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Cooling towers: how do they work and why are used in the sugar industry. Cooling towers are necessary for all processes involving thermal cycles, where it’s essential to remove all the unused or excess heat in order to continue the operations.There are three main types of cooling towers that are defined by how water or air pass through them. These types include crossflow, counterflow, and hyperbolic. There are also two varieties classified solely on airflow, known as induced draft and passive draft cooling towers.What is a cooling tower? A cooling tower is designed to remove heat from a building or facility by spraying water down through the tower to exchange heat into the inside of the building. Air comes in from the sides of the tower and passes through the falling water.
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Frigate Cooling Towers for Sugar Production – Kelvion
The Frigate cooling tower is a version of the successful Polacel CMDR range and named after the Frigate bird that can stay airborne for a week and is famed for …
Source: www.kelvion.com
Date Published: 12/21/2021
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Cooling Towers for sugar industries
* Proven and reliable. * Designed for heavy industrial use. * Simplified maintenance. Perfect Cooling Towers has manufactured cooling tower lines and related …
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Sugar – Paharpur Cooling Towers
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Source: www.paharpur.com
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Difference Between Cooling Tower and Spray Pond
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Keeping cooling water disinfected at a German sugar factory
German Sugar Factory Controls Cooling Circuit Disinfection … are cooling circuits in which the cooling water is cooled down by means of cooling towers.
Source: www.evoqua.com
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Advance Mist Cooling System for Sugar Process
Products for Sugar Industry. MIST COOLING SYSTEM is used as a superior alternative for various types of spray systems and conventional cooling towers.
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- Author: Mayuresh Daptardar
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- Date Published: Feb 13, 2017
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What is cooling tower and its types?
There are three main types of cooling towers that are defined by how water or air pass through them. These types include crossflow, counterflow, and hyperbolic. There are also two varieties classified solely on airflow, known as induced draft and passive draft cooling towers.
What is the main purpose of a cooling tower?
What is a cooling tower? A cooling tower is designed to remove heat from a building or facility by spraying water down through the tower to exchange heat into the inside of the building. Air comes in from the sides of the tower and passes through the falling water.
What does a cooling tower do in a refinery?
For refineries and chemical processing plants, open-circuit wet cooling towers — coupled with shell-and-tube or plate-and-frame heat exchangers — provide an economical method for rejecting heat. These towers are designed to wet bulb temperature and can cool water to a lower temperature than some other technologies.
Where are cooling towers located?
Cooling towers are usually located on rooftops or other outdoor sites. Because they are frequently out of sight, they are often neglected by operation-and-maintenance technicians, resulting in lower cooling-system efficiency.
How many types of coolers are there?
There are four main types of air coolers namely Desert air coolers, Personal air cooler, Tower air coolers and Window air coolers.
What industries use cooling towers?
The primary industries that use cooling towers include petroleum refineries, chemical manufacturing plants, primary metals processing plants, glass manufacturing plants, rubber products manufacturing plants, tobacco products manufacturing plants, and textile manufacturing plants.
What gas is released from cooling tower?
A common misconception is that they release pollution. In fact, what they actually release is water vapour – similar to, but nowhere near as hot, as the steam coming out of your kettle every morning. And this probably isn’t the only thing you never knew about cooling towers.
What is the difference between cooling tower and condenser?
A water cooling tower is used to cool water and is a huge heat exchanger, expelling building heat into the atmosphere and returning colder water to the chiller. A water cooling tower receives warm water from a chiller. This warm water is known as condenser water because it gets heat in the condenser of the chiller.
What is the most common type of cooling tower?
Mechanicaldraft cooling towers are the most widely used in buildings and rely on power-driven fans to draw or force the air through the tower. They are normally located outside the building.
How cooling towers are built?
They are often constructed as hyperboloid, doubly-curved concrete shell structures supported on a series of concrete struts. The foundations typically consist of an inclined pond wall forming a circular ‘tee’ beam with a wide concrete strip. The beam acts to resist the lateral load of the tower’s shell structure.
How chillers and cooling towers work?
It uses a process called ‘evaporative cooling’, where cooling water and air are in direct contact with each other, to lower the temperature of the hot water. This then allows small amounts of water to evaporate, and therefore continue to lower the temperature of the water circulating throughout the tower.
