Cooling Water Treatment Liberty 01

8/17/2019 Cooling Water Treatment Liberty 01

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COOLING WATERTRAINING PROGRAM


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Agenda

Basic Types of Cooling Systems

Fundamentals of Cooling WaterCooling System Problems

Treatment Programs

Questions


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The purpose of coolingsystems is to transferheat from one substanceto another

The substance that givesup its heat is “cooled”

The substance thatreceives the heat is the“coolant”

THE COOLING PROCESS


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Simple Heat Transfer

Hot Process In

Hot CoolingWater Out

Cooled Process Out

Cold CoolingWater In

BTU's

BTU's

Common Measurement of Heat A BTU is the amount of heat required toraise the temperature of 1 lb. of water 1°F

Heat E !han"ers areused for industrial

pro!ess !oolin"


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Basic T pes !f C!!ling

Water S stems There are three basic types of coolingater systems commonly used in

industry!!!"! #nce Through$! Closed %ecirculating

&! #pen %ecirculating


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ONCE THRO"GH

COOLING WATERS#STEMS


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Once T$r!%g$ S stems

Simplest type of systemWater passes ater through heat

e'changers only one time(ischarged bac) to original source*o recirculation occurs + mineral

content of ater remains unchanged


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Intake

Pu !

"isc#arge

E$%&PLES #otable $ater %&stems #ro!ess $ater 'eneral %er(i!e

CH%R%CTERISTICS A(". Temp. Chan"e) *+1,°F - . +/.0°C Amount of $ater Used) 2ar"e

Heat E c#anger


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, once+through cooling ater system uses largevolumes of ater to achieve the coolingprocess!!!


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-arge volumes of ater used-arge volumes of ater discharged

Water inta)e source typicallysea ater. la)e ater. or river ater(ischarge ater returned to the

same source. but in a di/erentlocation to prevent recycling


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,dvantages-o capital0operating costs1 Pumps234

Water undergoes minimal temperaturechange(isadvantages

-arge volumes of ater re5uired6nvironmental concerns1 ThermalpollutionCost1 6'pensive to treat large volumes


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C!nsiderati!ns6nvironmental7nta)e0(ischarge restrictions

Plants under increased pressure toreduce ater usageSeasonal

Water must meet minimal re5uirements,vailability1 %eliable supply neededQuality1 (egrades during 8dry times9


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CLOSE& RECIRC"LATING

WATER S#STEMS


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, closed recirculating system :closed loop; removes heatfrom a process by using a


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Cl!sed Recirc%lating

S stemsHeating or Cooling

E(ui! ent

Pu !

Cold

E$%&PLES 3iesel En"ine 4a!5ets Automobile 6adiators Chilled $ater %&stems

CH%R%CTERISTICS A(". Temp. Chan"e) 1,+1*°F -/.0+1,°C Amount of $ater Used) 2ow

Heat E c#anger

Hot


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S stemsSituations When Closed -oops are =seful>Critical Processes1 3igh heat ?u'systems(ischarge %estrictions1 @olume0thermalWater Source -imitations1 When ater isnot plentiful

6'tended 65uipment -ife1 6asier tocontrol corrosion in closed systems :e!g!chillers;


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%e!ondar&E !han"er

#ro!essE !han"er

#ump

Ma5eup

T)PIC%LS)STE&


S stems Three Basic Parts of

a Closed -oop!!!

PumpPrimary 3eat6'changerSecondary 3eat6'changer


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S stemsWater temperatures range from &A F +" CD in a chiller system to &EA C

$ FD in a hot ater heating system!*o theoretical ater loss from thesystemWater losses occur from lea)s around

e'pansion tan)s. seals and valves-osses average A!"+A!EG of systemcapacity per day


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S stems HaIor ProblemsCorrosion

Corrosion Product Build+upPlugging1 Small ori


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OPEN RECIRC"LATING

WATER S#STEMS


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#pen recirculating systems are open to theatmosphere at the to er! ,s the ater?o s over the to er. heat pic)ed up by theprocess is released by evaporation! Thecooling ater then returns to the heate'changers to pic) up more heat!


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Open Recirc%lating S stem

&akeu!Water

Pu !

