با مسیرکنارگذر در ورودی آب برج خنک کننده جریان متقاطع است. در این روش بخشی از آب رفت به مدار برگشت وارد شده و موجب تعدیل دمای آب خروجی از برج خنک کننده می شود. استفاده از کنترل کننده دور برای پمپ های سیرکولاتور چرخش آب نیز از دیگر روش های کنترل دبی برج خنک کننده جریان متقاطع می باشد.

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محاسبات برج خنک کننده جریان متقاطع

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الف) ظرفیت برج خنک کننده جریان متقاطع

برای تعیین ظرفیت برودتی کولینگ تاور کراس فلو باید ابتدا با در دست داشتن دبی آب در گردش و دمای ورودی و خروجی طراحی شده برای سیستم ظرفیت برودتی واقعی (Real Capacity) را محاسبه نمود و سپس با در نظر داشتن دمای دامنه و دمای نزدیکی به دمای مرطوب محیط ضریب ظرفیت(ضریب تاثیر) را محاسبه نمود و توان برودتی طراحی را از فرمول زیر محاسبه نمود.

Design Capacity = Real Capacity * Factor of Safely

ب) محاسبه آب مصرفی برج خنک کن جریان متقاطع

تبخیر آب در برج خنک کننده جریان متقاطع به طور مرتب موجب افزایش غلظت مواد محلول باقی مانده و زیاد شدن ناخالصی ها در آن می شود و از این رو لازم است که برج خنک کننده جریان متقاطع به طور مستمر زیر آب کشی شده (جریان تخلیه یا بلودان) و آب سختی‌گیری شده جایگزین آن شود. این عمل ممکن است به صورت دستی و یا اتوماتیک صورت پذیرد . به این منظور باید شیر و فلنچ خروجی جریان زیر آب‌کشی را در تشتک برج خنک کننده جریان متقاطع نصب نمود. دامنه آب مصرفی ناشی از زیر آب کشی و جایگزینی آن با آب تازه سختی گیری شده بین 0.0012 و 0.0006 گالن بر دقیقه به ازای هر تن تبرید در نظر گرفته می شود.

مقدار تقریبی مصرف آب در برج خنک کننده جریان متقاطع در اثر تبخیر به ازای هر تن تبرید نیز بین 0.2 تا 0.3 لیتر بر دقیقه یا 3 تا 4.5 گالن بر ساعت می باشد. در نتیجه با به دست آوردن این دو فاکتور، مقدار آب جبرانی برابر با مجموع آب حاصل از تبخیر و آب تخلیه ناشی از آب زیر کشی است .

آب مصرفی برج خنک‌کننده جریان متقاطع = جریان زیرآب‌کشی + جریان تبخیر

ج) میزان حجم هوای مورد نیاز در واحد زمان در برج خنک کننده جریان متقاطع

تقریباً به ازای هر گالن‌ در دقیقه بین 90 تا 100 فوت مکعب در دقیقه در نظر گرفته می شود و چنانچه به ازای هر تن تبرید ظرفیت چیلر 3 گالن در دقیقه در نظر گرفته شود مقدار جریان هوای لازم به ازای هر تن تبرید 300 فوت مکعب در دقیقه خواهد بود.

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کاتالوگ برج خنک کننده جریان متقاطع

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یکی از مهمترین مبنای انتخاب صحیح برج خنک کننده در دست داشتن کاتالوگ محصول با مشخصات فنی کامل از طرف تولید کننده می‌باشد که مبنای اصلی بسیاری از طراحی‌ها در نظر گرفته می‌شود. کاتالوگ برج خنک‌کننده دارای اطلاعات مفیدی می‌باشد که هر از این اطلاعات می‌تواند به عنوان راهنمای خوبی برای طراحی، انتخاب، نصب و راه‌اندازی این دستگاه مطرح باشد. اطلاعات مفیدی که از یک کاتالوگ توسط سازنده عنوان می گردد می تواند  شامل بخش های زیر می‌باشد.

• طول، عرض و ارتفاع (ابعاد کولینگ‌تاور) که این بخش تأثیر بسزایی در ظرفیت و نحوه جانمایی برج خنک کن خواهدداشت.

• وزن خشک(Dry Weight) و وزن در حال کار (Oprerating Weight)که تأثیر بسزایی در طراحی و آماده سازی فنداسیون محل قرارگیری دارد.

• سایز ورودی و خروجی اتصالات اصلی که تأثیر مستقیمی بر نحوه پایپینگ و لوله‌کشی برج خنک‌کن دارد.

• میزان آب در گردش استاندارد (دبی‌اسمی) که تأثیر بسزایی در نحوه کارکرد صحیح کولینگ تاور خواهدداشت.

• میزان مصرف انرژی الکتروموتور که در نحوه کابل‌کشی و راه‌اندازی نوع مدارالکتریکی(ستاره یا مثلث) دارد.

برج خنک کننده مدار باز

Wet cooling tower

As you are aware, the basis of most types of cooling towers is based on the latent heat transfer of evaporation from water to air and thus the creation of humidity in the air. This model of industrial cooling is called wet cooling tower (open cooling tower).

Why do we also call open cooling tower wet ??

The main reason for naming this equipment as a cooler or wetter tower is to create high humidity in the air (100% humidity) and in other words, to convert dry inlet air into saturated air at the outlet of the cooling tower.

How does a wet cooling tower lower the water temperature?

Open or wet cooling tower originally evaporates a small amount of water flow (approximately 1%) by creating a direct contact (at cooling levels) between the weather and the heat required to evaporate this amount of water by the main stream of water. And causes the mainstream water temperature to cool (99% remaining).