Cooling towers for sugar industry
Cooling towers for sugar industry
Cooling towers: how do they work and why are used in the sugar industry
Cooling towers are necessary for all processes involving thermal cycles, where it’s essential to remove all the unused or excess heat in order to continue the operations.
This is what cooling towers are for, as they play an integral role in heat management. If the cooling towers are not present in the industrial complex, the heat that is not eliminated would tend to accumulate. This, in turn, would make it difficult to continue the production process. Cooling towers help stabilise the entire thermal production area and even help to eliminate waste.
In which industries are cooling towers used?
There are many sectors in which cooling towers are used.
From refineries to sugar factories, not forgetting everything related to energy production and even distilleries. In addition to this, there are also many industries of radically different types: cooling towers are used in chemical, food and even pharmaceutical industries. Not only that: cooling towers are also used in sectors such as glassware.
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Understanding The Different Types Of Cooling Towers
Understanding The Different Types Of Cooling Towers
Cooling towers were essentially created to eliminate excess warmth from water used in industrial operations and send it out into the surrounding biosphere. Surprisingly, there are many different techniques for achieving this process. Since there is a high degree of variation between how these devices operate, they are classified within a number of distinct groups.
There are three main types of cooling towers that are defined by how water or air pass through them. These types include crossflow, counterflow, and hyperbolic. There are also two varieties classified solely on airflow, known as induced draft and passive draft cooling towers.
Crossflow cooling towers
Crossflow cooling towers use a splash fill that allows in-flowing to air move in a horizontal path over the stream of water from the upper reservoirs. Crossflow systems are some of the more expensive equipment types, but they are also some of the easiest to maintain. However, these cooling systems are more vulnerable to frost than others.
Counterflow cooling towers
In a counterflow system, the in-flowing air travels in a vertical path over the splash fill as the water streams down from the reservoir above. Counterflow systems are usually smaller than their crossflow counterparts. These cooling towers are more expensive due to the fact that more energy is needed to push the air upward against the down-flowing water.
Hyperbolic cooling towers
Hyperbolic systems are well-built and require a minimal amount of resources. Though they require few resources, these cooling towers are able to efficiently manage large-scale tasks within big chemical or power plants.
Hyperbolic systems use a chimney stacking technique that allows the cooler, outside air to push the damp, warmer air inside the tower. Splash fill is placed around the bottom of the tower and the water that sprays over it is cooled by the passage of upward-flowing air.
Induced draft cooling towers
Induced draft or mechanical draft cooling towers use some type of mechanical pressure, like a fan system, to push air upward inside the tower. Induced draft systems can also force air into the tower with a blow-through or pull it out through a draw-through.
Passive draft cooling towers
Passive or natural draft cooling towers combine the upward motion of warmed air with a steep chimney architecture to organically pull air throughout the tower. Although passive draft systems may have either a counter or crossflow transport design, hyperbolic towers are always passive draft.
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Other Uses of Water
What is a cooling tower?
A cooling tower is designed to remove heat from a building or facility by spraying water down through the tower to exchange heat into the inside of the building. Air comes in from the sides of the tower and passes through the falling water. As the air passes through the water, heat is exchanged and some of the water evaporates. This heat and evaporated water flow out the top of the tower in the form of a fine cloud-like mist. The cooled water is collected at the bottom of the tower and pumped back into the plant or building for reuse. Cooling towers provide large scale air-conditioning where land and (or) water are expensive, or regulations prohibit the return of once-through cooling waters 1.
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What are cooling towers used for?
Cooling towers are primarily used for heating, ventilation, and air conditioning (HVAC) and industrial purposes. Cooling towers provide a cost-effective and energy efficient operation of systems in need of cooling. More than 1,500 industrial facilities use large quantities of water to cool their plants 2. HVAC systems are used typically in large office buildings, schools, and hospitals. Industrial cooling towers are larger than HVAC systems and are used to remove heat absorbed in the circulating cooling water systems used in power plants, petroleum refineries, petrochemical plants, natural gas processing plants, food processing plants, and other industrial facilities.