Blo*do*n

E$%&PLES %pra& #onds Coolin" Towers E(aporati(e Condensers

CH%R%CTERISTICS A(". Temp. Chan"e) 7,+8,°F -11.1+10.9°C Amount of $ater Used) Moderate

Heat E c#anger

Cooling To*er


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Heat Transfer Principle

Process In

Cold C#illedWater Out

Process Out

War C#illedWater In

BTU's

:pen re!ir!ulatin" s&stems wor5 on the basisof two prin!iples... HEAT T6A;%FE6

E


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Open Recirc%lating S stems

3eat TransferProcess in hichheat is transferredfrom onesubstance toanother!

6vaporationProcess by hichthe hot cooling

ater releases itsheat to theatmosphere so

that it can returncool ater bac) tothe heate'changers


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Open Recirc%lating

S stemsCooling to er provides t o conditionsthat enhance the evaporation process!!!Brea) ater into tiny droplets. thusproviding more escape routes for atermolecules to evaporate!Fans provide rapid ?o of air through

the to er hich removes evaporatedater molecules and allo s even more

to escape!


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Open Recirc%lating

S stems Three Classi

"! *atural (raft$! Hechanical (raft&! 6vaporative Condensers


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Nat%ral &raft C!!ling

T!'er3ot air rises!!!(ra s cool. dry. outsideair through the ater.

hich enhancesevaporationHoist. arm air naturallyrises up K out of theto erShape causes air to movemore 5uic)ly through thelo er section. here the

ater is ?o ing

Hot %ir + Water ,a!or

C#i ne-

Hot.Water S!ra-s

Hot Water

CoolWater

&akeu!Water

Water Basin +Su!!ort


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H per(!lic Nat%ral &raft

C!!ling T!'er


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Mec$anical &raft T!'ers

=se mechanically operated fans to moveair through the cooling to er>

Forced Draft Towers

Induced Draft Towers


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)!rced &raft T!'ers

Push air throughto er

=se limited tosmaller systemsdue to highhorsepo er

re5uired

"ra/tEli inator

Hot %ir

Hot Water In

Solid Sides

&akeu!Water

CooledWater Basin Cooled

Water

0ans


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Ind%ced &raft T!'ers

Pull air through to erClassi


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E*ap!rati*e C!ndenser

, cooling to er that combines aclosed recirculating cooling system

ith an open recirculating one7nstead of having the recirculating

ater open to atmosphere at theto er. the ater is carried inside ofcooling coils


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E*ap!rati*e C!ndensers

VaporIn

Liquidout

Water Makeup

Condenser Coil

Water Distribution System

0an%ir Inlet

Pu !

%ir "isc#arge

%ir "isc#arge

0an

Pu !

%ir 0lo*

CondensingCoil

Eli inator

BleedTu2e

Blo*.T#roug# T-!e "ra*.T#roug# T-!e


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C!!ling T!'er C!mp!nents

BasinCold Well

(rift6liminators-ouversCellsFillSpray *oLLles

Hot %ir + ,a!or

"ri/tEli inators

Cross0lo*%ir

&akeu!Water

CoolWater

Basin

Lou1ers

%ir

HotWater

In

0an


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C!!ling T!'er C!mp!nents

TOWER BASIN: ,rea under the cooling to er here CWis collected and held until it is pumped bac) to thee'changers!COLD WELL: (eeper part of to er basin here the

screens K pumps are installed to circulate the ater!DRIFT ELIMINATORS: %emoves entrained ater dropletsfrom the air leaving the to er! The moisture laden air isforced to change direction and ater droplets are removed!LOUVERS: Sloping boards on the outside of the to ers

here air enters! Prevent ater spray from leaving theto er!CELLS: Cooling to ers are divided by partitions thatseparate it into distinct sections! 6ach cell has its o n fansystem!


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T!'er )ill

7ncreases contactbet een air K ater

Brea)s ater intosmall drops or a


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T!'er )ill

Splash+Type Fill1Bars made of ood or plastic are used tobrea) ater into droplets

Film+Type Fill1Plastic. ood or metal pac)ing thatdivide inlet ater into thin


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Control ,al1e

Water Inlet Ori/ices "eck

Water "e!t# Cera icNo33le

"eck

Water "istri2utor

Header StructuralSu!!orts

S!ra-No33les

Laterals

Spra N!++lesInlet Water &istri(%ti!nS stem

Pressuri3ed s!ra- #eaders

%preads hot water uniforml& a!ross the top of the tower

To*er deck *it# gra1it-distri2ution t#roug# #oles


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W$ "se Water f!r

C!!ling,PlentifulN %eadily ,vailableN Cheap6asily 3andled1 Pumpable

Can carry large amounts of heat(oes not e'pand0contract much atnormally encountered temperatures

(oes not decompose


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W$ "se Water f!r

C!!ling,Speci


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W$ Isn-t Water Perfect

f!r C!!ling,(issolves everything it touches1HetalN earthN stone

=ni5ue dissolving ability has earnedater the title!!!


