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ASHRAE JOURNAL ashrae.org AUGUST 2015 20 TECHNICAL FEATURE Frank Morrison is manager, global strategy at Baltimore Aircoil Company in Jessup, Md. He is past chair of ASHRAE TC 3.6, Water Treatment. BY FRANK MORRISON, MEMBER ASHRAE Saving Water With Cooling Towers Saving water with cooling towers. At first glance, this statement seems counterintuitive. Cooling towers save energy but aren’t they major users of water? This article will help readers understand the critical role evaporative heat transfer systems play in a sustainable environment, explore how water is consumed in such systems, and review the strategies that help minimize the use of both water and energy. The first water-cooled systems used potable water to provide heat rejection with the cooling water wasted to a drain. Cooling towers were developed to recycle more than 98% of this water, resulting in tremendous reduc- tions in both water and energy use as these systems grew in size and popularity. Evaporative heat rejection also enables higher system efficiencies, which conserves water at the power plant and reduces emissions of greenhouse gases and other pollutants. This is because thermoelec- tric power generation accounts for 38% of freshwater withdrawals in the United States—essentially equal to that withdrawn for irrigation. 1 By reducing the electrical energy consumed at the site, less power is required to be generated and less water is used at the power plant and in the extraction and pro- cessing of the plant’s fuel source. For example, in some climates, the total water use (source and site) between air- and water-cooled chillers is almost equal. 2 The lower energy use also enables a higher percentage of renew- able, clean power from solar and wind at a given facility. Energy is also required to treat and distribute water. The balance between the use of these two natural resources is often referred to as the “energy/water nexus.” Today, water supplies are challenged in many areas of the world, including Atlanta (recent drought) and California (current drought). Therefore, it is critical that all water consuming systems, no matter where they are located, optimize their use of this resource. Methods to conserve water include using low-flow bathroom fixtures, repairing leaks in water-distribu- tion systems, and taking advantage of relatively simple techniques to help ensure that evaporative heat rejec- tion systems use only the amount of water required to save energy, maintain optimized system performance, minimize system maintenance, and ensure a long sys- tem life. PHOTO COURTESY OF NCSA, UNIVERSITY OF ILLINOIS AT URBANA-CHAMPAIGN This article was published in ASHRAE Journal, August 2015. Copyright 2015 ASHRAE. Posted at www.ashrae.org. This article may not be copied and/or distributed electronically or in paper form without permission of ASHRAE. For more information about ASHRAE Journal, visit www.ashrae.org.
Transcript
Page 1: Saving Water With Cooling Towersarco-hvac.ir/wp-content/uploads/2016/01/2015Aug_020-033...in cooling ponds used in some industrial applications also evaporates; cooling towers simply

A S H R A E J O U R N A L a s h r a e . o r g A U G U S T 2 0 1 52 0

TECHNICAL FEATURE

Frank Morrison is manager, global strategy at Baltimore Aircoil Company in Jessup, Md. He is past chair of ASHRAE TC 3.6, Water Treatment.

BY FRANK MORRISON, MEMBER ASHRAE

Saving Water With Cooling TowersSaving water with cooling towers. At first glance, this statement seems counterintuitive. Cooling towers save energy but aren’t they major users of water? This article will help readers understand the critical role evaporative heat transfer systems play in a sustainable environment, explore how water is consumed in such systems, and review the strategies that help minimize the use of both water and energy.

The first water-cooled systems used potable water to

provide heat rejection with the cooling water wasted to

a drain. Cooling towers were developed to recycle more

than 98% of this water, resulting in tremendous reduc-

tions in both water and energy use as these systems grew

in size and popularity. Evaporative heat rejection also

enables higher system efficiencies, which conserves water

at the power plant and reduces emissions of greenhouse

gases and other pollutants. This is because thermoelec-

tric power generation accounts for 38% of freshwater

withdrawals in the United States—essentially equal to that

withdrawn for irrigation.1

By reducing the electrical energy consumed at the site,

less power is required to be generated and less water is

used at the power plant and in the extraction and pro-

cessing of the plant’s fuel source. For example, in some

climates, the total water use (source and site) between

air- and water-cooled chillers is almost equal.2 The lower

energy use also enables a higher percentage of renew-

able, clean power from solar and wind at a given facility.

