Reducing water consumption of an industrial plant cooling unit using hybrid cooling tower

Water consumption is an important problem in dry zones and poor water supply areas. For these areas use of a combination of wet and dry cooling towers (hybrid cooling) has been suggested in order to reduce water consumption. In this work, wet and dry sections of a hybrid cooling tower for the estimation of water loss was modeled. A computer code was also written to simulate such hybrid cooling tower. To test the result of this simulation, a pilot hybrid tower containing a wet tower and 12 compact air cooled heat exchangers was designed and constructed. Pilot data were compared with simulation data and a correction factor was added to the simulation. Ensuring that the simulation represents the actual data, it was applied to a real industrial case and the effect of using a dry tower on water loss reduction of this plant cooling unit was investigated. Finally feasibility study was carried out to choose the best operating conditions for the hybrid cooling tower configuration proposed for this cooling unit.