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Preci!itationRain

,egetation4E1a!oration5

Soil Ponds and Lakes

Ri1ers

R u n o / /

&oist %ir to Continent

H dr!l!gic C cle

> 6ain falls to earth

> Be!omes "round water > Enters ponds? la5es? ri(ers? o!eans> E(aporates ba!5 into air > 6ain a"ain


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Water c!ntains . t pes !f

imp%rities

&INER%LS

%IR

E%RTH

Calciu&agnesiu

Sodiu

Iron

O -genCar2on

&ono ideCar2on

"io ide

Cla-Silt

Sand

465 "issol1ed Solids 475 "issol1ed Gases 485 Sus!ended &atter

6A=; $ater in purest natural form


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T'! S!%rces !f Water

Surface Water

-o in dissolved solids3igh in suspended solids

Quality changes 5uic)ly ith seasons K eatherround Water

3igh in dissolved solids-o in suspended solids

3igh in iron K manganese-o in o'ygen. may contain sul


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Imp!rtant Pr!perties !f

Water"! Conductivity

$! 3ardness&! ,l)alinity

! p3


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Pure"istilled

Water

"istilledWater *it#

Salt

C!nd%cti*it

Heasure of ater9sability to conductelectricityPure ater ill notconduct an electricalcurrent

,s minerals accumulate.conductivity increases

;A @

;A @

C2+

C2+


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C!nd%cti*it

Proportional toamount of dissolvedsolids in the ater

=sed to measure T(SHicrosiemens:us0cm;Calcium. magnesium.al)alinity. silica.

sodium Conductivity Corrosion0ScalePotential

(id you )no The oceans alonecontain enough

dissolved matter to buryall of the land on earthunder ""$ feet &metersD of mineraldeposits


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Hardness

,mount of Calcium K Hagnesium present3ardness reacts ith other minerals suchas carbonate al)alinity. phosphate. Ksulfate

Tendency to come out of solution K formhard deposits in heat e'changersCa0Hg inversely soluble ith temperaturePotential for hardness deposition a/ectedby al)alinity levels


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Al/alinit

Carbonate K Bicarbonate 7ons%eact ith hardness to form scale:e!g! Calcium Carbonate;Hust maintain ithin speci


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pH

%CI"IC B%SIC

H-drogen Ions Increase

6 7 9 : ; < = > 6? 66 67 68 698

Measure of h&dro"en ions present in water...H@ ions ++ pHH@ ions ++ pH

!H SC%LE


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C!ncentrati!n !f

&iss!l*ed S!lids#nly pure ater can evaporate*o dissolved solids leave theli5uid ater7f there are no other aterlosses from the system. theevaporation process causes anincrease in the concentrationof dissolved solids in therecirculating cooling ater!

;

6

87

:9

ConstantE1a!oration


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C!ncentrati!n !f

&iss!l*ed S!lidsHineral scale ill form if thedissolved solids concentration in thecooling ater becomes too highSupersaturation


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Impact !f Bl!'d!'n !n

C!ncentrati!n Rati! Blo do n1(eliberate

discharge ofater to preventthe dissolvedsolids fromgetting to high

;

6

87

:9

Constant E1a!oration

;

87

:9

Constant E1a!oration

6

Wit#@eroBlo*do*n

Wit#ContinuousBlo*do*n&aintaining9 C-cles


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Ma/e%p Water

,mount of aterre5uired toreplace aterlost byevaporation andblo do n

E(aporation

Ma5eup

Blowdown

&akeu! AE1a!oration

Blo*do*n


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H!lding Time Inde0

,mount of timere5uired for theconcentration of any

ion to reach one+halfof it9s originalconcentration7mportant for proper

selection K dosingof treatmentchemicals

T A ;? #ours


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W$at is Range 1Appr!ac$


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CT is Range 1 Appr!ac$

%ange is temperature bet een theater inlet K e'it states

,pproach is the di/erence intemperature bet een the cold atertemperature K entering air et bulbtemperature


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IMPORTANT COOLING TOWERCALC"LATION


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E2APORATION RATE

6%% O :%ecirculation %ate T "! ; 0"AAA

6%% O ++++++++++++++++++m&0hr


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C cles !f C!ncentrati!ns

C#C O :Chosen ater ion

concentration in B!(; 0 : Chosenater ion concentration in H!=;