Energy is also required to treat and distribute water. The

balance between the use of these two natural resources is

often referred to as the “energy/water nexus.”

Today, water supplies are challenged in many areas

of the world, including Atlanta (recent drought) and

California (current drought). Therefore, it is critical

that all water consuming systems, no matter where

they are located, optimize their use of this resource.

Methods to conserve water include using low-flow

bathroom fixtures, repairing leaks in water-distribu-

tion systems, and taking advantage of relatively simple

techniques to help ensure that evaporative heat rejec-

tion systems use only the amount of water required to

save energy, maintain optimized system performance,

minimize system maintenance, and ensure a long sys-

tem life.

PHOT

O CO

URTE

SY O

F NC

SA, U

NIVE

RSIT

Y OF

ILLI

NOIS

AT

URBA

NA-C

HAM

PAIG

N

This article was published in ASHRAE Journal, August 2015. Copyright 2015 ASHRAE. Posted at www.ashrae.org. This article may not be copied and/or distributed electronically or in paper form without permission of ASHRAE. For more information about ASHRAE Journal, visit www.ashrae.org.

Page 2: Saving Water With Cooling Towersarco-hvac.ir/wp-content/uploads/2016/01/2015Aug_020-033...in cooling ponds used in some industrial applications also evaporates; cooling towers simply

A U G U S T 2 0 1 5 a s h r a e . o r g A S H R A E J O U R N A L 2 1

TECHNICAL FEATURE

Evaporative heat rejection systems encompass open

circuit cooling towers, closed circuit cooling towers, and

evaporative condensers. For the purposes of this article,

the term “cooling tower” will be used synonymously for all

of these devices, except as noted.

EvaporationThe primary consumption of water in a cooling tower

is through evaporation—a process that is also used by the

human body to help regulate its internal temperature.

In a cooling tower, the warm water from the system

comes into contact with the entering air, usually over

a heat transfer surface such as fill, where a small por-

tion of the recirculating water evaporates, cooling the

remaining flow. This process is very energy efficient as

approximately 1,000 Btu (1055 kJ) are required to evapo-

rate 1 lb (0.454 kg) of water at standard design condi-

tions (1,000 Btu/lb [2,326 kJ/kg]).

In contrast, air-cooled heat exchangers must move far

more air to reject the same heat, consuming additional

fan energy in the process, usually at a much higher system

temperature since the dry-bulb temperature is higher

than the wet-bulb temperature of the air. These higher

temperatures result in greater energy use by the cooling

system, often 30% or more as in the case of an air-cooled

versus a water-cooled chiller.

Note that the difference between the dry bulb and wet

bulb of the air is known as the wet-bulb depression. In

areas of high wet-bulb depression, such as the American

Southwest, evaporative heat rejection offers even greater

energy efficiency by enabling significantly lower system

temperatures.

While water is “consumed” by evaporation in the cool-

ing tower, the water is not “lost” or destroyed, unlike

what occurs when natural resources such as oil or natural

gas are consumed. This pure water, sometimes visible

as plume from the cooling tower discharge in cooler

weather, is returned to the environment as part of the

natural water cycle. Water in reservoirs, lakes, rivers, and

in cooling ponds used in some industrial applications also

evaporates; cooling towers simply put evaporation to work

to efficiently cool the buildings and processes that serve

our society.

Evaporation is a function of the heat rejection load and

the psychrometric properties of the air entering the cool-

ing tower. Many “rules of thumb” exist for calculating

peak evaporation, such as:

• 2.0 gpm of water evaporated per 1,000,000 Btu/h

(0.0004 L/s·kW) and

• 3.0 gpm of water evaporated per 100 tons

(0.0004 L/s·kW).

While these rules of thumb can be useful for calculat-

ing design makeup flow rates, sizing piping, and esti-

mating water treatment regimens, they significantly

overestimate the annual water use by a cooling tower

by not taking into account load profiles and the effect of

weather conditions throughout the year. Besides being

proportional to the heat load, the evaporation rate is

strongly influenced by both the entering air dry-bulb

and wet-bulb temperature. At off peak wet-bulb tem-

peratures, which occur the majority of the year, the

evaporation rate is reduced by up to 30% or more versus

design as can be seen in Figure 1.