As expected, in this model of the cooler tower, heat and mass transfer occur simultaneously. Heat and heat energy transfer from the water stream to the air stream and in this energy transfer due to the entry of water vapor into the air, a kind of mass transfer also takes place. In fact, in a nutshell, a wet cooling tower cools the water during a return process by simultaneously transferring heat and mass. For this reason, this cooling model is also called open circuit cooling tower.

An important point to observe: In a wet cooling tower, due to the evaporation of a part of the water flow and its loss, it is necessary to add a certain amount of compensatory water to the circulating water flow in order to compensate for this evaporation and loss. For this reason, this model of cooling towers is mostly used for areas that have no problem in supplying this amount of compensatory water.

Auxiliary article link: Calculating compensatory water in the cooling tower

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The purpose of a wet cooling tower is to cool the water.

In many industrial environments, water is used to cool appliances and equipment that generate heat (such as condensers, heat exchangers, turbines in power plants, and chillers in air conditioners). This fluid after cooling , Recovered and returned to the industrial environment for reuse. This is done by cooling the hot water in the wet cooling tower by contact with a stream of unsaturated air, which leads to a percentage of water evaporation and sensible heat transfer as well as latent heat of evaporation from water to air and thus cooling. Water (in adiabatic conditions).

The cooling process in the wet cooling tower is done in such a way that the high temperature water flow (hot water) after entering and passing through the packings or cooling surfaces is in contact with the fresh air flow of the outside environment and is cooled. And accumulates cold water in the pan or storage tank (the air flow entering the cooling tower can be natural air entering through the louvers or the induced air flow created by the fan or impeller)

In the fluid circulation cycle in a wet cooling tower, water containing heat is exposed to direct contact with the air stream, and when the weather is in contact, the water temperature begins to decrease for two reasons.

• 1) Direct heat transfer from water to outside air due to the difference between inlet hot water temperature and dry outdoor air (tangible heat)

• 2) Indirect heat transfer due to evaporation of part of the water flow and as a result of water heat consumption to provide the necessary energy for evaporation (latent heat of evaporation)

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Parameters affecting the better performance of the wet cooling tower

• Spray and spray water flow at the outlet of nozzles or nozzles (water dispenser)

• Cross Sectional Area

• The amount of aeration or volumetric flow of induced air flow created by the suction or blowing fan (Air Flow)

• Non-sedimentation of internal equipment over time due to constant evaporation of water flow in areas such as nozzles, packing, water dispenser

• Smooth rotation of the cooling tower impeller and simultaneous static and dynamic fan balance

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Application of wet cooling tower

Wet cooling tower, which is considered as one of the most widely used sources of cooling and water cooling, is used as an important component in many industrial and commercial processes. In fact, in expressing the application of wet cooling tower, two basic cases can be mentioned.

Chiller cooling tower: Cooling the chiller condenser circuit

Industrial cooling tower: Cooling of circulating water in industry such as oil refineries, petrochemicals, smelting and rolling metals in induction furnaces and nuclear power plants

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Benefits of Wet Cooling Tower

• Convenient economic efficiency compared to CCTV and hybrid cooling tower types

• No harm to the environment in terms of creating biodegradable pollutants

• Very high efficiency due to the creation of a direct heat exchange surface between the climate

• Lighter and portable in all types of fiberglass cooling towers

• Reduce the outlet cold water temperature to close to the humid ambient temperature

• Production time of wet cooling tower is much shorter than hybrid and dry types

• Low maintenance costs due to the low price of peripherals compared to dry and hybrid cooling towers

• Easy maintenance

• Ability to assemble on site and in very large dimensions

• Creating the ability to assemble and produce in a multicellular way and thus control energy consumption

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Evolutionary process in the wet cooling tower

First, let's take a look at the wet cooling tower process.

The use of natural flow cooling towers began in Europe and Germany. The construction of this wet cooling tower was initially made of wood and over time it was made of wood and metal. In the new type, the wet cooling tower is made of reinforced concrete. The physical shape of this type of cooling tower also underwent changes. First it was constructed in the form of a cylinder and later it was built in the form of two cut cones on top of each other. Its new shape is hyperbolic, which gives good strength to the wet cooling tower and is better compatible with the natural flow of air passing through the tower shell. The new design of this tower needs less materials because it needs less volume.

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Wet cooling tower types

1. Wet cooling tower opposite flow

2. Cross-flow wet cooling tower

3. Cubic wet cooling tower

4. Wet conical cooling tower

1-1) Wet cooling tower upstream

If in a wet cooling tower, water is sprayed under a counter-flow (non-aligned) with the air flow, the cooler is of the counterflow or counter-flow type (Counter Flow Cooling tower). Opposite flow cooling tower generally has dry air inlet from all four sides. Opposite flow wet cooling tower is very efficient due to air suction and air contact with water in different layers of packing media. In practice, this model of industrial coolers is recommended for environments with low and medium relative humidity.

Opposite flow cooling towers are typically used in arid areas with low relative humidity. This equipment will have a much higher efficiency in arid areas than other types of cooling towers. In arid and tropical regions, due to the large difference between dry temperature and humid ambient temperature, water flow in different stages (packing layers) is reduced and in each layer of packing or cooling surfaces will have a certain amount of temperature decrease. In other words, in a wet cooling tower, the opposite flow of water in the altitude factor (HTU) and the large number of layers of cooling surfaces is in contact with the air flow and the temperature decreases gradually.