B!( O Blo do n aterH!= O Ha)e =p ater


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MA3E "P WATER

CALC"LATION

H!= W,T6% O :6!% C#C; 0 :C#C+ ";+++++++++++ m&03r

6!% O 6vaporation %ateC#C O Cycle of Concentrations


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BlOW&OWN WATER

CALC"LATION

H!= W,T6% O :6!% ; 0 :C#C+ ";+++++++++++ m&03r

6!% O 6vaporation %ateC#C O Cycles of Concentration


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COOLING TOWER E))ICIENC#

CALC"LATIONCT 6FF7C! O: ti+to 0 ti+ t b ; "AA

ti O 7nlet temperature of ater to theto er

to O #utlet temperature of ater fromthe to er

T b O et bulb temperature of air


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E4ERCISE


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CORROSION

&ICROBIO

0 O U L I N

G S C

% L E

C!!ling S stem Pr!(lems

-eft unchec)ed theseproblems cause

-oss of heat transfer

%educed e5uipment life65uipment failures-ost production-ost pro


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MINERAL SCALE


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Mineral Scale

Cooling Water contains manydi/erent minerals ++ normally theseminerals are dissolved in the ater=nder certain conditions mineralscan come out of solution and forminto hard. dense crystals called

SC,-6


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Scaled Heat E c#anger Tu2es

Mineral Scale

Common ScalesCalcium CarbonateHagnesium SilicateCalcium PhosphateCalcium Sulfate7ron #'ide

7ron Phosphate#thers!!!

CaPO9

CaCO8


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Mineral Scale

The Follo ing Factors ,/ectScale Formation!!!

Hineral ConcentrationWater TemperatureWater p3Suspended SolidsWater Flo @elocity


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Temperat%re 1 Scale

Tendenc

Scaling Tendenc-

T e ! e r a

t u r e


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Mineral Scale

Scale forms in hot areas of coolingsystems%educes heat transfer eMciencyHechanical0Chemical cleaning=nder deposit corrosion :pitting;Plant shutdo n65uipment replacement


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Pre*enting Mineral Scale

-imit concentration of scale formingminerals1 Blo do n. clarify0


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Mineral Scale

Three Classi

Crystal Hodi


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:r"anophosphates or"ani! dispersantsdistort the !r&stal stru!ture of s!ale so that it

does not be!ome ti"htl& adherent

Cr stal M!difiers

&inerals do not align ina tig#t atri


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Se5%estrants

Polyphosphates K anionic dispersantsform a comple' ith troublesome

minerals to prevent them from formingscale

Treated Untreated


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&ispersants

Compounds such as polyacrylates arelarge molecules that impart a charge

causing scale forming minerals torepel each other+

#arti!le

+

+

+

+++ +

+

++

+

#arti!le

+

+

+

+++ +

++

+

+


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CORROSION

&efiniti!n


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&efiniti!n

Corrosion is nature's way of returning processedmetals to their native states as chemicalcompounds or minerals.

For example, iron in its natural state is anoxidized compound (i.e., Fe 2 O , FeO, Fe O ! ", #utwhen processed into iron and steel it loses oxygenand #ecomes elemental iron (Fe$". %n the

presence of water and oxygen, nature relentlesslyattac&s steel, reverting the elemental iron (Fe$"

#ac& to an oxide, usually some com#ination ofFe 2 O and Fe O ! .

M!re Tec$nical


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M!re Tec$nical&efiniti!n

1. Definition of corrosion in the context ofCorrosion Science:

the reaction of a solid with its environment.

2. Definition of corrosion in the context ofCorrosion Engineering:

the reaction of an engineering constructional metal(material" with its environment with a conse uentdeterioration in properties of the metal (material".


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C!rr!si!n

Battery ,nalogy,nodeCathode6lectrical CircuitHetal lost atanode

e +

Electrol-te

% n o

d e

C a

t # o

d e

Simplified C!rr!si!n Cell


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Simplified C!rr!si!n Cell

0e 7

C%THO"E

%NO"E

O 7OH +

e +

STEP 6

STEP 7

STEP 8

STEP 9

Water *it#"issol1ed &inerals

Base &etal

O 7

e +e + e +


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)!%r Step C!rr!si!n

M!delStep " 1 ,t the anode. pure iron begins to brea)do n in contact ith the cooling ater! Thisstep leaves behind electrons!Step $ 1 6lectrons travel through the metal to thecathode!Step & 1 ,t the cathode. a chemical reactionoccurs bet een the electrons and o'ygencarried by the cooling ater! This reaction forms

hydro'ide!Step 1 (issolved minerals in the cooling atercomplete the electrochemical circuit bac) to theanode!