Figure 1 also illustrates that water use increases in drier

climates and is reduced in more humid climates for the

same heat load. Furthermore, in cooler weather, the

heat load to be rejected is typically lower, especially on

HVAC applications, further reducing the evaporation.

Several water use calculators are available that can dem-

onstrate the variation in evaporation rate with varying

climate, load and design conditions.

BlowdownWhen water is evaporated in a cooling tower, pure water

vapor enters the air moving through the unit, leaving any

dissolved solids or minerals in the remaining water. Left

unchecked, the recirculating water will become increas-

ingly saturated with mineral content, scaling heat trans-

fer surfaces and increasing the corrosivity of the water.

FIGURE 1 Evaporation vs. wet bulb and relative humidity for a fixed, constant load; tower airflow at full speed for all cases.

Wet Bulb (°F)

1.3

1.2

1.1

1.0

0.9

0.8

0.7

0.6

Evap

orat

ion (g

pm o

r L/s

)(B

ase

= 1.0

at 7

8°F

[25.6

°C] W

B an

d 50

% R

H)

Base = 1.0

40 45 50 55 60 65 70 75 80 85 90

30% RH50% RH70% RH

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A S H R A E J O U R N A L a s h r a e . o r g A U G U S T 2 0 1 52 2

To keep dissolved solids to an acceptable level, a small

amount of water must be bled from the system in propor-

tion to the evaporation rate to achieve the desired “cycles

of concentration.” Cycles of concentration (COC) mea-

sures the ratio of the dissolved solids, such as calcium,

chlorides, or magnesium, in the recirculating water to

the concentration found in the incoming makeup water

supplied to the cooling tower. The COC can be calculated

according to the following formula:

COC = (Evaporation/Blowdown) – 1 (1)

Evaporation and blowdown are measured in gpm (L/s).

Conversely, the formula for calculating blowdown, also

known as the bleed rate, based on the desired COC is as

follows:

Blowdown = Evaporation/(COC – 1) (2)

The COC that can be achieved is dependent on the qual-

ity of the incoming makeup water, the water treatment

program, and the system’s construction materials (and

not just those of the cooling tower). While four or five

cycles is often used as a target value for a typical system,

this value can range from two cycles on a system with very

poor supply water quality up to 30 or more when very

soft water, such as air conditioning condensate, is used

as makeup water. Thus, a regulation requiring a single,

fixed minimum COC can be misguided, as the COC that

is achievable is dependent on site-specific factors, which

can vary with each installation and over time. Even in

cases where the water quality is generally good, high lev-

els of a single constituent, such as chloride or silica, can

exist, which can limit the maximum achievable COC.

Several calculators, including one from the California

Energy Commission, are available to assist in determining

the proper COC value for a given facility. Additionally, a

water treatment professional, either internal or external

to the facility, should be consulted to analyze the site and

help to establish an optimized, balanced water treatment

program designed to control scale, fouling, corrosion, and

biological growth while conserving water.

In the past, a fixed bleed rate often was employed, but

this method should not be used. Instead, the desired COC

setting can be maintained in several ways, two of which

are described below.

The most common method is the use of a conductivity

controlled blowdown system, consisting of a conductiv-

ity probe, a controller, and a motorized blowdown valve.

The conductivity controller signals the blowdown valve

to open as necessary to maintain the desired COC. Water

treatment chemicals can affect the conductivity of water,

and this effect needs to be considered when adjusting set-

tings on the controller.

Another technique involves the use of flow meters on

the makeup and blowdown lines. In this method, the

blowdown valve is opened in proper proportion to the

makeup flow to maintain the desired COC. However,

drift, leaks, filtration backwash, and other uncontrolled

water losses can result in a lower COC than desired, in

turn leading to excessive water loss, so these factors must

be properly accounted for when using this method.

For either system, the blowdown valve should be located

before the introduction of any chemical treatment to

allow the chemicals to mix thoroughly in the tower,

while reducing the loss of treatment chemicals.3 Regular

inspection, calibration, and maintenance of the motor-

ized blowdown valve and the conductivity probe or flow

meters will help to sustain the desired setting over time.