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Cooling towers and Legionnaires’ disease
Cooling towers contain large amounts of water and are potential breeding grounds for Legionella bacteria if they are not properly disinfected and maintained. Water within cooling towers is heated via heat exchange, which is an ideal environment for Legionella heat-loving bacteria to grow. Legionnaires’ disease can be acquired when an individual breathes in water droplets containing Legionella bacteria. The disease was named in 1976, when American Legion members who attended a Philadelphia convention, suffered from an unusual pneumonia (lung infection). Outbreaks due to Legionnaires’ disease from contaminated cooling towers still occur today 3.
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Cooling Solutions for Chemical Process Plants
Cooling Solutions for Chemical Process Plants
Heavy industrial applications such as manufacturing, chemical processing and oil-and-gas refining use cooling towers and other equipment to cool the water integral to their operations. As environmental regulations and challenging market conditions place higher demands on these industries, improved cooling technologies are emerging to help address the challenges.
Some modern cooling towers include modular, pre-assembled components that can be shipped “just in time” to the job site to reduce construction time and manpower requirements.
In the oil-and-gas industry, many cooling towers currently in service were built as part of the original refinery construction, and they are fast approaching the end of their service lives. In order to meet modern production demands and industry requirements, these towers must be upgraded or replaced with more efficient products, and better long-term maintenance plans must be instituted.
Cooling Tower Operation and Types
Cooling towers are specialized heat exchangers that reduce the temperature of water by bringing it in contact with air. Water, which has been heated by an industrial process, is pumped to the cooling tower through pipes. The water sprays through nozzles onto banks of heat transfer material called fill, which slows the flow of water through the cooling tower and exposes as much water surface area as possible for maximum air-water contact. As the water flows through the cooling tower, it also is exposed to air that is pulled through the tower by an electric-motor-driven fan.
When the water and air meet, a small amount of water is evaporated, creating a cooling action. The cooled water then is pumped back to the process equipment, where it absorbs heat. It then will be pumped back to the cooling tower to be cooled once again.
Different types of cooling towers are suited for different industrial cooling needs. Field-erected towers (FEP) are constructed on site, designed for large heat loads and are engineered to address the specific application.
Field-erected towers are well suited for power and heavy industrial uses, and they are frequently found in refineries and chemical processing plants.
Factory-assembled towers (FAP) are constructed in modules at a manufacturing facility and then shipped to the processing plant in as few pieces as possible for final assembly. Factory-assembled towers are available in many cooling capacities and box sizes, and they include standardized mechanical and structural components.
For refineries and chemical processing plants, open-circuit wet cooling towers — coupled with shell-and-tube or plate-and-frame heat exchangers — provide an economical method for rejecting heat. These towers are designed to wet bulb temperature and can cool water to a lower temperature than some other technologies. But, refineries and processing plants also employ other methods to achieve cooling.
Air-Cooled Heat Exchangers
Evaporative cooling towers such as those described above use heat transfer fill to effectively distribute the hot process water and increase its surface area for more efficient cooling. The trade-off is that many fill types require relatively clean water to run effectively. Lower quality water containing particles and debris will clog the fill and reduce performance.
For situations where water is scarce, unavailable or expensive, air-cooled heat exchangers are an alternative cooling technology. Air-cooled heat exchangers are built to handle the high heat loads common in oil-and-gas and chemical processes, require infrequent maintenance and do not evaporate water for cooling.
Air-cooled heat exchangers use only airflow to cool hydrocarbon products and other fluids in tubes. Hot process fluid from the plant flows through fintubes while cooling air flows across them. Air-cooled heat exchangers work well for higher temperature hydrocarbon applications. These heat exchangers are employed by the oil-and-gas industry because water or water chemistry maintenance is not required, and they do not create the vapor plume of evaporative towers. However, because they are designed to dry bulb temperature, they cannot cool water or process fluids to temperatures as low as wet cooling towers.
Other specialized heat exchangers such as evaporative condensers and closed-circuit fluid coolers are also employed to cool processes and fluids throughout chemical plants.