1-2) Wet cooling cooling tower

If the air in the cooling tower is sucked from both sides and the dry and cool air flow is inlet cross (perpendicular) to the water flow flow, this equipment is considered as cross flow or cross flow (Cross Flow Cooling Tower). Cross-flow cooling tower mainly has air inlet (Louvre) from both sides. This type of open circuit cooling is generally in uniform contact with dry inlet air in all packing layers or heat exchange surfaces.

Due to the uniform contact of the air with the water of the wet cooling tower, cross-flow is mostly used in areas with high relative humidity (sultry areas) such as the north and south of the country. This type of cooling is actually designed by creating surface temperature reduction units or NTUs in the field of water temperature reduction. By passing the air flow seamlessly through the packing media, the fresh air with the lowest relative humidity is in contact with the water flow and during this contact the water will face a decrease in temperature. Therefore, it can be inferred that the cross-flow cooling tower has larger dimensions than the reverse flow cooling tower.

The main units in the design of wet cooling tower are cross-flow type in the design of NTU units (number of surface heat transfer units in the Cooling Tower). This open-circuit cooling model also has the ability to produce a rectangular shape, which indicates a better location of the cross-flow cooling tower compared to the counter-flow types. Due to the reduction of HTU units in the design of open circuit cooling tower with cross flow air circulation system, the final height of this equipment is smaller than the height of other types of wet cooling towers.

1-3) Cubic cooling tower

Cubic Cooling Tower (Cubic Cooling Tower) is one of the types of open circuit cooling with a fixed water spray system, which is why this cooling tower model is named because of its appearance (cubic shape). The water distribution and spraying system in a cubic cooling tower actually consists of a series of fixed spray nozzles (Nozzle) or in the so-called water spray nozzle (like a shower head). The water at the outlet of these nozzles is sprayed and sprayed on the packing or cooling surfaces. The aeration system of the cubic cooling tower can be designed in the type of fan or impeller and axial blower or centrifugal fan. Cubic wet cooling tower is generally produced and supplied with FRP fiberglass body and HDGS galvanized .

The cooler tower with cubic structure has a lot of applications compared to other types of cooling towers due to the fixed water spray system. Cubic open circuit cooling tower has a higher efficiency than circular cooling types due to further reduction of outlet water temperature. Cooling towers with these specifications are generally easier to maintain due to the lack of a rotating water spray system.

This equipment has Void Space or less empty space in terms of covering the packing surface with water, and the main reason for this in the cubic cooling tower is the presence of a square spray nozzle in the production of this equipment. Square spray nozzle or spray deck with the necessary overlap in the design of this equipment prevents the creation of any empty surface without spraying water on the cooling tower straw. In fact, the cubic wet cooling tower has numerous advantages over the circular cooling tower in terms of water spray system design.

1-4) Circular cooling tower

The Round Cooling Tower also has a Rotary Water Distrobtion system and the main reason for this name is due to the rotating and conical appearance of this model. The spraying system of this equipment usually has a water dispenser or a central sprinkler head (Sprinkler Head). The circulating cooling tower water distributor is responsible for distributing the water flow on the media packing surfaces in a rotating and rotating manner. The air circulation system of this model of circular industrial cooling is generally of the axial fan type and more in the induction suction type.

Cone wet cooling tower mainly has larger surface dimensions than cubic cooling. The reason for the larger dimensions of this equipment is to create a lot of empty spaces that are created by the outlets of the pipe branches from the water dispenser. On the other hand, due to the large surface area in the circular cooling tower, this type of cooling tower is mostly used in spaces with height restrictions. Capacities above 150 tons of refrigeration are mostly assembled and designed on site. The eliminator or dripper section also has poorer performance than the honeycomb drip tower of the cubic cooling tower. The reason for the poor performance of the circular eliminator is the lack of coverage of the high surface of the water dispenser outlet in the cylindrical cooling tower.

Industrial cooling tower کولینگ تاور صنعتی

Industrial cooling tower

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Industrial cooling tower is a producer of cold water in industry and a source of cooling for industrial equipment. This model of cooling tower is also called cooling tower for industrial use. In this type of use of water cooling source, the purpose is to cool large devices. In industry, most equipment requires constant ventilation and cooling for permanent operation. In order to stabilize and stabilize the temperature of these machines, a cooling tower is used.  Cooling tower is more used in industrial devices, especially in heating equipment, than in the field of cooling of air conditioning systems (chiller cooling tower) .

The main use of cooling towers is to adjust the temperature of heat sources and heavy machinery such as boilers, injection machines and induction furnaces. An induction furnace requires the transfer of additional heat generated to the outside environment after a melting process. The air around the furnace naturally cannot dissipate large volumes of this heat energy to the outside environment. The water fluid with a very high specific heat capacity achieves this goal and after receiving heat returns to the cooling tower for recovery. In plastic injection systems, the mold must be cooled within a certain time during a plastic injection process. Cooling of the mold is done by industrial cooling tower or water cooling chiller.

A simple and conceptual example of the use of a cooling tower in industry:

Cooling tower = industry thermal waste bin

What is the unique property of water in cooling industrial equipment?

Water is a unique fluid in the sciences of heat transfer and fluids. The main reason for the special nature of water fluid in cooling and refrigeration systems is the high specific heating capacity of this fluid in heat absorption. The specific heating capacity of a fluid is in fact its potential for absorbing and dissipating heating energy. Water is the best possible option for cooling industrial equipment due to having the highest heating capacity in fluids. Water needs to be regenerated by absorbing large amounts of heat from industrial machinery. Reset the water temperature and reduce it to the standard level in the cooling tower.

Important Note: Despite the special high heating capacity of water, in some cases oil is used to absorb heat !!