A filter or strainer ahead of the flow meters and valves is

also good practice to protect these devices.3

Maintaining the proper COC is important to system

water and energy efficiency. Too high a COC setting for

the site-specific conditions can lead to scaling and corro-

sion of the system, leading to poor heat transfer, higher

energy use, and shortened equipment life. Too low a COC

setting will generally result in better recirculating water

quality, but at the price of higher than necessary water use

and loss of associated treatment chemicals.

Reducing EvaporationAs previously stated evaporation is the largest use of

water in a cooling tower and is primarily dependent

on the load and the psychrometric properties of the air

entering the cooling tower. So reducing the load that must

be handled will not only save energy but also directly

reduce the evaporation required along with the associated

blowdown. Load reduction techniques include, but are

not limited to, optimal building orientation, using better

insulation, more energy-efficient production processes,

and heat recovery.

As an example, more efficient chillers can reduce the

heat load on the cooling tower. A chiller with a full load

efficiency rating of 0.55 kW/ton (0.16 kW/kW) (6.39 COP)

will evaporate 2.4% less water per peak ton than a chiller

operating at 0.65 kW/ton (0.18 kW/kW) (5.41 COP). This

TECHNICAL FEATURE

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A U G U S T 2 0 1 5 a s h r a e . o r g A S H R A E J O U R N A L 2 3

is due to the reduced amount of non-productive, waste

compressor work (heat) that must be rejected to the atmo-

sphere, in this case, 0.10 kW/ton (0.03 kW/kW) (35 COP).

Furthermore, as the amount of water evaporated is

directly proportional to the load and the blowdown is

proportional to the evaporation, there will be a corre-

sponding reduction in the amount of blowdown required.

Assuming four cycles of concentration, for every gallon

(3.79 L) of evaporation avoided there will be an additional

TABLE 1 Effect of reduced condenser water temperature and cooling tower fan speed on energy and water use in a water-cooled chiller system.

OPERATING MODE BASE TOWER PRIORITY REDUCTION VERSUS BASE

CH ILLER PRIORITY REDUCTION VERSUS BASE

Tower Conditions(EWT/LWT/WB) 95.0°F/85.0°F/78.0°F 95.0°F/85.0°F/58.4°F 79.7°F/70.0°F/58.4°F

Tower Fan Speed (Percent of Design) 96% 47% 53.0% 96% 0.0%

Evaporation (gpm) 11.34 9.60 15.3% 9.23 18.6%

Blowdown (gpm) 3.78 3.20 3.08

Makeup (gpm) 15.12 12.80 12.31

Chiller Energy Consumption (kW/ton) 0.586 0.586 0.0% 0.442 24.6%

Tower Energy Consumption (kW/ton) 0.041 0.005 87.8% 0.041 0.0%

Chiller + Tower Energy Consumption (kW/ton) 0.627 0.591 5.7% 0.483 23.0%

Note: Assumptions for all cases: Cooling tower flow 1,120 gpm; chiller at full load; COC of 4.0; relative humidity 50%.

0.33 gallon (1.25 L) reduction in the required blowdown

volume to maintain the same recirculating water quality.

While many believe that load reduction is all that can

be done to reduce evaporation, several other techniques

can have a meaningful impact. As illustrated in Table 1, the

psychrometric properties of air can be used to minimize

water consumption and reduce system energy use with a

water-cooled chiller system. In the first case, the cooling

tower is operated at full fan speed at a wet bulb that will

TECHNICAL FEATURE

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A S H R A E J O U R N A L a s h r a e . o r g A U G U S T 2 0 1 52 4

produce 70°F (21.1°C) leaving water

temperature. In the second case

using the same wet bulb, the cool-

ing tower fan speed is modulated to

maintain a fixed leaving water tem-

perature to the condenser. In both

cases, system energy is significantly

reduced, as is water use.

Each method saves resources at off-

peak conditions and results in a win-

win situation in terms of both energy

and water savings for the operator.

However, in the case shown previ-

ously, the lower condenser water

temperature has the overall advan-

tage in terms of more significant

energy savings and additional water

savings on the majority of instal-

lations. While these two full-load

cases are illustrative, actual control

strategies should seek to operate at

the optimum chiller speed, cooling

tower fan speed, and condenser flow

resulting in the lowest system energy

consumption for the given load and

ambient conditions.