) fl


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)act!rs Infl%encing

C!rr!si!np3 Temperature(issolved SolidsSystem (epositsWater @elocity

Hicrobiological Jro th


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6??

6?

?: ; < = > 6?

C o r r o s

i o n

R a

t e D R

e l a t i 1 e

U n

i t s

!H

C!rr!si!n 2s6 pH


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C!rr!si!n 2s6 Temperat%re

Corrosion Rate

T e ! e r a

t u r e

=n "eneral? for e(er& 1*°F in

water temperature? !hemi!alrea!tion rates double.

O $ C % !f


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Ot$er Ca%ses !fC!rr!si!n

(issolved SolidsComplete circuit from cathode to anode

System (eposits,nodic pitting sites develop under deposits

Water @elocity Too lo O deposits

Too high O 6rosionHicrobiological Jro th

(epositsN Produce corrosive by+products

T !f C! ! i!


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T pes !f C!rr!si!n

All cooling system metallurgy experiences somedegree of corrosion. The objective is to

control the corrosion well enough to maximizethe life expectancy of the system...

"! Jeneral Corrosion$! -ocaliLed Pitting Corrosion&! Jalvanic Corrosion

G l C! ! i!


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Base &etal

General Etc# Uni/or %ttack

Water : r i " i n a l

T h i ! 5 n e s s

General C!rr!si!n

Preferredsituation

Ta)e a smallamount of metalevenlythroughout the

system,node very large

Pitti C! ! i!


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Base &etal

Locali3ed Pitting %ttack

Water : r i " i n a l

T h i ! 5 n e s s

Pitting C!rr!si!n

Hetal removed atsame rate but froma much smallerarea,node very small#ften occurs underdeposits or ea)

points-eads to rapidmetal failure

G l* i C! ! i!


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Gal*anic C!rr!si!n

#ccurs hen t odi/erent metals arein the same systemHore reactive metal

ill corrode inpresence of lessreactive metalPotential for galvaniccorrosion increases

ith increasingdistance on chart

%cti1e End

Passi1e End

&agnesiuGal1ani3ed Steel&ild SteelCast Iron6=.= Stainless Steel T-!e 8?9 4%cti1e56=.67.8 Stainless T-!e 86; 4%cti1e5Lead Tin&unt3 SteelNickel 4%cti1e5


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Gal*anic C!rr!si!n

" it !f ! ! i!


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"nit !f c!rr!si!n

Hills per year :mp y; " mpy O A!A$E mm 0 year

Aff t !f C! ! i!


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Affects !f C!rr!si!n

(estroys cooling system metalCorrosion product deposits in heat e'changers3eat transfer eMciency is reduced by deposits

-ea)s in e5uipment developProcess side and ater side contaminationoccursWater usage increases

Haintenance and cleaning fre5uency increases65uipment must be repaired and0or repaired=nscheduled shutdo n of plant

M t$!d T! C! t !l


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Met$!ds T! C!ntr!lC!rr!si!n

=se corrosion resistant alloys1 U,dIust :increase; system p31 Scale,pply protective coatings1 7ntegrity=se “sacri


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An!dic C!rr!si!nIn$i(it!rs

Stop corrosion cellby bloc)ing theanodic site

Severe localiLedpitting attac) canoccur at anunprotectedanodic sites ifinsuMcientinhibitor is present

,nodic 7nhibitorsChromates*itrites#rthophosphatesSilicatesHolybdates

Cat$!dic C!rr!si!n


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Cat$!dic C!rr!si!nIn$i(it!rs

Stop corrosion cellby bloc)ing theelectrochemicalreaction at thecathodeCorrosion rate isreduced in direct

proportion to thereduction in the siLeof the cathodic area!