Challenges for Oil and Gas
In oil-and-gas refineries, industrial equipment is often jacketed or sleeved with flowing water to cool fluids and absorb process heat. This equipment generates a large heat load that can disrupt operations if not properly handled. Cooling towers are used to cool this process water for reuse. The towers must be able to handle the heat load as well as any problems unique to the industry. Leaks in the process can cause hydrocarbons to contaminate the cooling water and vice versa. Lower quality, nonpotable water often is used to cool plant processes. Meeting environmental regulations limiting hydrocarbons, water usage and drift rates present challenges to plant operators. New industry regulations often require cooling towers to lower the drift rate to 0.0005 percent of circulating water flow, which can be difficult to achieve in older evaporative cooling towers. Many cooling towers currently in use are not equipped to handle these demands.
A few decades ago, field-erected towers commonly used wood structural members. These cooling towers are coming to the end of their service lives, experiencing mechanical failures, requiring unplanned maintenance that interferes with production and impacting facility productivity. The heat transfer fill in the towers also degrades over time, getting plugged with waste from dirty cooling water and breaking down from the weight of debris.
A good portion of the industry is in need of new towers and better long-term maintenance plans. “A lot of the existing cooling towers are either aging out or suffering from lack of proper maintenance,” says Alan Christian, president of Christian Power Equipment Inc., a company that specializes in equipment for power, process and pollution control. “It’s significant enough that I would call it a trend [in the industry].”
Replacing Old Towers
Replacing aging wooden cooling towers is a challenging undertaking. Because they are integral to the production process, maintenance, repair and replacement must be accomplished within short scheduled outage periods. Some replacements are done one cooling cell at a time, allowing the plant to continue to operate — a practice known as online construction. Rental of temporary cooling equipment often is necessary.
In order to combat replacement logistical challenges and high costs, cooling tower manufacturers offer both field-erected and factory assembled towers. Refineries and chemical plants can replace old, deteriorating towers with modular field-erected towers or pre-assembled package towers that are project and site specific.
“A lot of these refineries were established between 1950 and 1970 when the original towers went in. They built up the refineries around [the towers],” says Pam McLaughlin, sales engineer at Hastik-Baymont Inc., a company that specializes in engineered equipment solutions for the oil-and-gas and process industries. “Most places, unless they’re new grassroots refineries, don’t have a whole lot of lay-down area to do tower repairs or replacements on a basin that’s already erected. There’s just not a lot of available space.”
Field-Erected Solutions: To work with these constraints, some manufacturers have modularized the production and field-assembly processes for counterflow, field-erected towers. Often, modular cooling towers erect faster and require less site lay-down area compared to traditional tower construction methods while offering the same capabilities to keep up with large heat loads. Modular components can be shipped “just in time” to the job site, reducing construction duration and manpower requirements. Assembly processes are safe, and uniform factory-assembled modules ensure consistent product quality.
Factory-Assembled Tower Considerations: Factory- assembled cooling towers are a viable alternative for oil-and-gas applications. They offer fast delivery and installation and more site placement flexibility. They also allow for shorter outages and loss of production time. In case of expansion, additional cells may be added to provide more cooling capacity. Factory-assembled cooling towers designed for process applications are available in either counterflow or crossflow designs and include heavy-gauge, corrosion-resistant structural components and mechanical drive trains built for reliability and long service life.
In conclusion, as environmental and market demands put pressure on oil-and-gas refineries and chemical processing plants, they must take measures to ensure their facilities and equipment are modern and efficient. Old deteriorating cooling systems must be replaced by new technologies, made with durable materials and components, backed by reputable manufacturers, and supported by knowledgeable engineers and service technicians. Cooling systems also must be part of comprehensive monitoring and maintenance programs that extend the equipment’s profitable service life and alert plants to potential problems before a crisis arises.
Frigate Cooling Towers for Sugar Production
First customer
Our first customer was a sugar factory in France. The order was placed at the beginning of 2020, which meant we had to transform the Frigate concept into a reality within five months.
During the detailed engineering phase, we held bi-weekly meetings with a multi-disciplinary team. Then we had a trial assembly at our Doetinchem factory in the Netherlands to make sure the blocks fitted perfectly. Our development team monitored the assembly and filmed it for training purposes.