Blowdown ReductionAfter evaporation, blowdown is the

next largest use of water in cooling

towers. As the blowdown is propor-

tional to the evaporation rate, the

blowdown can be reduced simply by

using the techniques for reducing the

evaporation rate described above.

Beyond this, the maximum COC for

a given cooling tower system should

be established, which is a function of

the makeup water quality, the water

treatment program used, and the

construction materials of the tower

and of the remainder of the system.

Increasing COC can reduce the

required blowdown (and the amount

of water used) considerably, though

the volume saved decreases dramati-

cally at higher cycles as can be seen in

Figure 2. However, the risk of scaling

and/or corrosion can increase signifi-

cantly at higher cycles. Consequently,

operators and water treatment

professionals must weigh the ben-

efit from smaller and smaller water

savings versus risk when setting an

aggressive COC target for a given

system. Higher cycles call for closer

monitoring of system parameters.

To enable the cooling tower to

tolerate higher cycles and/or the

challenges of unconventional water

sources, more corrosion resistant

construction materials can be used,

ranging from a stainless steel or poly-

urethane-lined cold water basin up to

a complete unit fabricated from Type

304 or even Type 316 stainless steel.

The materials used in the remainder

of the system, including piping, heat

exchangers, and valves, must also be

taken into consideration since these

components also come into contact

with the same recirculating water. A

best practice for the system designer

is to evaluate the composition and

quality of the makeup water source(s)

early in the design stage and consult

with water treatment professionals

and equipment manufacturers on

the most appropriate construction

materials and water treatment strate-

gies for the site.

Systems operated at a high COC

can often benefit from filtration to

help minimize the concentration

of suspended solids from airborne

contamination. Keeping suspended

solids low reduces fouling of heat

transfer surfaces, helps keep micro-

biological growth under control, and

improves the effectiveness of water

treatment programs. A cyclonic type

separator or sand filter is typically

used to remove solids from the water,

in conjunction with a sump sweeper

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A U G U S T 2 0 1 5 a s h r a e . o r g A S H R A E J O U R N A L 2 5

package in the tower basin to help

keep particles in suspension. These

systems are backwashed periodically,

which can be a hidden use of water.

Ideally, backwash cycles should be

run only when necessary and for only

as long as required to keep the filtra-

tion system operating properly.

Blowdown typically is discharged

into the sewer for disposal. The

sewer charge is often based on the

makeup flow rate and in some cases

can be as much as or more than the

expenditure for water. However, the

blowdown is only a small fraction

of the makeup flow. To account for

the portion of the makeup flow that

will not have to be handled by the

water treatment plant, many locali-

ties will allow an evaporation credit

that substantially reduces the sewer

charge. Depending on the utility, the

blowdown may need to be metered

or a calculation can be applied based

on the target COC to earn this credit.

In some cases, blowdown can also be

recovered and used for other applica-

tions though the higher mineral and

chemical content of this water must

be taken into account.

Finally, on some sites, pretreatment

of the makeup water by softeners

or reverse osmosis (RO) has been

used to increase the COC to conserve

water. However, most softeners use a

brine solution for regeneration and

RO systems generate RO reject water,

both of which must be disposed of

properly, offsetting some of the ben-

efits. Restrictions on the use of such

systems are appearing in many areas

of the country for this reason.

Drift and CarryoverDrift is defined as the relatively

small droplets of water that leave

the cooling tower, while carryover

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A S H R A E J O U R N A L a s h r a e . o r g A U G U S T 2 0 1 52 6

is generally considered larger droplets that are “carried

over” into the leaving airstream and may originate from

condensation on cold surfaces inside the tower. Drift

eliminators located in the leaving airstream help to keep

this entrained water in the cooling tower. With current

eliminator technology, this loss is quite small, on the

order of 0.005% or less of the recirculating flow. For a 100

ton (352 kW) cooling tower, this water loss is less than 1

gph (1.10 mL/s) at full flow and heat load, which is quite

small compared to the evaporation and bleed rate.