Other fluids, such as oil, are widely used in the refrigeration and defrosting of some equipment. The reason for using oil in the fluid circulation system to dissipate heat from industrial engines is not only because of this issue. In addition to heat absorption in industrial engines, the oil fluid is responsible for reducing the amount of friction between parts and bearings.

Generally, in systems that use oil circulation to lubricate the engine, etc., water is also used to dissipate oil heat to the environment. In this case, the water by circulating in a heat exchanger transfers the oil heat to the outside environment through the cooling tower.

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Types of cooling tower applications in industry

Pneumatic plastic injection machine cooling

For cooling oily plastic injection machine

Adjusting the temperature of the induction furnace in the process of melting metals

Permanent temperature adjustment of water or absorption chillers (in all large factories with central ventilation)

Adjusting the temperature of hydraulic oil in industrial gearboxes (in all heavy and machine industries)

Cooling of hydraulic oil in shell and tube heat exchangers by cold water (like hydraulic press machine)

Reducing the temperature of thermal oils such as trans oils (different parts of non-ferrous metals reduction industries)

Reducing the temperature of hot air produced in air compressors (power generating plants)

Adjustment of sulfuric acid temperature in stainless steel converters (anti-acid) after dilution process (battery factory)

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Use of industrial cooling tower in plastic injection

This industry is in fact one of the most important industries for the production of plastic and polymer parts in the country and even in the world. Plastic injection machines in both air and oil types perform the process of injecting granular materials into special molds. The main task of the cooling tower in the plastic injection industry is to cool the mold for injecting materials by water.

Why does the plastics injection industry need a cooling tower?

In answer to this question, it should be stated that when the granular material enters this equipment in the hopper part, after heating to a very high temperature, it enters the mold part for molding. Well, naturally, the cooling of the molten granular material in the form requires heat dissipation to the outside environment, which is the responsibility of the cooling tower of the injection device.

All plastic injection machines have an inlet and outlet with a specified size for water circulation in the cooling tower circuit. Of course, in some cases, the injection machine has two inlets and outlets of water (one to cool the mold and the other to cool the oil), which is called the injection of oily plastic.

How can the capacity of the cooling tower required in plastic injection circulating systems be estimated?

The cooling capacity of the cooling tower in the plastic injection industry is estimated depending on the size of the inlet and outlet connections and the type of plastic injection machine. Based on the size of the mold and oil cycle cooling connections in the injection machine, the amount of water circulation required to cool this machine can be easily calculated. The manufacturer easily calculated the injection device.

Cooling tower in oil and petrochemical industry (refineries)

In a crude oil or fuel oil refinery, the goal is to cool the oil in the distillation tower to lower temperatures in a step-by-step manner (step by step). The temperature of crude oil sometimes rises even above 400 ° C, in which case water is used to cool the oil in the distillation tower. The cooling water required in the distillation tower is supplied by the cooling tower or cooling tower.

What is the reason for the increasing use of cooling towers in the petrochemical industry?

Due to the increasing production of oil and gas in the country, today the oil and petrochemical industry needs more cold water systems. On the other hand, cooling water consumption, sediment and severe clogging in these industries was a major problem. Due to the advancement of science and technology today, Damagostar Company is proud to present a new generation of cooling tower called low consumption hybrid cooling tower and has been able to make a great contribution to the oil and petrochemical industry during the cooling cycle of distillation towers.

Cooling tower in metal smelting industry

Iran is one of the largest producers of metal industries and metal smelting in the world. Increasing the consumption of iron equipment increases sales and thus increases the percentage of melting in furnaces of metal smelting industries. Metal smelting industry in its induction furnaces sector needs water cooling systems. The task of cooling and reducing the temperature of the induction furnace during melting is the responsibility of the cooling tower.

In simpler terms, the cooling water cooling tower required in the main water circulation cycle of the induction furnace (plant) and the capacitor bank provides the DC link and the control panel. Generally, CCTV cooling tower is used in this refrigeration cycle to reduce water consumption costs and also to prevent sediment and clogging.

Is the main reason for the decrease in melting rate of the induction furnace cooling tower?

The answer to this question is yes. Non-observance of design principles in the water circulation system in the induction furnace is the main reason for this. The calculation of the cooling capacity of the cooling tower in the cold water circulation circuits in an induction furnace should be based on 100% of the melting rate. Today, unfortunately, due to lack of technical knowledge, most metal smelting and rolling companies use a maximum of 60% of furnace power for smelting.

What is the main reason for alarms in induction furnaces? What does this alarm have to do with the cooling tower?

The low capacity of the cooling system in the cooling cycle of the induction furnace increases the temperature of the furnace. The induction furnace temperature alarm system in industry is generally set between 35 and 45 ° C. Now, if the cooling tower does not have the ability to dissipate heat from this equipment (furnace) or in other words, the cooling power of the cooling tower is less than the heating capacity of the furnace, the furnace temperature will increase over time and cause alarm in the system.

A common proverb among cooling tower manufacturers about metal smelting companies: No matter how much you buy a smelting tower.

"Our pride in the cooling tower"

Cooperation with Qeshm smelting and zinc companies, Zanjan zinc explorers, Kabkan steel, Tabadakan steel, Etihad steel machine building (Qazvin)

Brys Steel, Natanz Steel, Isfahan Steel

Application of cooling tower in wood industry (chipboard)

The use of cooling towers in the cooling of the chipboard industry may be a little unbelievable. Adhesive is one of the most important materials used in the production of chipboard. This adhesive is subjected to a sharp rise in temperature during a chemical treatment, which is the most important task of the cooling tower in the chipboard industry. Generally, the estimated capacity of a cooling tower in this industry depends on the amount of adhesive produced and the size of the coil connections around the furnace.

