Industrial Cooling Towers

A cooling tower is a heat rejection device, which extracts waste heat to the atmosphere though the cooling of a water stream to a lower temperature. Common applications for cooling towers are providing cooled water for air-conditioning, manufacturing and electric power generation. The generic term "cooling tower" is used to describe both direct (open circuit) and indirect (closed circuit) heat rejection equipment. → more

Industrial cooling towers can be used to remove heat from various sources such as machinery or heated process material. The primary use of large, industrial cooling towers is to remove the heat absorbed in the circulating cooling water systems used in power plants, petroleum refineries, petrochemical plants, natural gas processing plants, food processing plants, semi-conductor plants, and for other industrial facilities such as in condensers of distillation columns, for cooling liquid in crystallization, etc.[3] The circulation rate of cooling water in a typical 700 MW coal-fired power plant with a cooling tower amounts to about 71,600 cubic metres an hour (315,000 U.S. gallons per minute)[4] and the circulating water requires a supply water make-up rate of perhaps 5 percent (i.e., 3,600 cubic metres an hour). → more

Cooling Towers have one function:
Remove heat from the water discharged from the condenser so that the water can be discharged to the river or recirculated and reused.
Some power plants, usually located on lakes or rivers, use cooling towers as a method of cooling the circulating water (the third non-radioactive cycle) that has been heated in the condenser. During colder months and fish non-spawning periods, the discharge from the condenser may be directed to the river. Recirculation of the water back to the inlet to the condenser occurs during certain fish sensitive times of the year (e.g. spring, summer, fall) so that only a limited amount of water from the plant condenser may be discharged to the lake or river. It is important to note that the heat transferred in a condenser may heat the circulating water as much as 40 degrees Fahrenheit (F). In some cases, power plants may have restrictions that prevent discharging water to the river at more than 90 degrees F. In other cases, they may have limits of no more than 5 degrees F difference between intake and discharge (averaged over a 24 hour period). When Cooling Towers are used, plant efficiency usually drops. One reason is that the Cooling Tower pumps (and fans, if used) consume a lot of power. → more

Quantitatively, the material balance around a wet, evaporative cooling tower system is governed by the operational variables of makeup flow rate, evaporation and windage losses, draw-off rate, and the concentration cycles → more

With the building of the block brown coal power station with optimized equipment technology (BoA) a new chapter at the power station Niederaussem began. Between 1997 and 2002 the most modern brown coal power station block of the world with a gross achievement of 1,012 megawatts (950 MW net) developed with a far higher efficiency (43%) than the other plants (as low as 31%). RWE invested €1,200 million into the project. Beside the new power station block, whose building is with a height of 172 metres one of the tallest industrial building in the world, the largest cooling tower in the world (200 metres), which serves also as chimney of this unit, had already been built. By the development Niederaussem became one of the largest and most modern coal-fired power stations of the world. The official opening of the new block took place in the summer 2002. In the presence of Wolfgang Clement, the then North Rhine-Westphalia Prime Minister and Gerhard Schroeder the then Federal Chancellor the new power station went on to the grid.
Since 21 July 2006 RWE spent €40 million building a fluidized bed drying unit with waste heat technology (WTA) as pilot project for the drying process of the raw brown coal. In addition the free waste heat of the power station is used. It is hoped that in the next few decades efficiencies can be achieved to so as to increase over-all efficiency of electricity production by brown coal to 50%. The largest and most modern power station is an example to the industry. → more

A heat exchanger is a piece of equipment built for efficient heat transfer from one medium to another. The media may be separated by a solid wall, so that they never mix, or they may be in direct contact.[1] They are widely used in space heating, refrigeration, air conditioning, power plants, chemical plants, petrochemical plants, petroleum refineries, natural gas processing, and sewage treatment. The classic example of a heat exchanger is found in an internal combustion engine in which a circulating fluid known as engine coolant flows through radiator coils and air flows past the coils, which cools the coolant and heats the incoming air.

A pressure vessel is defined as�"a vessel in which the pressure is obtained from an indirect source or by the application of heat from an indirect source or a direct source. The vessel proper terminates at: (a) the first circumferential joint for welded end connections; (b) the face of the first flange in bolted flange connections; or (c) the first threaded joint in threaded connections." Pressure vessels include but are not limited to compressed gas storage tanks (i.e., air, oxygen, nitrogen tanks, etc.), anhydrous ammonia tanks, hydro pneumatic tanks, autoclaves, hot water storage tanks, chemical reactors and refrigerant vessels, designed for a pressure greater than 15 psi and a volume greater than 5 cubic feet in volume or one and one-half cubic feet in volume with a pressure greater than 600 psi.

Large scale industrial distillation applications include both batch and continuous fractional, vacuum, azeotropic, extractive, and steam distillation. The most widely used industrial applications of continuous, steady-state fractional distillation are in petroleum refineries, petrochemical and chemical plants and natural gas processing plants. Industrial distillation[14][20] is typically performed in large, vertical cylindrical columns known as distillation towers or distillation columns with diameters ranging from about 65 centimeters to 16 meters and heights ranging from about 6 meters to 90 meters or more. When the process feed has a diverse composition, as in distilling crude oil, liquid outlets at intervals up the column allow for the withdrawal of different fractions or products having different boiling points or boiling ranges. The "lightest" products (those with the lowest boiling point) exit from the top of the columns and the "heaviest" products (those with the highest boiling point) exit from the bottom of the column and are often called the bottoms. → more

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