Eliminators with a maximum drift rate of 0.005% or less

should be specified on new cooling towers and retrofitted

whenever possible on older units. Eliminators, or com-

binations of eliminators, with drift rates as low as 0.001%

are available. However, the higher airside pressure drop

of many of these designs must be taken into account as

the higher airflow restriction can negatively impact ther-

mal performance, which forces the cooling tower to use

more energy to perform the same cooling duty.

Eliminators, typically PVC or other plastic material,

must be kept in good condition, spaced properly, and

inspected routinely per manufacturer guidelines (Photo 1).

Proper eliminator maintenance will help minimize drift

and eliminate “blow through,” especially in high veloc-

ity areas, which can dwarf the stated drift rate. Warped

or damaged eliminators should be replaced. Only when

properly installed and maintained can eliminators

achieve their stated drift rate.

Important reasons to minimize drift include limiting

particulate emissions, eliminating spotting on cars near

the cooling tower, and most importantly, minimizing the

risk of Legionnaires’ disease. However, water savings,

FIGURE 2 Bleed rate ratio versus cycles of concentration.

6

5

4

3

2

1

0

Blee

d Ra

te R

atio

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Bleed Ratio Base = 4.0 COC

Cycles of Concentration

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A U G U S T 2 0 1 5 a s h r a e . o r g A S H R A E J O U R N A L 2 7

even with the most efficient elimina-

tors, is typically not a benefit. Besides

being a very small volume com-

pared to evaporation and bleed, any

drift leaving the cooling tower only

serves to reduce the amount of water

required to be bled from the unit

when using a conductivity controlled

blowdown to maintain the desired

cycles.

Two exceptions to this would be

where makeup and blowdown flow

meters are used to maintain the

water quality, or where the blowdown

is captured and used for another

purpose such as toilet flushing. Thus,

claims of “water saving” drift elimi-

nators can often be misleading. Low

drift rates can also be very difficult,

expensive, and time consuming to

accurately verify.

Splashout, Leaks, and OverflowsSplashout can occur at the air inlet

faces of the cooling tower where the

falling water can “splash out” of the

unit itself. Splashout must be mini-

mized with good air inlet louvers that

capture any water from the fill or

plenum and return it to the basin.

As with eliminators, the louver sec-

tions, whether slat type or cellular,

must be maintained properly and

operators must ensure they are tight

fitting with the proper spacing. Spray

nozzles should also be kept clean and

free flowing over the heat transfer

surfaces, not only to minimize scaling

and maximize thermal performance

but also to reduce splashout. Clogged

nozzles can also cause water to over-

flow hot water-distribution basins

or spray out through the top of the

PHOTO 1 Proper inspection and maintenance of drift eliminators is critical.

cooling tower, resulting in unneces-

sary water losses.

Leaks can occur in a variety of areas,

but most often from the cold water

basin seams. Obviously, any leaks in

TECHNICAL FEATURE

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A S H R A E J O U R N A L a s h r a e . o r g A U G U S T 2 0 1 52 8

the cooling tower or system pipework should be corrected

immediately. The use of welded stainless steel or poly-

urethane lined cold water basins can also help minimize

leaks by eliminating seams in the basin. Loss of treated

water can be especially costly as it includes both the cost of

the water and the water treatment chemicals.

Another method to reduce water use and lower treat-

ment costs is by minimizing the volume in a water-cooled

system, including the design of the system pipework.

These savings take place from the initial fill to every time

the system is drained for cleaning. Closed circuit cooling

towers keep the process flow in a clean, closed loop and

the volume of the open spray water loop is limited to the

internal volume of the unit, which can be considerably

less than a system using an open circuit cooling tower.

Note that upon shutdown of a cooling tower, all the

water above the operating level will flow back into the

cold water basin, which must have volume available to

accommodate this water without overflowing the cold

water basin. Such overflows can be a significant, yet

often hidden, water use, occurring every time the system

pump shuts down. Designers must ensure that the model

selected has an adequately sized cold water basin or

remote sump for the project.

Once installed, the water levels in the cold water basin

of the cooling tower must be properly set for unit startup

and to avoid wasting water upon shutdown through the

overflow connection. Using the makeup valve arrange-

ment, whether mechanical or electronic, the operating

level of the cold water basin should be set close to the

lowest possible level, such that air is not drawn into the

cooling tower pump to avoid system flow issues and noise,

while allowing the maximum basin volume to accommo-

date the shutdown water.

