Cooling Tower Design

While designing the tower, the data requested from the business & process department are only the water flow rate (m3/hour), and the water inlet-outlet temperatures (°C) to the tower. The wet thermometer value is determined by us, if a special measurement has been made by the employer at the operation-site site, this value is taken into account. (You can check the table below.)

As a result of engineering calculations made with water flow, water inlet-outlet, and wet thermometer values, the heat transfer surface area (fill type-height) required to achieve the desired cooling and the air flow rate to be drawn by the fan are calculated with iterations. When choosing a tower, the data of air density entering the tower, air velocity, water load and resistance against the fan are of importance. Our experienced engineer staff carefully calculates all the values by revealing all their knowledge and dedication.

All the mentioned values make up the main external-internal dimensions and technical details of the tower. The design of cooling towers with GRP main construction is carried out with the necessary weight and size profiles, experience, and with the help of special calculations. The electric motor, reducer, driveshaft, and fan assembly are selected by similar programs and calculations to create the main details of the tower and proceed to the bidding stage.

Turkey Provinces - Wet Bulb Temperatures Table (Values that must be used for tower design.)

City	Summer Dry °C	Summer Wet °C	City	Summer Dry °C	Summer Wet °C
Adana	38	26	Karabük	32	25
Adıyaman	38	23	Karaman	34	21
Afyon	34	21	Kars	30	20
Ağrı	34	25	Kastamonu	34	22
Aksaray	34	20	Kayseri	36	22
Amasya	31	21	Kırıkkale	35	21
Ankara	35	20	Kırıklareli	35	24
Antalya	39	28	Kırşehir	35	21
Artvin	30	26	Kilis	39	23
Aydın	39	24	Kocaeli	36	25
Balıkesir	38	25	Konya	34	21
Bayburt	33	23	Kütahya	33	21
Bilecik	34	23	Malatya	38	21
Bingöl	33	21	Manisa	40	25
Bitlis	34	22	K.Maraş	36	22
Bolu	34	23	Mardin	38	23
Burdur	36	21	Muğla	37	22
Bursa	37	25	Muş	32	20
Çanakkale	34	25	Nevşehir	28	21
Çankırı	34	23	Niğde	34	20
Çorum	29	22	Ordu	30	23
Denizli	38	24	Osmaniye	38	26
Diyarbakır	42	23	Rize	30	26
Düzce	34	24	Sakarya	35	25
Edirne	36	25	Samsun	32	25
Elazığ	38	21	Siirt	40	23
Erzincan	36	22	Sinop	30	25
Erzurum	31	19	Sivas	33	20
Eskişehir	34	22	Şanlıurfa	43	24
Gaziantep	39	23	Tekirdağ	33	25
Giresun	29	25	Tokat	29	20
Gümüşhane	33	23	Trabzon	31	25
Hakkari	34	20	Tunceli	37	22
Hatay	37	28	Uşak	35	22
İskenderun	37	29	Van	33	20
Isparta	34	21	Yalova	33	24
İçel(Mersin)	35	29	Yozgat	32	20
İstanbul	33	24	Zonguldak	32	25
İzmir	37	24

What should be considered when designing a water cooling tower?

Designing a water cooling tower involves careful consideration of various factors to ensure optimal performance, energy efficiency, and safety. Here are the key aspects that should be taken into account during the design process:

1. Cooling Requirements: Determine the cooling load requirements based on the heat generated by the process or equipment that needs to be cooled. Proper calculation of the cooling load is essential to size the cooling tower appropriately.
2. Water Quality: Consider the quality of the water source, including factors such as hardness, pH level, and the presence of impurities. Water treatment processes may be necessary to prevent scale formation, corrosion, and biological growth within the cooling system.
3. Environmental Conditions: Take into account the local climate, including ambient temperature, humidity levels, and seasonal variations. These factors can affect the cooling tower's efficiency and performance.
4. Site Location: Consider the available space, accessibility, and environmental regulations at the site. Adequate space is needed for the installation of the cooling tower, fan clearance, and maintenance activities.
5. Cooling Tower Type: Choose an appropriate cooling tower type based on the specific requirements of the application. Options include counterflow, crossflow, mechanical draft, natural draft, and hybrid cooling towers. Each type has its advantages and limitations.
6. Material Selection: Select suitable materials for the tower structure, fill media, and other components. Common materials include fiberglass reinforced plastic (FRP), galvanized steel, and treated wood. The choice of material should consider factors such as corrosion resistance, durability, and maintenance requirements.
7. Airflow Design: Design the cooling tower to facilitate efficient airflow. Proper fan sizing, placement, and blade pitch are crucial for maximizing heat exchange between the air and the water.
8. Water Distribution System: Design an efficient water distribution system to ensure uniform water flow over the fill media. Uneven distribution can lead to reduced cooling efficiency and increased energy consumption.
9. Energy Efficiency: Implement energy-efficient features, such as variable speed drives (VSD) for fans and pumps, to optimize energy consumption based on varying cooling loads. Properly sized fans and motors also contribute to energy efficiency.
10. Maintenance and Access: Design the cooling tower with easy access points for maintenance and cleaning. Consider features like removable panels, ladders, and platforms for safe and convenient access to internal components.
11. Safety Considerations: Incorporate safety features, such as guardrails, safety grating, and signage, to ensure the safety of personnel working on or near the cooling tower.
12. Regulatory Compliance: Ensure that the design complies with local, state, and federal regulations, including environmental standards and water usage restrictions.
    

By carefully considering these factors, engineers can design water cooling towers that are efficient, reliable, and safe for long-term operation. Collaboration with experienced professionals and adherence to industry best practices are essential in the design process.