The ultimate Mist Creation Technology is the best alternative to conventional cooling towers. This advanced Mist Creation System can achieve an approach of 1 to 20C to WBT as against 5 to 60C approach for conventional cooling tower. Hence guaranteed cold water temperature of around 300C could be obtained throughout the year in our tropical climate. Also, the spraying head is equivalent to the height of cooling towers thus requiring same pumping power. As Mist Creation System does not require fans for cooling it saves huge amount of power. Also, as there are no moving parts involved in Mist Creation System the maintenance cost is negligible and system runs trouble free.
This article will review basic type of cooling systems utilized in process/chemical plants and other industries. It will also explain why new Mist Creation System is superior than conventional cooling towers.
In process/chemical plants, product vapour generated in the process is condensed in a heat exchanger and is recovered back.
The condensation of steam/vapour requires a cooling medium. In early days, this was achieved by using water from a river, a basin or seawater. The cold water is pumped through a heat exchanger and the warm water is discharged back to the water source. This is called once through cooling system.
A once through system is an open loop system. The necessity to reduce the huge amount of water gave birth to the idea of closed loop system. Thus, the wet cooling system came into effect.
In a wet cooling system, water is circulated to condense the steam in the same type of heat exchanger that is used once for cooling. The warm water, instead of being returned to the water source, is cooled in a cooling tower using air as the cooling medium. Only the water carried away due to evaporation, drift and blow-down needs to be replenished by make-up water. Thus, requirement of water quantity is vastly reduced.
Wet Cooling Systems
Wet Cooling Tower System
We will first consider the wet cooling tower system.
The Wet Cooling Tower System is based on the principle of evaporation. The heated water coming out of the surface condenser is cooled as it flows through a cooling tower, where air is forced through the tower by either mechanical or natural draft. Nowadays, mostly, all wet cooling towers are mechanical draft cooling towers, where the air flow is accomplished by the fans.
The principle cooling device used in an induced draft cooling tower are fans which run at the top of Cooling Tower (CT). Air enters through side louvers and escapes from the top. Water enters at the top and trickles down while getting cooled by air draft.
A correctly designed induced draft CT can give an approach of 4 to 6°C to WBT with a ∆T of 10°C. Even a very highly efficient CT can not give an approach less than 4°C to WBT. Moreover, if ambient temperature or humidity levels rise, efficiency of CT reduces.
Mist Cooling System
MREPL has come out with a solution by designing Mist Cooling System which is a high efficiency system, which ensures an approach of 1°C to prevailing WBT with a ∆T of 12 to 15°C even in adverse climatic conditions.
In tropical conditions, worst WBT even at coastal applications is maximum 30.5°C. Hence MCS will always maintain cold water of around 31°C+1°C throughout the year. No other cooling system can operate with such efficiency and it makes cooling tower/spray pond systems obsolete.
Various Models of Mist Cooling System / Tower to Suit Site Conditions:
Model – I: Open Type Mist Cooling System:
Here, MCS ensures an approach of 10C to design WBT with a ∆T of 12 to 150C. Water loss due to drift is 0.1 to 0.25% depending on wind speed.
Model – Ii: Louver Type Mist Cooling System
Here MCS pond is closed from sides, up to a height of 8 to 10 m by louver type cover sheeting. This reduces the plot size by 60% of open pond design. MCS ensures an approach of 1 to 20C to WBT with a ∆T of 12 to 150C. Drift loss comes down to 0.02% and also space requirement reduces considerably.
Salient Features of Open/Louver Type Mist Cooling System (Mcs):
Cold Water Temperature:
Mist Cooling System ensures an approach of 10C to WBT with a ∆T of 120C to 150C.
Energy Savings:
Due to such high temperature drop obtained, water quantity required at the process side is much less. MCS requires water pressure equivalent to the height of cooling tower. Hence, considerable amount of energy is saved on circulation water pumping. Also, MCS does not require any fans for cooling. Thus, a huge amount of energy is saved on circulation and cooling.
