ENCON GROUP (INDIA)

Presentation on
Efficiency & Performance
Enhancement
of Cooling Towers
Using High Efficiency
Energy Efficient Products
- Our Activities
- Energy Efficiency
- Selection of Cooling Tower
- Fills
- Water Distribution
- Fans & Motors
- Technical Know How
- Calculating Total Efficiency of Fan
- Why E-Glass Epoxy FRP
- Properties Comparison Between FRP & GRP
- Encon Fan Range
- Difference between ENCON FRP Fans & Aluminum
- Quality Assurance
- Wind Tunnel Testing
- ENCON Products Testing
- Determining Natural Frequency
- Performance Testing Method
- Case Studies & ENCON CT Supplies
- Why Pultruded
 Our Activities

• Energy efficient fans for various industrial applications.

• Performance evaluations of cooling tower.

• Tailor made, low maintenance cost FRP/Pultruded Cooling towers.

• Renovation of existing Cooling Towers to improve the performance with

appropriate internals.

• annual maintenance contracts

 Energy Efficiency

1. Selection of Cooling Tower

2. Efficient Fills
3. Water Distribution
4. Fans & Motors
1. Selecting a cooling tower

Heat dissipation (kCal/hour)

Range
Approach
Water flow rate
Water quality
Water availability
 2. Fill Media

• fills provides surface area to hot water and cools down

through evaporation
• fills impacts electricity use
• efficiently designed fill media reduces pumping head costs
• fills influences heat exchange: surface area, duration of
contact, turbulence
Film Fill
Splash Fill
 Optigrid

Floating hanger design allows OPTIGRID fill layers to float for excellent fit
in slanted cross flow towers.

It is a non fouling fill due to small surface area exposed to water

OPTIGRID reduces the pressure drop in the tower, provides improved

splash surface & maximum strength.

Used extensively in utilities,

refineries, sugar and steel mills, and
food processing plants due to dirty
water .

OPTIGRID has proved successful in

replacing wood decks and older
type plastic grids.
Optigrid- Fills
4. Water Distribution
System
Types of Drift Eliminators

0.001% Drift Losses

 4. Cooling Tower Fans

• Fans must overcome system resistance, pressure loss:

impacts electricity use
• Fan efficiency depends on blade profile
• Replace metallic fans with E-Glass FRP Blades (20-30%
savings)
• Use blades with aerodynamic profile (85-90% fan
efficiency)
Encon Fan
 Technical Know How
• ENCON GROUP is having Simulation department and MRL Design Software
for designing Cooling Tower
 Calculating Total Efficiency of Fan
Performance : by Optimizing Fan dia. & no. of Blades
Efficiency : by Lower H.P.

ƞ = Q x TP
1000 x KW

Q = Airflow (M3 / Second)

TP = Total pressure (Pascal)
nf = Fan efficiency

 E & C Resistance : Selection of High-Grade FRP

UV Degradation (Epoxy Resin) Composites
 Vibration : Higher dampening property
 Noise : Lower level (< 85 dbA)
 Why E-Glass Epoxy FRP

 Corrosion resistance
 Higher Efficiency due to improved
Aerodynamics characteristics
 Structural Integrity
 High strength to Weight ratio
 General adaptability to complex Geometries
 Why E- Glass Epoxy FRP
 Epoxy Resin
• Superior mechanical strength
• Greater chemical resistance
• Lower water absorption ENCON
• Higher heat resistance
• High dynamic strength
Selection
• High fatigue strength
• Better surface finish
• Corrosion resistance
• Higher Efficiency due to improved Aerodynamics characteristics
• Adaptability to complex Geometries

 Polyester (GRP)
• Cheaper quality standard
• Weak resin structure
• High Water absorption
 Properties Comparison Between FRP & GRP

Properties FRP Laminates GRP Laminates

Tensile Strength (psi) 45,000 – 100,000 18,000 – 55,000

Modulus of Elasticity in Tension 105 25 -35 10 – 28

psi
Flexural Strength (psi) 45,000 – 100,000 18,000 – 80,000
Sheer Strength (psi) 17,000 – 30,000 12,000 – 18,000