Cathodic 7nhibitorsBicarbonatesPolyphosphatesPolysilicatesVinc

General C!rr!si!n


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General C!rr!si!nIn$i(it!rs

Protect metal by


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FOULING


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F#=-7*J is the accumulation of solid material. other thanscale. in a ay that hampers the operation of e5uipment orcontributes to its deterioration

C!mm!n )!%lants


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C!mm!n )!%lantsS%spended S!lids

Silt. Sand. Hud and 7ron(irt K (ustProcess contaminants. e!g! #ilsCorrosion ProductsHicrobio gro thCarryover :clari


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)act!rs Infl%encing)!%ling

WaterCharacteristicsWater TemperatureWater Flo @elocityHicrobio Jro thCorrosionProcess -ea)s

Affects !f )!%ling


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Affects !f )!%ling

Foulants form deposits in hot and0or lo?o areas of cooling systemsShell+side heat e'changers are the

most vulnerable to fouling(eposits ideal for localiLed pittingcorrosion

Corrosive bacteria thrive under depositsHetal failure results

Ec!n!mic Impact !f


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Ec!n!mic Impact !f)!%ling

(ecreased plant eMciency%eduction in productivityProduction schedule delays7ncreased do ntime for maintenanceCost of e5uipment repair orreplacement

%educed e/ectiveness of chemical inhibitors

)!%ling


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)!%ling

Three -evels #f ,ttac) Can Be6mployed To ,ddress The 6/ects #f

Fouling!!!

"! Prevention$! %eduction&! #ngoing Control

Pre*enting )!%ling


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Pre*enting )!%ling

PreventionJood control of ma)eup clari


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)!%ling

Chemical TreatmentCharge %einforcersWetting ,gents

C$arge Reinf!rcement Mec$anism


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C$arge Reinf!rcement Mec$anism

,nionic polymers increase strength ofcharge already present on suspended solids

eep particles small enough so they do not

settle out

%li"htl& anioni!suspended

parti!le

%uspended %olidwhi!h has adsorbed

hi"hl& anioni!

!hemi!al

Hi"hl& Anioni!Chemi!al

Wetting Agents


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Wetting Agents

SurfactantsPenetratee'istingdepositsWash a ay frommetal surfaces

#arti!le Build+up

$ith $ettin" A"ent


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MICROBIOLOGICALGROWTH

Micr!(i!l!gical Gr!'t$


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Micr!(i!l!gical Gr! t$

Water treatment isabout managingthree fouling

processes!!!CorrosionScale

Hicrobio

The microbial foulingprocess is!!!

The most comple'

The least understood The hardest tomeasure and monitorControlled using the

least desirable. moste'pensive. Kpotentially haLardousproducts



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Micr!(i!l!gical Gr! t$

Three inds #f TroublesomeHicroorganisms 7n Cooling Water!!!

"! Bacteria$! ,lgae&! Fungi

Bacteria


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Bacteria

Bacteria e'tremely small

Compared to ahuman. a bacteriais li)e a grain ofsand to the Sears

To erSiLe allo s many

:millions; to


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Bacteria

There are as manybacteria in "$ oL! ofcooling ater as thereare people living inthe =nited States

There are A.AAAtimes as manybacteria in a EA.AAA

gallon cooling systemas there are people inthe orldX

17o . Coolin" $ater

9?D??? $/,M'A2

Coolin" %&stem

Bacteria


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Bacteria

Types of Bacteria"! Slime Forming$! ,naerobic Corrosive&! 7ron (epositing

! *itrifyingE! (enitrifying

Bacteria


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Bacteria

Sli e 0or ers

Iron "e!ositing%naero2ic

T-!ical Rods

Bacteria


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Bacteria

Produce acidic aste that lo ers p3andcauses corrosion

Produce large volumes of iron depositsthat foulProduce acids from ammonia thatincrease corrosion K lo er p3Form stic)y slime masses that foul Kcause reduced heat transfer

T'! Classificati!ns !f


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T ! Classificati!ns !fBacteriaPlan)tonic1

Free+?oating bacteria in bul) ater

Sessile1Bacteria attached to surfaces#ver YEG of bacteria in a cooling

system are sessile and live in B7#F7-HS

Bi!films


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Bi!films

Contribute to allcooling ater problems=nderdeposit corrosion

Trap silt K debris hichfoul heat e'changersand to er


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FLOW

ThermalFoulant Condu!ti(it&

CaC:8 1.8+1.9Ca%: 1.8Ca#: 1./M"#: 1.8Fe : ide 1.9Biofilm ,.