 Application of cooling tower in metal forming industry

The industry of forming metals and polymer materials includes extruders and die-casting machines. This equipment basically has a certain number of inlets and outlets of water circulation in its condenser. Depending on the production capacity of various parts such as hose pipes, copper filaments and other output products of these devices, the water circulation capacity and as a result the cooling capacity of the cooling tower are calculated.

Application of industrial cooling towers in power plants

The cooling tower is used in this application in very large capacities in the industry of power plants, solar power plants, nuclear power plants and combined cycle power plants. The purpose of the cooling tower in steam power plants is to cool the steam output of gas turbines. Due to the widespread use of steam power plants and the frequent use of gas and steam turbines in the equipment cycle of this industry, water cooling systems are of great importance. Most of the country's power plants use cylindrical cement cooling towers to cool their circulation system. High water consumption of this type of industrial cooler is in fact one of the biggest problems of this equipment that today dry and combined cooling tower has replaced this model of refrigeration sources.

Application of industrial cooling tower in cement industry

Cement production industry has faced significant progress today due to the current need of construction structures for this material. The use of cooling towers in the cement industry is important for cooling water before the concrete mixing process. In the past, ice mixing was used in cement production and ready-mixed concrete. Lack of economic justification in this sector due to the high cost of buying ice led to the widespread use of cooling towers in this industry.

In addition to the above application, the industrial cooling tower is also used to cool the circulating water cycle in the mixer in the cement industry. Today, in most cement factories such as Lamerd Cement, Ahvaz Cement, Portland Cement and other cement industries, the cooling tower produced by Damagostar Company is used.

کولینگ تاور کانتر فلو

برج خنک‌کننده جریان مخالف

برج خنک کننده جریان مخالف یا کانترفلو (Counter Flow) وظیفه خنک کردن آب توسط جریان‌ هوای مخالف جهت ‌پاشش را برعهده دارد و یکی از رایج‌ترین انواع برج خنک کننده یا کولینگ تاور محسوب می‌شود.در برج خنک کننده جریان مخالف آب از بالای برج به سمت پایین پاشیده شده و هوا نیز از قسمت پایین (لوور) توسط فن مکنده‌ای که در داخل دهانه مکش هوا قرار‌ دارد در خلاف جهت جریان آب مکش می‌شود و در این برخورد رو در رو بین آب و هوا ، قطرات آب به صورت مرحله ای در برخورد با هوا خنک تر می‌شوند. برج خنک کننده جریان مخالف در دسته بندی انواع کولینگ تاور مدارباز یا برج خنک کننده مرطوب محسوب می شود و به دلیل مخالف بودن جریان آب و هوا دارای راندمان بسیار بالایی در انتقال حرارت و کاهش دمای آب می باشد.

در واقع بدلیل عملکرد خوب برج خنک کننده جریان مخالف در 80 درصد کاربری های صنعتی و غیرصنعتی از این مدل سردکن صنعتی یا کولینگ تاور بهره وری می شود. برج خنک کن جریان مخالف عموماً قادر است که دمای آب را تا حدود 3 درجه بالاتر از دمای مرطوب محیط خنک نماید و همین قابلیت در واقع سبب افزایش راندمان برج خنک کننده جریان مخالف گردیده است. به دلیل مزایای فراوان این مدل برج خنک کننده در زمینه تهویه مطبوع و صنعت امروزه بیشتره تولیدات کولینگ تاور و برج خنک کننده صنعتی از نوع جریان مخالف می باشد.

انواع برج خنک کننده جریان مخالف 

نوع تماس بین آب و هوا به صورت جریان مخالف در انواع کولینگ تاور مداربسته خشک ، مدارباز مرطوب و برج خنک کن ترکیبی (هیبریدی) مورد استفاده قرار می‌گیرد. از طرفی دیگر برج خنک کننده مدارباز جریان مخالف وابسته به شکل ظاهری و سیستم توزیع آب همچنین به دو دسته کلی مکعبی و مخروطی(استوانه‌ای) تقسیم‌بندی می‌شود که هر یک از این مدل ها کاربرد منحصر به فرد خود را دارد. بدنه برج خنک‌کننده جریان مخالف به صورت بتنی، ورق‌های گالوانیزه و همچنین می‌تواند از متریال کامپوزیتی یعنی فایبرگلاس تولید و عرضه گردد. به صورت مختصر می توانیم انواع برج خنک کاری جریان مخالف را به شرح ذیل دسته بندی کرد.

•  برج خنک کننده جریان مخالف مدارباز مرطوب

الف) کولینگ تاور کانترفلو مکعبی:

بیشترین کاربرد در تولیدات برج خنک کننده جریان مخالف از دسته بندی با استراکچر مکعبی صورت می پذیرد. برج خنک کننده جریان مخالف مکعبی دارای جریانی ناهمسو بین آب و هوا می باشد که دارای سیستم پاشش آب ثابت با ظاهر مکعبی می باشد.

ب) کولینگ تاور کانترفلو مخروطی:

برج خنک کننده گرد ، استوانه ای یا مدور یکی از قدیمی ترین انواع کولینگ تاور جریان مخالف به شمار می آید که در بیشتر کاربری های مربوط به سیستم خنک کاری کندانسور چیلرهای تراکمی و جذبی ( در کاربری برج خنک کننده چیلر) مورد استقبال قرار می گیرد. مزیت بزرگ برج های خنک کننده جریان مخالف مخروطی در عملکرد بسیار خوب سیستم هوادهی و گردش مناسب هوای مکش شده توسط فن یا پروانه کولینگ تاور می باشد.