Bond Strength (lb.) 1,600 – 3,200 2,000 – 3,000

Heat Resistance (0C) 105 – 180 95 – 150

Water Absorption (%) 0.05 – 0.30 0.2 – 2.5

Effect of Strong Acid slight Some attack

Effect of Strong Alkaline slight Some to severe

Impact Strength Izod (ft.lb/inch of 19 – 35 10 – 25

notch)
Rupture in Tensile (N/mm2) 53 22

Rupture in Shearing (N/mm2) 68 53

Encon Fan Range

Fan diameter 2 ft – 64 ft

No. of Blades 4 – 24

Air Flow Up to 3000 M3/sec

Pressure Up to 1400 Pascal

Speed 81 to 3000 RPM

Power rating 0.25 to 1600 HP

Operating -45 0C to 230 0C

temperature
 Difference between ENCON FRP Fans &
Aluminum
No Items ENCON Fans Aluminum / GRP

1 Efficiency 81% - 90% 56% – 65%

2 Design Aerodynamic High Profile Old conventional

design designed
3 Material High Grade Epoxy (CIBA - Aluminum Casting
USA) laminated with FRP
(Vetrotex -France)
4 Blade Hollow Blade (Less Solid Blade (More
Weight) Weight)
5 Axial Low Axial thrust on Gear High Axial thrust on
Box Gear Box
6 Energy Saving 20% up for Energy Saving Energy Saving is Nil
Guarantee Guarantee
7 Endurance Life > 10 years Aging effect after 2 - 3
years
 Difference between ENCON FRP Fans &
Aluminum
No Items ENCON Fans Aluminum / GRP
8 Skin Friction Negligible skin friction due to More Drag losses due to
smooth surface without loss rough surface
of Efficiency & Wear & Tear

9 Heat Distortion High , due to Epoxy Base N.A.

Resistance Material

10 Maintenance Cost Zero Maintenance Cost due to More Maintenance Cost &
high grade material Downtime for assembling &
Dismantling
11 Leading Edge Provided with extra re- Leading Edge deteriorates
Protection enforcement of Epoxy resin frequently after 6 months
operation

12 Degradation Protected from Erosion, High prone to Erosion,

UV degradation & Abrasion Corrosion, UV degradation,
resistance Abrasion causing of
Fatique/Aging effect

13 Fan replacement Only individual blade to be Discarding Pair of blade

replaced
 Quality Assurance

• The Aerodynamic performance of FRP Fan can be evaluated in

Wind Test Bench as per AMCA 210-8 Standard

• Raw material are selected out of stringent quality as per

ISO/ASTM Standard followed 100% in house process inspection

• Life span of ENCON FRP Fans are normally above 15 years of

operation with proper maintenance and without any loss of
performance
Wind Tunnel Testing
ENCON Products Testing

Dynamic Balance
Machine
 ENCON Products Testing

Static Balance Machine

Determining Natural Frequency
 Performance Testing Method

PERFORMANCE TEST : CTI Code CTI Member

OUR ENGINEER WILL BE CONDUCTING THE ‘ PERFORMANCE TEST’ OF

YOUR EXISTING
ALUMINIUM AND OUR FRP FANS IN PRESENCE OF YOUR OFFICIALS AND
SHALL BE
MEASURING THE FOLLOWING PARAMETERS :

 AIR FLOW
 POWER CONSUMPTION AT MOTOR TERMINALS.
 GRASIM INDUSTRIES LIMITED
GRASIM CELLULOSIC DIVISION
VILAYAT, GUJARAT

Make ENCON
MODEL NO. ENC-4C-800
QUANTITY 4 CELL
TYPE COUNTER FLOW
UNIT DESIGN CONDITIONS
CAPACITY M³/HR 800
HOT WATER TEMP. °C 42
COLD WATER TEMP. °C 32
WET BULB TEMP. °C 28
COOLING RANGE DEGREE 10
APPROACH DEGREE 4
GRASIM INDUSTRIES LIMITED
STAPLE FIBRE DIVISION
BIRLAGRAM, NAGDA