P P

Commonbiofilms are times moreinsulatin"than CaC:8s!ale

Bi!films

Hore insulating thanmost commonscales

%educe heat transfereMciency7ncrease dP acrossheat e'changers Kreduce ?o3ealth ris)s:legionella;

Algae


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Algae

%e5uire sunlight to groFound on to er dec)s K e'posedareasForm “algae mats”Plug distribution holes on to er dec)sPlug screens0foul e5uipmentConsume o'idantsProvide food for other organisms

)%ngi


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) g

=se carbon inood


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)act!rs Affecting Gr! t$!f Micr!!rganisms

Hicroorganism Sources1 ,ir or Ha)eupater

Cooling systems provide the ideal

environment for microbiological gro th*utrients1 ,mmonia. oil. organiccontaminants

Temperature1 RA+" A F acceptable

p31 !A + Y!A ideal-ocation1 -ight0*o -ight,tmosphere1 ,erobic0,naerobic

C!ntr!lling


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gMicr!(i!l!gical Gr!'t$Water Quality

6liminate organic contaminants :food;*o food O *o bugs

System (esign ConsiderationsClean basin. plastic. cover dec)s

Chemical Treatment ith Biocides



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( g $

Chemical Treatment With Biocides

#'idiLing Biocides*on+o'idiLing BiocidesBiodispersants


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MOLYBDATE-PHOSPHONATEPROGRAM (Moly/Phosphon !"#

M!l 7P$!sp$!nate Pr!gram


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p g

(esigned for system ith corrosive:lo hardness K0or al)alinity; atersHolybdate+based corrosion inhibitorPhosphonate for scale inhibition(ispersant polymer for foulingprotection



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p g

Well suited to aluminum industryWor)s ell in high heat ?u' systems

here heat transfer surfacese'perience high s)in temperaturesProvides protection over a iderange of operating parameters

Calcium1 A+EAA ppmH+,l)alinity up to $.AAA ppm

M!l 7P$!sp$!nate


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pPr!grams

Holybdate or)horse of programSurface active anodic corrosion inhibitor(oes not depend on controlleddepositionPromotes rapid o'idation of metalsurfaces to form a tightly adherent

layer of metal o'idesProtective layer impermeable to otheranions. especially chlorides and sulfates



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p g

Jeneral Control JuidelinesHolybdate1 +" ppm :as Ho# ;Phosphonate1 "+$ ppm :as P# ;Calcium1 A+EAA ppmH+,l)alinity1 EA +$.AAA ppm3T71 "$A 3ours ma'!

Temperature1 "&E+"ZA F ER+Z$ CDConductivity1$.AAA micromhos ma'!

M!l 7P$!sp$!nate


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pPr!gram Benefits7mproved 3eat Transfer

%educed energy costs

%educed Corrosion6'tended e5uipment -ife K reliability

*o impact on 5uenchabilityProduction not negatively impacted


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AL$ALINE/%INCPROGRAM

Al/aline78inc Pr!gram


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g

=ses lo levels of Linc together ithortho phosphate for corrosion controlPolymeric dispersant used forgeneral dispersancy K scale control,ttractive cost performance underhigh stress conditions

Basic program can be customiLed to


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Vinc provides cathodic corrosionprotection#rtho phosphate provides anodiccorrosion protection

The )ey to the success of the al)alineLinc program is the polymer

dispersant



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Polymer (ispersantHaintains Linc K phosphate in solubleform at higher p39s than they ould

under normal circumstances#perating at higher p39s allo programto provide e'cellent corrosionprotection at very lo levels of Linc :["!A ppm;,lso provides scale control



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Jeneral ,pplication %anges(ependent on Calcium K H+,l)alinityCa $AA ppm H+,l)alinity ".EAA ppmCa ".AAA ppm H+,l)alinity &AA ppm



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Jeneral Control JuidelinesVinc :soluble;1 A!E+$!A ppm#rtho P# 1 6'tremely variable

7nsoluble P# 1 "!E ppm or AG of totalP#Calcium1 "E+".AAA ppmH+,l)alinity1 EA +".EAA ppm

3T71 "$A 3ours ma'! Temperature1 " A F R" CD ma'!Conductivity1 .AAA micromhos ma'!


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STABILI%ED PHOSPHATEPROGRAM

Sta(ili+ed P$!sp$ate


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Pr!gram=ses high levels of orthophosphateto provide corrosion protectionPolymeric dispersant providescalcium phosphate stabiliLationSupplemental TolyltriaLole :TT; usedfor yello metal protection



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Pr!gram#perates at near+neutral p33igh levels of ortho phosphate :"A+"R ppm; provide anodic corrosioninhibitionPoly phosphate K calcium comple'provide cathodic corrosion protection

(ispersant polymer for CaP#stabiliLation

P!l mer &ispersant


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ey to program is polymericdispersant7nhibit inorganic scales such ascalcium carbonate K calciumphosphate

eep particles suspended in ater ++

control foulants such as1Hanganese K iron o'idesSuspended solids li)e mud K silt

P!l mer &ispersant


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Hechanism1 Charge %einforcementPolymer adsorbs onto particles Kincreases the \ charge naturallypresent

Treated particles repel each other%educes chances of collision K

agglomerationPrevents formation of deposits



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Pr!gram6'cellent choice hen!!!