• برج خنک کننده جریان مخالف مداربسته خشک

برج خنک کننده مداربسته خشک همواره دارای سیستم جریان هوای مکنده یا دمنده می باشد که در این نوع کولینگ تاور جهت چرخش آب درون کویل همواره در خلاف جهت مکش یا دمش هوا می باشد. این نوع کولینگ تاور تنها در کاربری های خاص در صنعت مورد کاربرد قرار می گیرد.

• برج خنک کننده جریان مخالف مداربسته هیبریدی

برج خنک کننده مداربسته هیبریدی یا ترکیبی یکی از پرکاربرد ترین انواع کولینگ تاور کانترفلو می باشد که مصرف آب بسیار کمی در فصول سرد و معتدل دارد. برج های خنک کننده هیبریدی یا ترکیبی بسیار کم مصرف بوده و به هیچ عنوان دچار رسوب و گرفتگی در مداربسته نخواهند شد. بیشترین راندمان در کولینگ تاور های جریان مخالف یا ناهمسو مربوط به این موضوع می باشد.

اجزای مختلف برج خنک کننده جریان مخالف 

• دینام: تأمین کننده نیروی مکانیکی و گشتاور چرخشی لازم در پروانه

• پروانه: ایجادکننده جریان مکشی در هوا از پایین به سمت بالا

• کاهش‌دور: کاهنده دور موتور به دور استاندارد مورد نیاز فن

• نازل آبپاش یا آب پخش کن: پاشش کننده آب بر روی پکینگ ها

• لوله‌های انشعاب پاشش: انتقال دهنده آب به نازل از ورودی برج خنک کننده

• بست کمربندی: اتصال دهنده نازل آبپاش به لوله های انشعابی

• پکینگ‌ها: پوشال های تراکمی داخل برج خنک کننده

• شبنم‌گیر: جلوگیری کننده از عبور چکه های آب به سمت پروانه

• بدنه و فریم اصلی: ساختار اصلی اسکلت برج خنک کن شامل ستونی های اصلی نگهدارنده سایر قسمتهای بدنه

• پنل: دیواره اصلی نگهدارنده و مهمترین قسمت بدنه کولینگ تاور

• تشت ذخیره آب(تشتک): محل جمع کردن آب خنک در برج خنک کن

• عرشه پروانه: محل خروجی هوای داغ و مرطوب اشباع

• ساپورت نگهدارنده: وظیفه نگهداری قطعات داخلی مثل پکینگ و قطره گیر

• پایه نگهدارنده موتور: نگهدارنده دینام

• پایه نگهدارنده پروانه: شاسی نگهدارنده پروانه و سیستم کاهنده دور

برج خنک کننده چیلر

Chiller cooling tower

Chiller is the air cooling device of towers and buildings and the heat absorbed from the environment is expelled by the cooling tower (chiller cooling tower). Heat is dissipated from the chiller in a section called the condenser, and the "chiller cooling tower" is actually responsible for cooling that section. A refrigerant or gas in a chiller is subjected to an increase in pressure and temperature by a compression or absorption cycle.

Brief definition of chiller cooling tower: Refrigeration or cooling source The cooling water flow in the condenser cooling circuits is water chillers (absorption or compression) which is responsible for re-cooling the hot and high pressure refrigerant leaving the compressor.

What is a chiller and how is it different from a cooling tower or cooling tower?

Specifically, the chiller is like the cooling tower of a water cooling device, and in other words, the chiller is considered as a source of refrigeration and cooling in central and industrial air conditioning systems. A compression chiller is basically a compression or compression cycle in a type of refrigerant (gases with the abbreviation R) and its passage through the condenser causes the gas to cool and in contact with water in the evaporator causes the water to cool in the Child Water cycle or The water cools. The chilled water of the chiller outlet can be transferred to the air conditioner and fan coil and absorb the heat of the environment of a residential or commercial building or tower, etc.

A brief comparison of a cooling tower with a chiller

In fact, in comparison with the chiller, the cooling tower can be synonymous with this device at temperatures above 25 degrees Celsius and can be considered as a refrigeration source, in which case it is called "industrial cooling tower " and can be used in other applications. Supplement of water chillers of compression or absorption type should be used. In common parlance, when we use a cooling tower to complete the cold water of a chiller condenser, the cooling tower is also called a " chiller cooling tower ".

Application on cooling and chillers in industry

In industry, it is sometimes not possible to reach low temperatures (below 25 degrees Celsius) in hot seasons by using a cooling tower. In this case, we use chillers with compression or absorption cooling cycles to reach cold water temperatures up to a temperature of about 5 to 7 degrees Celsius. In some industries, such as the soap industry, it is necessary to reach sub-zero temperatures, in which case compression chillers with sub-zero compressors are used. Chiller is in fact a source of water cooling to very low temperatures, but due to high costs, this equipment should not be used in the cooling system of all industries, and as much as possible, we can cool the water in industry and air conditioning systems with a cooling tower.

Is the cooling tower used in all compression and absorption chillers?

The answer to this question is no and it should be said that condenser chillers are of two types. The first case of chiller condenser is air or air cooled and is cooled by the ambient air fluid (by induction current fans) and the second case of chiller condenser has a shell and tube converter (Shell & Tube) and the task of providing cooling tower Cool water is required in chillers with water condenser. Therefore, the cooling tower is used only in the water circulation cycle and chiller cooling with water condenser systems.

What is the body of refrigeration and what is its connection with the cooling tower and chiller?

