How Cooling Towers Work (Working Principle)

This video explains how cooling towers work and the working principle behind all wet type cooling towers. This is an ideal video for HVAC, Power Plant Engineering and Chemical Engineering viewers (and many other industries).

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Why do we need cooling towers?
Cooling towers are used to reject heat from a building or process. Large residential buildings require cooling towers to reject heat. The heat is generated by electrical equipment inside the building, the generation of heat by humans and also the heat generated through solar gain -which is the heating of the building by the sun-.

But residential buildings are not the only places where heat must be rejected. Large power stations use cooling towers to reject heat and almost all modern industrial processes require some means of rejecting heat.

Evaporative Cooling
Evaporative cooling is the fundamental working principle of all wet type cooling towers. When water evaporates, it cools the molecules surrounding it; this is known as evaporative cooling. If you lick the back of your hand and blow across it, you will notice that your hand feels cooler as the water evaporates. When animals perspire (sweat), the effect is the same, perspiration builds upon the skin and the body is cooled as the water evaporates.
We will now look at how we can apply this principle to a cooling tower to understand just how cooling towers work.

How Cooling Towers Work (Working Principle)
Cool cooling water is pumped from the cooling tower basin to the process. The cool cooling water is heated by the process and its temperature increases. The warm cooling water is then pumped back to the cooling tower to be cooled.

The incoming warm water enters the distribution manifold and is discharged through spray nozzles inside the tower. The spray nozzles spray the warm water evenly over the entire fill. The water passes downwards through the fill whilst air passes upwards. As the water travels through the fill, some of it evaporates which causes the remaining water to be cooled; this is the evaporative cooling effect we discussed earlier. The cooled water that did not evaporate falls into the collection basin due to gravity, whilst the air continues its path upwards, through the drift eliminator, through the axial fan, then exits through the top of the tower.

To recap, water enters the tower and travels downwards. Air is induced into the base of the tower by a fan and travels upwards. Some of the water evaporates as it passes through the fill and this cools the remaining water that falls into the basin. A portion of the evaporated water is reclaimed by the drift eliminator, whilst the rest is discharged through the top of the tower as drift. That is how a counter flow induced draft cooling tower works, there are other cooling tower designs commonly used, but the working principles are similar.
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