Process Benefits:
MCS will supply cold water at a temperature very close to WBT (Approach of 1°C) as against an approach of 4 to 5°C in cooling tower. This will reduce the product vapour losses in shell & tube heat exchangers. This will ensure that your plant operates at an enhanced yield in summer & monsoon, also giving stable output throughout the year.
Hence. installation of MCS will ensure large commercial benefits to you in the form of additional product obtained at a higher yield.
Maintenance:
MCS has no moving parts. It does not use any Fills and Fins for cooling. Also, material used in the MCS is special grade-saran polymer, a highly non-corrosive material having a life of more than 10-15 years. This makes MCS absolutely maintenance free. As against this, conventional cooling towers require a heavy maintenance in the form of replacement of fills, louvers, fan blades, etc. every year.
Choke-Less Design of Nozzles:
MCS operates with a choke-less design. Size of smallest opening in MCS is more than one inch (25 mm) in diameter. Hence, chances of particles choking the system are remote.
- Table Top Design: Prevents water stagnation, minimizing algae formation by directing water to a covered suction pit.
- MCS Design for Dusty Environments: Unique suction pit design prevents dust entry, draining it via valve, and ensures clear water supply to circulation pumps.
System Flexibility (Capacity Turn Down Ratio):
MCS is offered with individual line isolation valve. MCS is the only system, which gives such a high flexibility in operation.
Hydro- Balance Valve:
HBV is provided to take care of sub-cooling, which may happen in winter. It is also helpful to release excess pressure which may develop on system at times.
Chemical Treatment:
Chemical dosing requirements are similar to that of cooling tower as same hold up of water is maintained in suction pit of table top MCS.
Pay-Back Period:
The pay-back period of the MCS in most of the cases, will be obtained in less than one year only.
Model-III: Induced Draft Mist Cooling Tower
Model-I & Model-II require higher basin size by 3 to 4 times in comparison to conventional IDCT. To eliminate this drawback, first time in the world, we have combined the technology of Mist Creation with induced draft Fan thus cooling the water most efficiently. This uses our Patented Technology of Mist Creator Nozzles. Mist Creator Nozzles breaks water in micron size, thus giving highest surface area for heat transfer.
This Technology completely eliminates fills inside cooling tower making it maintenance free. Due to elimination of fills it reduces air pressure drop across cooling tower and hence BkW of fan drops by 30 to 50% with respect to conventional IDCTs.
Models available from 50 m3/hr to 3000 m3/hr with an approach of 30C to WBT & ∆T of up to 150C.
Salient Features of Induced Draft Mist Cooling Tower (Model-Iii):
Approach & Temperature Drop:
An approach of 3 to 40C is ensured to design WBT with a ∆T up to 150C.
Fill-Less Design:
No fills used as required surface area is created by Mist Formation.
Footprint:
Footprint required is same as compared to Conventional IDCT.
Life Expentancy:
Rugged structure with Pultruded FRP/HDGI MOC and FRP casing with SS 304 Nozzles, ensuring a life of 15+ years.
Maintenance:
Choke-less design of our Mist Creator Nozzles ensure a maintenance free operation for lifetime. Guaranteed designed performance even in summer & monsoon.
Make-Up Water:
IDMCT requires same make-up water in comparison to conventional IDCT.
Gaurantee:
Guaranteed designed performance even in summer & monsoon.
Refurbishment of Conventional Induced Draft Cooling Tower to Induced Draft Mist Cooling Tower by installing Revolutionary Mist Creation System inside existing cooling tower. The fills are completely removed as nozzles carry out work of fills & at higher efficiency.
For more details Contact: Email: mistcreation@gmail.com, Website: www.mistcreation.com
Makarand A. Chitale, Whole-time Director at Mist Resonance Engineering Pvt Ltd, is a seasoned expert driving innovation in green energy solutions, sustainable practices, and energy-efficient products. A recipient of the G. S. Parkhe Industrial Merit Award, he leads the team towards delivering impactful and energy saving technologies.