Refrigerant ton is one of the most famous units of engineering sciences, it represents the transfer of energy over time, which in fact represents the amount of heat required to melt a ton of ice. The unit of refrigeration or refrigeration is basically equivalent to other units of energy transfer in time such as kilowatts (kw) and BTU per hour (btu / hour). Refrigeration body is one of the most common units used in cooling equipment such as cooling towers and chillers. The cooling capacity of cooling towers and chillers is usually expressed in terms of refrigeration. Each ton of refrigeration or tonnage is actually equivalent to 3.51 kW and 12,000 BTU per hour.

Explain two common design mistakes and choose a cooling tower or chiller cooling tower

Common Mistake 1: In some cases, on the advice of a consultant or chiller manufacturer, the circulating water capacity of the cooling tower is mistaken for the same refrigeration capacity. For example, a cooling tower capable of cooling 100 tons of water per hour is never the same as a 100-ton refrigeration cooling tower. It is important to note that the refrigeration capacity is never the same as the circulating water capacity of the cooling tower.

Common second simulation: The capacity of the cooling tower should not be the same as the capacity of the chiller and the cooling tower should always have more cooling capacity than the chiller, and the reason for this is that Qc (heat dissipated in the chiller condenser) is always equal to W or input work is greater than Qh or heat absorbed by the evaporator. In other words, QC> QH and the reason for the principle of energy conservation (Qc = Qh + W)

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The main components of the chiller condenser cycle and the cooling tower stand

The condenser cycle of water chillers includes chiller cooling tower, circulating electric pump, condenser and valves. The cooling tower is responsible for providing cold water back to the compression and absorption chillers, which will also vary depending on the refrigeration capacity of the chiller.

The main components of the cooling cycle of central air conditioning chillers

• Cooling Tower:

Refrigeration center and refrigerant heat dissipation by water to the outside environment

• Circulator pump (Pump):

Conduct water from the cooling tower to the chiller condenser at a standard rate to absorb excess heat

• Gate Valve:

Service valve and adjustment of circulating water flow rate in chiller and cooling tower condenser cycle

• Pipes and Connections:

This section is responsible for transferring a certain flow or mass from the water flow to the chiller and cooling tower.

• Condenser:

A type of heat exchanger (one of the main components of the chiller) to contact the cold water of the cooling tower output with the hot and high pressure refrigerant of the chiller compressor outlet.

• Resin Water Softener:

This section is responsible for controlling the amount of hard water solutes in the compensatory water injection cycle in the chiller cooling tower.

• Make up Tank:

• This tank or source actually supplies evaporated water inside the chiller cooling tower and causes the mass system in the condenser to be established.

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How to place the cooling tower in the chiller condenser circuit

In the cycle of a refrigerant (refrigerant gas and fluid), it should be noted that the purpose of the chiller is to compress or increase the pressure in the refrigerant and reduce the water temperature to lead to the fan coil and cool the environment. Naturally, a simple look at the PT diagram or pressure-temperature in a particular type of refrigerant can easily show that the exhaust gas from the compressor has a lot of pressure and temperature after exiting. Increasing the refrigerant temperature actually reduces the chiller efficiency at the inlet of the evaporator section, and this increased temperature in the refrigerant must be reduced by the condenser section before entering the evaporator. The gas temperature of water chillers is reduced in a heat exchanger between cold water and refrigerant. The water circulating in the heat exchanger in the condenser section of the chiller must be recirculated by the cooling tower after receiving the heat of the refrigerant and reducing its temperature.

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The main components of a chiller cooling tower

• Aeration and distribution and transfer of air from outside to inside:

This part actually includes the fan or impeller with the task of creating relative pressure and displacement of air, motor or mechanical energy generator (providing the required power to rotate the fan) and power transmission system (reducing the angular velocity of the engine).

• Water circulation or water supply section:

This part in the cooling tower is responsible for dividing, circulating and transmitting a certain flow and flow of water fluid and can include nozzle (sprinkler), sprinkler (water dispenser), float, flange, valve, coil, pipe and side connections.

• Energy and heat exchange surfaces section:

Cooling or heat exchange surfaces in a chiller cooling tower, depending on the type of open circuit or closed cooling tower, can be a coil (network of narrow tubes) or packing media (dense networks to create a contact surface between the weather) and in principle this part mediates And is a mediator between the flow of climate.

• Body and frame placement of peripheral equipment:

This part includes the cooled cold water outlet tank (pan or basin), panels or walls, louvers (cold air inlet shutters) and the hot air outlet part. The outlet section in the cooling tower is also called a fan stack or propeller choke.

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Types of chiller cooling towers

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• Opposite Flow Cooling Tower (Cooling Tower Counter Flow)

The air circulation system in this model of chiller coolers is in the opposite direction of spraying and falling water flow out of the nozzle or sprinkler. Kvlyngtavr eddy or counter (Counter Flow) in two cube and cone production and supply of the system water spray fixed towers cube-type nozzle pressure and while spraying system and dripping water towers, conical shape High-pressure nozzles are rotary or sprinkler . This model of cooling tower is divided into two general categories according to the geometry and type of water distributors.

• Cross-flow cooling tower (Crossflow or Abara cooling tower)

The air intake system in this model is a cooling chiller perpendicular to the water flow tower. This model is very suitable for environments with high relative humidity due to the constant dry air flow at the inlet to the cooling surfaces section. The use of this chiller cooling model is mostly recommended for the north and south of the country, such as Mahshahr, Sari, Mazandaran, Rasht, Gilan, Bandar Abbas, etc.

• Cubic Counter Flow Cooling Tower

This cooling tower model can generally be offered as single cell (Single Cell) and multi-cell (Multi Cell) in two modes of assembly of the factory door and also assembly at the project site and is named because of its square and cubic appearance. . For various reasons such as easier maintenance, easy transportation and handling, higher efficiency and less sedimentation are the most important advantages of this cooling tower model.