%estrictions on use of heavy metalsBul) ater temperature [ "EA F-o ma)e+up calcium K0or H+al)alinity3igh incoming #+P# levels



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Pr!gramJeneral Control Juidelines

Total #+P# 1 Z +"R ppm :Ca dependent;$!A ppm insoluble ma'!

Calcium1 "E +".AAA ppmp31 !Z+Z! :Cadependent;

3T71 Y 3ours ma'! Temperature1 "EA F CD ma'!Conductivity1R.EAA micromhos ma'!



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Pr!gramProperly controlled programs

6'cellent protection againstcorrosion and scaling

Poorly controlled program causesSevere CorrosionScalingFouling


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ALL ORGANICPROGRAM

All Organic Pr!gram


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*on+heavy metal0phosphate program,ll #rganic programs use high p3 Kal)alinity conditions to providecorrosion protection in a scaleforming cooling system environment#rganic scale inhibitors prevent

mineral deposits

All Organic Pr!gram


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,ll organic components ma)e this avery environmentally acceptableprogram

Contains no heavy metals that canbe precipitated :e!g! Linc sul


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#perates under al)aline conditions atp39s bet een Z!E+Y!(esigned for systems here ma)eup

calcium K H+,l)alinity cycle naturally toithin program guidelinesSupplemental acid0caustic feed may bere5uired to maintain proper H+,l)!Haintaining the proper calcium+al)alinity relationship is critical

All Organic Pr!gram


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Jeneral Control JuidelinesCalcium1 ZA+YAA ppmH+,l)alinity1 &AA+EAA ppm

Temperature dependentp31 Z!E+Y!3T71 Z 3ours ma'!

Temperature1 ""A+" A F &+ A CDConductivity1 .EAA micromhos ma'!

All Organic Pr!gram


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Properly controlled programs6'cellent protection againstcorrosion and scaling

Poorly controlled program causesSevere CorrosionScalingFouling


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O&IDI%ING BIOCIDES

O0idi+ing Bi!cides


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Penetrate microorganism9s cell alland burn+up the internals of theorganism

6/ective against all types of bacteria*o microorganism resistant too'idiLers

ill everything given suMcientconcentration levels K contact time

O0idi+ing Bi!cides


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Broad+spectrume/ectivenessma)es o'idiLers

primary biocidein large cooling

ater

applications

#'idiLersJas ChlorineBleach

,cti+BromBC(H3StabiliLed Bromine

O0idi+ing Bi!cides


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Biocide e/ectivenessp3 dependentCl$ 3#Cl K #Cl +

Br 3#Br K #Br +

3#Cl03#Br Biocidal] p3OZ!A3#Cl1 $$G3#Br1 Z&G

Bromine morebiocidal

( O C l o r

( O ) r

$

*$

2$

$

!$

+$

$

-$

$

/$

*$$

! + - / *$ ** *2

p

$

*$

2$

$

!$

+$

$

-$

*$$

O C l 0 o r

O ) r 0

OCl

O)r

$

/$

C$l!rine Ad*antages


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6conomical Traditional technology

C$l!rine &isad*antages


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Slo er )ill at high p3Consumed by ammonia. sul


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3igher biocidal activity at signi


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Bromine is more aggressive to 36(P, chlorine source is needed to generate,CT7+B%#H on site!

(ry products have


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NON-O&IDI%INGBIOCIDES

N!n9O0idi+ing Bi!cides


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#rganic compounds that react ithspeci


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Jenerally not used as the primarybiocide in larger systems due to cost

Typically slug fed at high dosages

#ften used for clean+up orcontingency reasons



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(i/erent microorganisms e'hibitdi/erent levels of resistance tovarious non+o'idiLing biocides

Speci


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*o practical method of directlytesting levels of non+o'idiLingbiocides in CW

#ptimal dosage K applicationfre5uency should be determinedthrough indirect measurement

Hicrobio counts. sessile monitoring.,TP. to'icity testing. biofoulingmonitors


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Cooling Water Treatment Liberty 01

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