COOLING TOWER PLUME ABATEMENT: INTEGRATION OF FOG HARVESTING MESH TECHNOLOGY

Abstract

The visible plumes emitted by industrial cooling towers not only represent significant water loss but also contribute to environmental pollution and local humidity issues. These plumes can reduce visibility, affect air quality, and cause corrosion and damage to nearby structures, leading to serious operational and environmental challenges. This study investigates the integration of fog harvesting mesh technology into industrial cooling towers as a method for plume abatement and water recovery. In this research, an analytical model was developed to predict water capture efficiency. The analytical model was validated through comparisons with three independent studies on fog harvesting efficiency. The results demonstrated a closely aligned with experimental results, though some discrepancies were observed due to factors such as mesh clogging, droplet coalescence, and dynamic airflow interactions, which were not fully accounted for in the model. The relative error in predictions ranged from a minimum of 7.1% to a maximum of 34.02%, emphasizing the need for further refinements to improve accuracy under real-world operating conditions. Despite these variations, the model remains a valuable predictive tool for optimizing fog harvesting mesh designs, providing insights into key parameters that influence efficiency. Additionally, an innovative dome-shaped fog harvesting mesh design was proposed. The design's efficiency was calculated using the model, resulting in an estimated efficiency of 21.1%. Using MATLAB, the design was further optimized, leading to a predicted water capture efficiency of 31.75%. Moreover, a cost-benefit analysis demonstrated the system's economic viability, with a return on investment (ROI) of 257%, driven by water recovery and reduced maintenance costs. Overall, this research presents an analytical model to predict water capture efficiency, introduces a cost-effective design for plume abatement, and highlights the economic benefits of implementing this innovative approach.