Make ENCON
MODEL NO. ENC-1C-545
QUANTITY 1 CELL
TYPE COUNTER FLOW
UNIT DESIGN CONDITIONS
CAPACITY M³/HR 545
HOT WATER TEMP. °C 42
COLD WATER TEMP. °C 31
WET BULB TEMP. °C 27
COOLING RANGE DEGREE 11
APPROACH DEGREE 4
RELATIVE HUMIDITY % 100
WATER INLET PH PH 4.5-10
TDS PPM 3500-12000
HINDUSTAN
UNILEVER LIMITED
HARIDWAR
Make ENCON
MODEL NO. ENC-003-1C-0442
QUANTITY 1 CELL
TYPE COUNTER FLOW
UNIT DESIGN CONDITIONS
CAPACITY M³/HR 300
HOT WATER TEMP. °C 37
COLD WATER TEMP. °C 32
WET BULB TEMP. °C 28
COOLING RANGE DEGREE 5
APPROACH DEGREE 4
RELATIVE HUMIDITY % 100
 M/S ARVIND LIMITED. KALOL, GUJARAT

Supply of 216 M3/hr (1 CELL) (705 TR) IDCT FRP

Pultruded Cooling Tower
 BIRLA JINGWEI FIBRES
COMPANY LTD.
VILAYAT, GUJARAT

MAKE ENCON ENCON ENCON

TYPE COUNTER FLOW COUNTER FLOW COUNTER FLOW

UNIT DESIGN CONDITIONS DESIGN CONDITIONS DESIGN CONDITIONS

CAPACITY M³/HR 750 670 800

HOT WATER TEMP. °C 42.5 41.5 43

COLD WATER TEMP. °C 32.5 31.5 33

WET BULB TEMP. °C 28 28 28

COOLING RANGE DEGREE 10 9 10

APPROACH DEGREE 4.5 3.5 5

 Upgradation & renovation Cooling Tower

• Water distribution and spray

• Air flow

• Heat transfer area

• Drift loss

• Vibration
 Types of Upgradation

A) IMPROVEMENT IN THE APPROACH

B) CAPACITY INCREASE

C) POWER SAVINGS
 Hindalco - Renusagar Power Plant
Project- Cooling Tower Revamping
Parameters Before After (ENCON)
Water flow rate ( CMH) 13000 13000

HWT (o C) 44 40

CWT (o C) 36 34

WBT (o C) 26 26

Range (o C) 8 8

Approach (o C) 10 6

Reduction in Approach (o C) ------- 4

Hindalco –
Renusagar
Certificate
 Case Study
Customer:- THAI RAYON CORPORATION.
Project:-. Conversion of Bottel Type Counter Flow to Pultruded FRP Counter Flow

PARAMETER BEFORE AFTER

• CAPACITY M3/Hr. 500 900

• HWT °C 42 42
• CWT °C 36 32
• WBT °C 29 29
• FAN DIA. 16’-0”x 2 16’-0”x2
• MOTOR HP. 40HP.x 2 40HP.x2
• CAPACITY INCREASED. --- 80%
• % SAVINGS OF FAN --- 15%
POWER / CMH.
Thai Rayon
Certificate
 Case Study
Hindustan Zinc Ltd.

PARAMETER Design Actual After

Up gradation

Water 2000 2000 2000

FLOW/Cell
HWT OC 43 45.5 42.5
CWT OC 32 34.5 31.5
WBT OC 28 28 28
Approach OC 4 6.5 3.5
 Lanco Anpara Power Ltd.
Project - Wind Wall & Fan Installation (4 CT)
Parameter Before After (ENCON)

HWT 45.80 o C 44.30 o C

CWT 35 o C 33.50 o C

RANGE 10.8 o C 10.8 o C

VACUUM - 85 kPa o C - 89.9 kPa o C

EXHAUST HOOD TEPM 49.9 o C 48.4 o C

IMPROVEMENT IN - 0.9 kPa

VACUUM
Heat Rate Saved - 13.5 Kcal / KWh
Lanco Anpara Power Ltd.
Certificate
 Why Pultruded

• High corrosion Resistance

• Light weight and high strength
• Very long life without maintenance
• Fit and forget
• Safe Non-conductive, Non-magnetic
• Low life cycle – cost per year
• Flexible design
• Thermally insulated
• Very easy to cut
 Used In

 Petrochemicals  Foods
 Power Plants  Chemicals
 Oil & Gas  High Rise Buildings
 Textiles  Hotels
 Cements  Hospitals
 Pulp & Papers  Department Stores
 Steel & Metals
OEM
PHARMACEUTICAL / DRUGS