Investigation of a method to decrease water consumption and enhance productivity in wet cooling towers using dynamic time-related modeling for industrial experimental applications

This research examines the water and energy performance in wet cooling towers and identifies methods for enhancing efficiency and minimizing water and energy consumption by exploring methods to enhance system performance. A three-dimensional transient model, developed using MATLAB's open-source code software, was utilized to simulate the cooling tower's behaviour under various operating conditions. This research focuses on precise simulation of cooling tower behavior and demand modeling aided by regression. The model's accuracy was validated through experimental measurements in diverse environmental conditions. The key parameter and performance that is investigated in this paper is the temperature profile of the cooling tower, in which the performance algorithm and proposed methodologies are anchored in the operational temperature. The experimental results led to operational solutions for enhancing cooling tower performance. For winter conditions, the recommended action involves closing the upper part of the cooling tower and activating the two side fans. Specific approaches are suggested for mid-season and summer scenarios, focusing on make-up water consumption and ambient air temperature control, respectively. In addition, results indicated a close alignment between the model and the actual system, with discrepancies of less than 2% in energy consumption and 5% in water consumption. Analysis of proposed productivity enhancements and changes in supply policies indicated significant potential for energy and water conservation in wet cooling towers. Implementing these solutions could lead to an estimated annual reduction of 44% in water consumption and 4.2% in energy consumption.