HIDAYAT, Demas Ahmad Resha Putra and Kiono, Berkah Fajar Tamtomo and Suedy, Sri Widodo Agung (2026) STUDI PENINGKATAN PERFORMA COOLING TOWER DENGAN PENGGANTIAN TIPE INTERNAL PART FILLER PADA PLANT PETROCHEMICAL. Masters thesis, UNIVERSITAS DIPONEGORO.

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Abstract

Cooling Tower merupakan peralatan utilitas kritis dalam sistem pendingin industri Petrochemical. Kinerja Cooling Tower sangat dipengaruhi oleh karakteristik filler karena menentukan luas kontak, waktu interaksi, dan turbulensi aliran antara air dan udara. Pada unit Cooling Tower di fasilitas Petrochemical yang diteliti, performa menunjukkan gejala underperformance dengan meningkatnya nilai approach dan menurunnya kapasitas pendinginan. Penelitian ini menganalisis peningkatan performa Cooling Tower melalui penggantian filler Cleanflow dengan Cleanflow plus yang memiliki luas permukaan spesifik 140,7 m²/m³ (lebih tinggi 10,8% dari Cleanflow). Metode penelitian menggunakan standar CTI ATC-105 dengan pengukuran data primer dan analisis menggunakan pendekatan neraca panas, perhitungan evaporasi, serta metodologi effectiveness-NTU dan tower capability. Hasil pengujian menunjukkan peningkatan performa signifikan: tower capability meningkat dari rata-rata 89,00% menjadi 94,47%; heat transfer capacity meningkat dari 37,12 MW menjadi 39,60 MW (+6,68%); range temperatur meningkat dari 8,63°C menjadi 9,20°C; dan approach menurun dari 6,87°C menjadi 6,29°C. Analisis NTU menunjukkan peningkatan dari rata-rata 2,341 unit menjadi 2,889 unit (+23,4%), merepresentasikan peningkatan substansial dalam kapasitas perpindahan panas. Effectiveness meningkat dari 71,5% menjadi 75,9% (+6,1%), dan evaporasi meningkat dari 1,21% menjadi 1,29% (+6,6%). Analisis dampak energi menunjukkan trade-off yang signifikan. Penggantian filler menyebabkan peningkatan konsumsi daya fan dari rata-rata 146,19 kW menjadi 149,65 kW, mengakibatkan peningkatan konsumsi energi sebesar 27.700 kWh/tahun atau Rp 42-55 juta per tahun (asumsi tarif listrik Rp 1.500-1.850/kWh). Peningkatan evaporasi juga mengakibatkan kebutuhan makeup water dan energi pengolahan air yang lebih tinggi. Meskipun demikian, keuntungan substansial yang diperoleh adalah peningkatan efektivitas pendinginan yang signifikan, sehingga beban pada sistem chiller, compressor, dan heat exchanger berkurang signifikan. Penghematan energi dari pengurangan beban sistem lain ini lebih besar dari peningkatan konsumsi energi fan. Kesimpulannya, penggunaan filler Cleanflow plus efektif meningkatkan performa Cooling Tower dengan peningkatan signifikan pada tower capability, heat transfer capacity, NTU, dan effectiveness. Meskipun terdapat peningkatan konsumsi energi fan sebesar Rp 42-55 juta per tahun, keuntungan utama berupa peningkatan efisiensi pendinginan yang signifikan dan pengurangan beban sistem utilitas lainnya menghasilkan manfaat operasional keseluruhan yang melebihi biaya tambahan.
Kata kunci: Cooling Tower, filler, Cleanflow plus, number of transfer units (NTU), tower capability, effectiveness, perpindahan panas, efisiensi pendinginan, CTI ATC-105

Cooling towers are critical utility equipment in petrochemical cooling systems. Their performance is strongly influenced by the characteristics of the fill material, which determine contact surface area, interaction time, and airflow turbulence between water and air. In the observed petrochemical facility, the cooling tower exhibited underperformance indicated by increased approach temperature and reduced cooling capacity. This study evaluates performance improvement through replacement of the existing fill with Cleanflow Plus, which provides a higher specific surface area (140.7 m²/m³, approximately 10.8% greater than the original fill).
The study applies CTI ATC-105 standards using primary field measurements and thermal performance analysis, including heat balance, evaporative loss estimation, effectiveness–NTU method, and tower capability assessment. The results indicate significant performance enhancement: tower capability increased from 89.00% to 94.47%, and heat transfer capacity improved from 37.12 MW to 39.60 MW (+6.68%). The cooling range increased from 8.63°C to 9.20°C, while the approach temperature decreased from 6.87°C to 6.29°C.
NTU analysis shows an increase from 2.341 to 2.889 (+23.4%), representing a substantial improvement in heat transfer capability. Effectiveness increased from 71.5% to 75.9% (+6.1%), while evaporative fraction rose from 1.21% to 1.29% (+6.6%). Energy impact analysis reveals a performance trade-off: fan power consumption increased from an average of 146.19 kW to 149.65 kW, resulting in additional energy consumption of approximately 27,700 kWh/year (≈ Rp42–55 million/year). Increased evaporation also leads to higher makeup water demand and water treatment energy.
Despite these trade-offs, the upgrade delivers significant net benefits by improving cooling performance and reducing load on downstream equipment such as chillers, compressors, and heat exchangers. The resulting energy savings from reduced system loads outweigh the increase in fan power consumption. In conclusion, the implementation of Cleanflow Plus fill significantly improves cooling tower performance in terms of tower capability, heat transfer capacity, NTU, and effectiveness. Although there is an increase in fan energy consumption and makeup water requirement, the overall operational benefits exceed the additional costs.
Keywords: Cooling tower, fill, Cleanflow Plus, number of transfer units (NTU), tower capability, effectiveness, heat transfer, cooling efficiency, CTI ATC 105

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