The result
Since the first Frigate was delivered to the sugar factory successfully, Kelvion has received an order from a chemical site in Germany and is quoting for data center projects on three continents.
Industrial Cooling Tower Suppliers, Manufacturers, Dealers & Retailers for sugar industries
Search the Internet and you will come across several companies specializing in the manufacture of cooling towers. You will also find various portals displaying the list of top 10 cooling tower manufacturers. It’s easy to get confused, when buying a cooling tower.
When it comes to the Design, Manufacture, Supply ,Installation and Servicing of cooling towers, PERFECT Cooling Towers is counted amongst the top most cooling tower manufacturers in India.
So what sets us apart? Here are the Features which have helped us attain this unique distinction.
* Innovative designs using latest cooling tower technologies.
* Industry leader with over 10,000 towers built to our credit.
* Conservative thermal ratings.
* Long life construction.
* Compact and powerful Weather proof.
* Proven and reliable.
* Designed for heavy industrial use.
* Simplified maintenance.
Perfect Cooling Towers has manufactured cooling tower lines and related equipment for over 20 years. Our towers are second to none in quality and energy efficiency.
Our prices provide the best value for a Non-Corrosive Cooling Tower. The combination of our unique design one piece casing and the use of the most advanced technology make our towers some of the best available on the market.
As a leading Manufacturer of Cooling Tower, Counterflow Cooling Tower, Crossflow Cooling Tower, Cooling Tower Fill, Cooling Tower Sprinkler, Cooling Tower Nozzle, Cooling Tower Fan, FRP Cooling Tower, Square Cooling Tower, Round Cooling Tower, Induced Draft Cooling Tower, Evaporative Cooling Tower, Fiberglass Cooling Tower, Modular Cooling Tower, Packaged Cooling Tower, Industrial Cooling Tower and Cooling Tower Motor. we have become competitive in all types of cooling tower projects of any size and design. We are constantly developing newer methods to serve the growing needs in the industry and our efforts have led us to become a highly competitive, full service engineering, design and repair contractor. Our emphasis on performance and low maintenance continues to give PERFECT the edge in every project design. And our approach to project delivery allows us to begin any size commercial or industrial project before most of our competitors.
PERFECT COOLING TOWERS will continue in the tradition of service in the next decade, bringing innovative solutions to our clients with new technologies and techniques for increased cooling capacity and faster project delivery.
Paharpur Cooling Towers
Overview
Paharpur can provide you with a zero-downtime cooling solution for your Sugar plant.
Typically, cooling towers in sugar plants require regular maintenance owing to fouling of the nozzles, basin and in pipes.
Fouling is the collection of undesirable substances on the surface of fluid handling materials and this diminishes the efficiency of the operation. In such circumstances, Paharpur provides crossflow towers, on which complete maintenance can be carried out even during operation- which gives you the distinct advantage of zero-downtime.
The structures and hardware that we supply to the sugar industry in particular are Stainless Steel- to protect against corrosion. With accurate thermal performance and zero downtime, Paharpur ensures that you sail through the cooling operation for years and years.
Difference Between Cooling Tower and Spray Pond
In this article explained about Terms in cooling system, Design specification of cooling system and formula for Cooling System Efficiency. Finally discussed about difference between spray pond and cooling tower
Design specification of cooling system | Cooling Tower | Spray Pond
Condensing and cooling system plays a major role in sugar industry process house.
Essential Terms in cooling system
Evaporation
Dry Bulb
Wet Bulb
Absolute Humidity
Relative Humidity
Approach
Evaporation: In cooling process some quantity of water evaporated from the circulating water into the atmosphere in cooling system
Dry Bulb temperature (DBT): The DBT of the inlet or ambient air adjacent to the cooling tower as measured by a dry-bulb thermometer
Wet Bulb Temperature (WBT) : The lowest temperature to which the water can be cooled by contact with the air is the temperature indicated by the wet-bulb thermometer. The WBT readings are obtained by means of a mechanically aspirated psychrometer.
Relative Humidity: The ratio of the mole fraction of water vapour present in the air to the mole fraction of water vapour present in saturated air at the same temperature and barometric pressure is called relative humidity
Approach: The temperature difference between WBT of incoming air and outgoing temperature (cooling system outlet water) of water is known as “Cooling tower approach“.