• Cone or circular or cylindrical chiller cooling tower (Conic Counter Flow)

This type of industrial cooler is so named because of its conical and cylindrical appearance. The circular cooling tower has a rotating water flow distribution system and due to the rotational spraying, it has a rotating piece called a hydrogel, which is responsible for distributing water on the packings. Due to its large size, it is usually sent in the form of on-site assembly or as a traffic load.

Dry CCTV Cooling Tower (Cool Air Condenser)

Air Condenser or Air Cooler (also known as Dry Cooler) is basically the same as the air condenser system in air-cooled chillers and is sometimes used to convert water condensers into air condensers in most cases. Air condensers and CCTV cooling towers are generally used in cold areas with low dry temperatures and the most important advantage of this cooling tower model compared to other chiller coolers is the lack of water consumption and a sharp reduction in sedimentation in the chiller condenser section.

Hybrid CCTV Cooling Tower (Combined CCTV Tower)

In many water chillers in hot areas where the use of air condenser is practically not available and the issue of water supply to the cooling tower is practically not possible, and as a result, this issue of hybrid cooling towers, which is actually a combination of a fully open water spray cycle. And a closed water cycle is used. In principle, it should be noted that the hybrid or combined cooling tower is a good alternative to cooling the chiller condenser circuit in hot and dry areas. Today, most air conditioning design consultants use hybrid cooling systems in most designs and selections.

This model of chiller coolers, due to its very high efficiency compared to dry CCTV types, are the most widely used among open-circuit and CCTV cooling towers today. Evidence and theoretical science show that hybrid systems are much more useful and acceptable today in all industries, including machines. In essence, the hybridization of one system takes advantage of two systems simultaneously, which has led to the further improvement of the quality of the cooling and refrigeration industries in recent decades.

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Chiller cooling tower calculations

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Part 1) Calculation of refrigeration capacity of chiller cooling tower

The cooling capacity of the cooling tower in the chiller cooling system is a function of the required heat dissipated from the chiller to the environment. Generally, the condenser has a higher capacity than the evaporator in the chiller in terms of heat transfer, and this indicates that the capacity of the cooling tower is always greater than the cooling load of the chiller. In order to accurately calculate the refrigeration capacity and defrost capacity of the cooling tower, the following two basic formulas are used:

A) 2 * Absorption type of chiller refrigeration capacity = cooling capacity of the cooling tower

B) 1.3 * Refrigeration capacity of compression chiller = cooling capacity of cooling tower

In fact, the absorption chiller, due to having an absorber or absorber section, always requires more water circulation capacity for cooling, and this is due to the absorption cycle of ammonia and lithium bromide in the absorber.

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Part 2) Calculation of the amount of circulating water in the condenser cycle

In order to calculate the standard amount of circulating water in compression and absorption chillers per ton of refrigerant refrigeration load, the following two basic formulas are used to calculate the amount of flow and flow of circulating water in the cooling tower.

A) Circulating water flow in the cooling tower (in terms of GPM) = 3 * Refrigeration capacity of absorption chiller

B) Flow rate of circulating water in the cooling tower (in terms of GPM) = Q / 5000, which in fact Q is the same as the cooling capacity of the chiller in terms of Btu / h.

(gpm or gallons per minute is a unit of water flow, the other units are liters per minute and cubic meters per hour)

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Part 3) Calculation of the circulator head pump in the water circulation cycle between the condenser and the chiller cooling tower

In order to calculate the head and pressure of the circulator pump for water circulation between the cooling tower and the chiller condenser, the following formula is used.

Pump head = water pressure drop in cooling tower + nozzle to outlet distance difference + condenser static pressure drop + collector drop + (1.5 * piping length between tower and chiller)

More information:  Cooling tower calculations

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Principles of installation of chiller cooling tower

• Observe the installation and start instructions of the cooling tower or cooling tower according to the manufacturer's installation manual

• Comply with the standards of plumbing executive plans according to the chiller catalog

• Provide a suitable foundation for the installation and cooling tower

• Installation in the appropriate range (roof or completely free space)

• Use of hardener in compensating water circuit (Row Water)

• Use valves or valves to regulate water flow in the cooling lines to and from the chiller

• Correct selection of the pump and efficiency of the reserve pump next to the working pump in order to enter the circuit in case of emergency

• Using shock absorbers and expansion joints to repel the shocks of water flow inside the pipes

• Installation of one-way valve in the thrust pipe of circulator pumps, condenser circuit and cooling tower

• Do not use welded and threaded connections in the piping circuit

• Parallel piping of cold water back and forth to the chiller and cooling tower

• Different color of reciprocating hot water condenser outlet pipe (red) and cold water cooling tower outlet (blue)

• Use water flow control valve to control condenser cold water flow

• Use of thermometer in water circulation circuit and check of water temperature in chiller cooling cycle by cooling tower

Basic principles before starting the chiller cooling tower and starting the condenser circuit

• In the piping of the pump thrust and suction circuit, make sure that the connection flanges are installed correctly.

• Make sure that the flow control valves are set to a sufficient and standard level.

• Test the cooling tower belts in the reduction section so that they are not too tight or too loose.

• Turn the fan counterclockwise by hand from near the hub so that larger problems do not occur if it is locked.

• Check the electrical circuit of the building and the electrical panel of the cooling tower and chiller so that it does not have a large voltage drop.

• First, turn on the pump so that some water circulates inside the system. Then start the cooling tower fan and after ensuring the operation of these two parts, turn on the chiller.

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