An electric water level control can also be used to pro-

vide finer control of the level in the cold water basin. To

assist operators, a low level alarm can be used to help

protect the tower pump, and a high level alarm can be

added to alert the operator of possible overflow condi-

tions (which is now required by certain codes, such as

California Title 24). These sensors can be separate devices

or incorporated into the electric water level control

TECHNICAL FEATURE

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A S H R A E J O U R N A L a s h r a e . o r g A U G U S T 2 0 1 53 0

device. Finally, to avoid overflowing the hot water basins

on cross-flow designs, the gravity flow spray nozzles must

be properly sized for all expected flows and kept clean.

Alternative Sources of WaterAlternative sources of water can also be used to reduce

the use of potable water in cooling towers. Any water that

can meet the cooling tower manufacturer’s guidelines for

the construction material can be used. The most common

is reclaim, or recycled water, which is water that has pro-

cessed through a treatment plant. Rather than return this

water to a lake or river, the reclaim water is used for other

uses, including irrigation or makeup water for cooling

towers. “Purple” pipe, along with appropriate signage, is

used to distinguish such distribution systems from pota-

ble lines. This water is often good quality, although the

concentration of minerals is usually higher than potable

water, having been “cycled” through the system at least

once. As a result, usually the COC cannot be set as high

when using recycled water.

Rainwater can also be harvested from roof surfaces or

parking lots, filtered, disinfected, and stored for use in

cooling towers. Another popular alternative source of

water is air-conditioning condensate. As both rainwater

and condensate are “pure” water with few minerals, they

often must be blended with other water sources so they

are not overly aggressive. Such systems are frequently

operated at higher cycles of concentration since the water

is “soft,” even after blending.

The most critical aspect of using any of these alternative

sources of water is to monitor biological activity and mini-

mize the introduction into the cooling tower of possible

nutrient sources for biological growth. Such contami-

nants increase the risk in operating the cooling tower and

increase the water treatment requirements. For instance,

the use of untreated sink water would not be suitable,

as soap would serve as a nutrient source for biological

growth as well as foul heat transfer surfaces.

Hybrid Wet/Dry DesignsClosed circuit cooling towers and evaporative condens-

ers use a coil to contain the heat transfer medium in a

closed system. As such, the spray pump can be shut off

and these units operated in an air-cooled or “dry” mode

in colder weather. The amount of water saved with this

technique will depend on the sensible heat transfer sur-

face area available, the local climate, and the load profile.

However, any water savings is usually more than offset by

the increase in unit fan energy in the dry mode, especially

when considering the reduced loads and water consump-

tion typically experienced in colder weather (Figure 1).

By definition, the switch point for dry operation is at

100% fan speed and power draw, while the fan speed for

the unit operating in wet mode at this same point is only

a small fraction of the design speed and power draw.

Because of their higher first cost and the energy penalty,

standard closed circuit cooling towers and evaporative

condensers are not used to replace open circuit cooling

towers on the basis of cold weather water savings.

For areas where water is in short supply and/or expen-

sive, cooling tower manufacturers have developed hybrid,

wet/dry designs that can save significant amounts of

water, yet still offer the low system temperatures critical

to efficient operation. These units incorporate a wet heat

exchange section along with a dry cooling section (Photo

2). Such systems are equipped with controls that balance

the use of water and energy to provide the desired level of

system efficiency. By handling a portion of the load dry,

typically ranging from a minimum of 20% all the way up

to 100% in colder weather, evaporation and the associ-

ated blowdown can be reduced proportionally while also

reducing or eliminating plume, which can be an advan-

tage on certain projects. Many of these hybrid units are

also closed circuit cooling towers, which have the added

benefit of keeping the process fluid in a clean, closed

loop that is separate from the external spray water loop.

Keeping the process fluid isolated helps maintain system

efficiency and reduce equipment cleaning and mainte-

nance over time.

Adiabatic designs precool the air with wetted pads

before the air enters a dry finned heat exchanger

enabling reduced condensing or fluid temperatures and

lower system energy use compared to air-cooled heat

PHOTO 2 Hybrid closed circuit cooling towers with dry and wet heat exchange sections.