Design specification of cooling systems
Water recirculation quantity calculation in cooling system of sugar process
To estimate cooling system capacity in sugar plant boiling house from four sources
1. Evaporator condenser: Quantity of vapour goes to condenser from evaporator set last body. Its quantity having generally in the range of 5 to 8% on cane.
2. Pan condensers: Total vapour load on condensers form all pans having 20 to 25% on cane. In case of back-end refinery it will increased upto 25 to 30% on cane.
3. Vacuum filter condenser: Total load on condenser including vapour and humid air having 0.8 to 1.2% on cane.
For more information please go through the below link
Rotary vacuum filter Equipment capacity details in sugar industry
4. Miscellaneous: Cooling water will be also used for odd duties such as ejector for vacuum crystallizers, NCG (non-condensible gases) and condensers common air ejector. Its total water requirement approximately 100% to 150% on cane
The total quantity of water circulating through the cooling system is about approximately 40 to 50 times the amount of vapour condensed. Its quantity depended upon the so many parameters like condenser efficiency, cooling system efficiency and wet bulb temperature.
For example 5000 TCD (210 TCH) plant cooling system water required
Vapour Load = 8% ( by evaporators) + 25% (By pans) + 1% (by vacuum filters) = 34% on cane
Total vapour load on condensers = 210 x 34% = 71.40 T/hr
Water required for vapour condensation = 71.40 x 50 = 3570 t/hr
Water required for ejectors = 210 x 150% = 315 t/hr
Total water required in cooling system = 3570 + 315 = 3885 t/hr ~ 4000 T/hr
Evaporation Rate in cooling system
The heat load to be removed in the cooling system is determined from the quantity of water and the change in temperature
Q = M x Cp x ( Ti – To)
Here Q = Quantity of heat load to be removed in evaporated in Kcal/kg
M = Water recirculation flow rate through the cooling system in T/hr.
Cp = Specific heat of water in Kcal/kg/oC
Ti = Water inlet temperature to cooling system ( Before cooling)
T0 = Water outlet temperature to cooling system ( After cooling)
For example M = 4000 t/hr ( recirculation flow rate),
Cp = 1 Kcal/kg/oC
Ti = 40 oC
T0 = 32 oC
Q = heat load to be removed in evaporated = 4000 x 1 x 8 = 32000 Kcal/kg
Latent heat of vaporization of water = 2260 KJ/kg = 540 Kca/kg
W = Quantity of water evaporation = 32000/540 = 59 T/hr
The proportion of the circulating water evaporated is about 2 to to 2.5% in circulation flow rate.
The cooling is directly dependent on the difference between the water temperature and the wet bulb temperature, both these temperatures are major factors affecting the size of the cooling system.
The wet bulb temperature is a function of the local conditions, and varies significantly during the course of the year.
A smaller quantity of water returning at a higher temperature may have the same heat duty to be removed as a system a larger quantity of water returning at a lower temperature.
However the higher temperature system will require a smaller cooling system because the difference between water and wet bulb temperature is higher.
Thus it is important to ensure that condensers have a close approach, returning the smallest quantity of water at the highest temperature possible.
Cooling System Efficiency
The efficiency of cooling system design of condenser play a very important role in reducing the consumption of water and power.
The efficiency “ “of the cooling system
Ti = temperature of the warm water entering the cooling system
To = temperature of the cold water leaving the cooling system
Twb= wet-bulb temperature.
Types of cooling system
There are two principal types of cooling system used in sugar factory
1. Spray Pond
2. Cooling Tower
The water is cooled by contact with cooler ambient air either in conventional cooling towers or in spray ponds. Most of the cooling occurs by evaporation and only a small proportion is by sensible heat transfer. Thus a significant proportion of the condensed vapour is evaporated in the cooling system.
Spray Pond Cooling System
Introduction: The spray pond cooling is the one of the simplest method of cooling the condenser water. In spray pond warm water is broken up into a spray by means of nozzles.
The hot water coming out of condenser is sprayed through the nozzles to expose maximum surface area of water to air for effective cooling.