TECHNICAL FEATURE

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A S H R A E J O U R N A L a s h r a e . o r g A U G U S T 2 0 1 53 2

rejection, with a lower volume of water evaporated com-

pared to a typical evaporative condenser or closed circuit

cooling tower. To minimize water treatment needs, the

sumps are typically drained once per day, but the sump

is designed to keep the volume low to minimize this

water loss.

When considering these hybrid designs, it is important

to weigh the potential savings in water, water treatment,

sewage, energy, and maintenance costs, along with such

factors as the availability of water on the site, against the

higher initial cost of such equipment. Systems with high,

constant year-round loads typically benefit most from

these technologies. An accurate assessment of potential

water savings must be made, taking into account both

load profiles and ambient conditions, to properly calcu-

late the potential payback for such investments. Other

drivers may also influence the decision to use hybrid tech-

nologies, such as reduced water availability to a facility, a

desire to limit plume in colder weather, or a critical need

to be able to operate dry in the event of a loss of the water

supply to the site.

Tracking Water UseTracking cooling tower water use through makeup

and/or blowdown flow meters can be a wise invest-

ment. This data provides useful information on

how well the system and water treatment program

are operating over time so system parameters and

maintenance schedules can be adjusted for peak

overall performance. For instance, by metering the

makeup and blowdown flows, the COC for the system

can be tracked and the savings and benefits of water

conservation efforts can be more easily established,

as well as helping earn a sewage credit for evapora-

tion. Several codes and standards, such as ASHRAE

Standard 189.1-2013 and California Title 24-2013,

have incorporated requirements for such flow meters.

Some water utilities also offer rebates on energy and

water saving equipment, which can offset the cost of

such monitoring. Finally, efforts to reduce water and

energy use can help earn LEED points through direct

energy and water savings and possibly innovation

credits.

TECHNICAL FEATURE

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A U G U S T 2 0 1 5 a s h r a e . o r g A S H R A E J O U R N A L 3 3

Summary Cooling towers play an integral role in the conserva-

tion of both energy and water and as such are a key

part of a sustainable future. This article describes

many relatively simple techniques and best practices

necessary to reduce the use of water in cooling tow-

ers, along with consideration of alternative makeup

water sources and hybrid wet/dry designs. No matter

what the choice of equipment or techniques used, the

manufacturers’ operating and maintenance guidelines

must be followed to ensure optimal performance and

service life.

The items listed in the Bibliography, including “Saving

Energy with Cooling Towers,” the companion piece to

this article, can also be consulted for further guidance.

Finally, the services of a water treatment professional

should always be used when treating evaporative heat

rejection equipment to maximize thermal performance,

conserve water, and extend equipment lifetimes, while

effectively controlling scale, corrosion, and biological

growth.

References1. Maupin, Molly A., et al. 2014. “Estimated Use of Water in the

United States in 2010.” Circular 1405, U.S. Department of the Interior. U.S. Geographical Survey.

2. Hydeman, Mark. 2008. “A Comprehensive Comparison of Air- and Water-Cooled Chillers Over a Range of Climates.” Seminar 48 at the ASHRAE Annual Conference.

3. Aherne, A.J. 2015. Best Practice Guidelines: Water Conservation In Cooling Towers. Australian Institute of Refrigeration, Air Condition-ing, and Heating.

BibliographyANSI/ASHRAE/IES Standard 90.1-2013, Energy Standard for Buildings

Except Low-Rise Residential Buildings.

ANSI/ASHRAE/IES/USGBC Standard 189.1-2014, Standard for the Design of High-Performance Green Buildings.

California Title 24–2013, Building Energy Efficiency Standards for Residen-tial and Nonresidential Buildings.

Hamilton, J., T. Bugler, J. Lane. 2010. “Water/Energy nexus, com-paring the relative value of water versus energy resources.” Cooling Technology Institute Technical Paper. TP10-16.

Morrison, F. 2014. “Saving Energy with Cooling Towers.” ASHRAE Journal (1).

Torcellini, P., N. Long, R. Judkoff, D. 2003. “Consumptive Water Use for U.S. power production.” National Renewable Energy Lab. NREL/TP-550-33905.

TECHNICAL FEATURE

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