Advantage
a) Pumping cost is low
b) Head required is less
c) Lesser wastage of water
d) Low drift losses
e) Least choking
f) Easy to maintain
g) High Durability and long life
Disadvantages
a) Large area is required. Approximately 25-50 times the area of cooling tower
b) Spray losses due to evaporation and windage losses
c) There is no control over the temperature of cooled water.
e) Cooling efficiency is low.
f) Cooling effect reduces with reduced wind velocity.
g) When load on the plant increases it does not respond to change.
Cooling Tower
Introduction: The cooling tower are desired when positive control on the temperature of water is required, the space occupied by the cooling system is considerable factor and the plant is situated near the load center.
Higher the surface area, more time of exposure, lower relative humidity, higher difference between WBT of air and water inlet temperature and cross flow gives effective cooling and reduced the tower size.
The cooling tower are mainly divided into two groups as Natural draft or Atmospheric cooling tower and Mechanical draft tower as per the air flow through the tower.
Advantages
a) Less floor space area required
b) Induced draft design with fan motor
c) More efficient compare to spray ponds.
Disadvantages
a) The carry over losses which are 0.2-0.6 % of water flow ,causes corrosion of blades forms the fog around tower with increase in carry over losses make up water required is also increased.
b) The drift droplets have the same chemical impurities as the circulating water and the deposition of these chemicals on object causes potential environmental concern.
c) Cooling tower where sewage effluent is uses for making up is highly conductive for growth of algae.
d) More maintenance.
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Keeping cooling water disinfected at a German sugar factory
Challenge
Südzucker produces 5.4 million tons of sugar a year. Situated in Obrigheim, located in the Palatinate region, the Offstein Sugar Factory is one of the largest and oldest of nine sugar factories in Germany. Yearly, 1.4 to 1.8 million tons of sugar beets are processed. During the harvesting campaign (September to December), this is about 16,000 tons of beets daily – around the clock. Syrup and sugar are produced from the beets. A part of the syrup is temporarily stored and later processed into white sugar. Cooling water, among other things, is required for the production process. For this, there are cooling circuits in which the cooling water is cooled down by means of cooling towers. To prevent the microbial contamination of the cooling water, chlorine dioxide is a perfectly suitable disinfectant. Chlorine dioxide as a means of disinfecting cooling water is already being deployed at multiple Südzucker factories – at the location in Obrigheim in two closed cooling circuits. While up until now chlorine dioxide has been used as a ready-to-go solution, an alternative to the continuous production of chlorine dioxide has been sought after.
Solution
In order to continually generate chlorine dioxide, the decision was made for the DIOX-A 5000 chlorine dioxide generator by Evoqua Water Technologies. The completely reworked system with a capacity of 5 kg/h max. is consistent with all installation and workplace safety requirements. Both the mechanical construction as well as the controls have been newly designed. The generator, which produces the chlorine dioxide according to the chlorite / hydrochloric acid principle, has been approved as a drinking water disinfectant according to drinking water regulations. From the concentrated solutions of sodium chlorite (24.5 % NaClO2) and hydrochloric acid (30 – 38 % HCl), after mixing with a double injector in the reaction chamber, a watery chlorine dioxide solution is prepared. The double injector assures that the concentrated chemicals do not come into contact in undiluted form.
Mist Type Stainless Steel Single Entry Condenser
Due to unique design of our Advance MCS, you can expand your sugar factory without any extension of your spray pond. While expanding the plant capacity there arises need for expansion of Spray Pond, causing tremendous civil construction cost as well as consuming additional space. Considering this aspect, MREPL has introduced a new concept of Revolutionary 8-way Header Design with Enhanced Efficiency Mist Creator Nozzles. It is now possible to install entirely new MCS for Final expanded capacity of Sugar Plant by replacing old Spray System in the existing Spray Pond only, saving considerable cost and space. This is achieved without compromising the original efficiency of our Mist Cooling System. Advance MCS ensures a constant cold water temp. of 32°C with a temperature drop of 10°C to 12°C throughout year with a very low working pressure of 0.8 to 1 kg/cm2. Advance MCS has been successfully commissioned at various plants with Gravity type pond also.
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