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Optimizing the performance of

Cooling System

Chatchawan Boonchoo
Senior Power Plant Chemistry Specialist

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Content

 Evauating the cooling system to determine the materials that


can be affected by water quality
 Evaluating the water quality constituents.
 Evaluating the water treatment options
 Establishing the treatment and operational regime for the
system

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Water Balance In An Open Evaporative Cooling
Water System
Windage Loss (W) Evaporative Loss (E)

Environment:
Health & Safety Recirculating Cooling Water (R)

Heat Exchanger

MAKEUP
(M) Heat Exchanger
Efficiency
Holding Water
Volume (H)

Quality
Availability & Environment:
Cost Chemical
BLOWDOWN
(B)
Discharge
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Terms & Symbols Related To Water Balance In Open
Evaporative Cooling Water Systems

Recirculating Water R, m3/hr total cooling water circulated by pumps per hour
Quantity
Holding Water V, m3 total water volume held in cooling water system including piping
Volume and cooling water tower basin
Evaporative Lossess E, m3/hr water lost by evaporation per hour
Windage Loss W, m3/hr water lost by windage + drift
Blowdown Water B, m3/hr water quantity discharged per hour in order to control
concentration
Make Up Water M, m3/hr water supplied to the cooling system to maintain system water
volume
Temperature Drop T, °C difference of cooling water temperature between the cooling
Through Cooling tower inlet and outlet
Tower
Concentration Factor CF concentration of dissolved solids in circulating water compared
(Cycles of to makeup water
Concentration)
Retention Time TR time required for water to make one trip around the circulating
loop
Holding Time Index, HTI  represents the time required to dilute an added chemical to
or Half Life 50% of its concentration
 time required to concentrate makeup solids by a factor of 2
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 an important factor for establishing effective biofouling, scale
& corrosion control programme
Calculations
Makeup M = E + B + W
Concentration Factor (or cycles of concentration)
CF = [X] Circulating Water
[X] Makeup Water

Evaporative Losses E = Rx T
H
As a rule of thumb
H = Latent heat of water evaporation,
E = 1.4% x R if T = 10°C
E = 0.8% x R if T = 10°F Approx 578 kcal/kg at 40°C

Blowdown B = E ,
(CF -1)

Holding Time Index = 0.693 x V ,


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Or Half Life B+W
Calculation continued/…...
e.g. an open recirculating system has following operating and chemical
parameters.
Calculate evaporative losses, concentration factor, blowdown and makeup.

R = 3,500 m3/hr [Cl] make up water = 250 ppm


T = 9°C [Cl] recirculating water = 750 ppm

ANSWERS
1) Evaporative Losses (E) = R x T = 55 m3/hr
578

2) Concentration Factor (CF) = 3 (from chloride analysis)

3) Blowdown (B) = E = 55 = 27.5 m3/hr


(CF - 1) 2

4) Makeup (M) = E + B = (55 +27.5) = 82.5 m3/hr


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Chemical Consumption Calculation

System Volume
(By adding NaCl and Ciculating when reached steady state(around 2-3 hrs))

SV(Cu.M)=Wt.of NaCl(Gm.)/ ( Cl ion increase(ppm)x1.65*)

*1.65 is converts Cl ion to NaCl

Chemical Consumtion

Continious Feed.
Consump.(Kg./Hr)=ppm.in circulating water x (MU/CC) x (100/%of AI)x(1/1000)

Slug feed (Kg./Time)= ppm.in circulating water x SV. x (100/%of AI)x(1/1000)

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Problems in Cooling Water Systems
Efficiency drop in
heat exchangers

Plugging of
Corrosion heat exchangers Microbiological
(mild steel, (algae, fungi
yellow metal) Leakage from & bacteria)
heat exchangers

Reduction of
materials strength

Increased pump
pressure and reduction
Scale of flow rate
(Calcium carbonate Sludge
calcium phosphate (general deposits)
Acceleration of
Silicates and sulphates)
corrosion

Adsorption and waste


of chemicals

Dirty Appearance

These problems occur most frequently in open evaporative cooling water systems since the
dissolved solids are concentrated in the cooling9 water by evaporation.
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Water Treatment Concerns

Biofouling

Corrosion Products

Corrosion Under-Deposit Corrosion Deposition

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Langelier Saturation Index (LSI)

 A numerical value for the scaling potential of calcium carbonate (CaCO3)


 The equation is a numerical combination of:
 Total dissolved solids
 Temperature
 Calcium hardness
 Alkalinity
 pH
 A positive LSI is scale forming, a negative LSI is corrosive, and zero is perfect
equilibrium

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Langelier Saturation Index (LSI)

 A procedure for calculating LSI in the field

 Langelier Saturation Index (LSI)=Actual pH of Cycled water-pHs


 pHs (pH saturation)= P3-P2
 P3=(log (TDS,mg/l)x0.10)+12.27
 P2=((Highest Expected Temp,F)x0.00912)+P1
 P1=log(Calcium(mg/l. as CacO3)xTotal alkalinity (mg/l. as CaCO3)

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LSI&RI Calculation

CC
1.Estimate water quality MU 3 4 5 6 MU
pH 7.39 8.24 8.45 8.62 8.76 pH=1.35*logM-Alk+5.36 7.943649
EC. 360 1080 1440 1800 2160 ** pH=1.7177*log M-Alk.+4.1333 7.420658
M-Alk. 82 246 328 410 492 pH=1.465*log M-Alk.+4.54 7.343737
T-H 108 324 432 540 648
Ca-H 73 219 292 365 438
Mg-H 43 129 172 215 258
SiO2 10 30 40 50 60
Cl 50 150 200 250 300
SO4 20 60 80 100 120
Temp.(oC) 60 60 60 60 60

P1 3.78 4.73 4.98 5.18 5.33 P1=Log(Ca*T-Alk)ppm.asCaCO3


P2 5.05 6.01 6.26 6.45 6.61 P2=[Temp(oF)*0.00912]+P1
P3 12.51 12.56 12.57 12.58 12.59 P3=[Log TDS*0.1]+12.27
pHs 7.46 6.55 6.31 6.13 5.98 pHs=P3-P2
LSI -0.07 1.69 2.14 2.49 2.78 LSI=pH(act)-pHs
RI 7.52 4.86 4.17 3.64 3.20 RI=2pHs-pH(act)
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Methods of Treatment for High LSI

Acid Feed
 By reducing pH in cooling water, the equation
 LSI = pH ‐ pHs
 means that LSI will be reduced, therefore calcium carbonate scaling
potential is reduced

 Proper dilution of acid is critical to contact all points of the system.


It is important to equip the system with safeguards if acid feed is
lost or inefficient

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Methods of Treatment for High LSI#2

 Organic phosphonates combined with polymers can withstand LSI to +3.0


 Usually safe to maintain LSI at +2.5

 Another method of controlling LSI is softened make‐up, but requires


manhours for regeneration and maintenance

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Cooling Water Treatment

 Objective of a cooling water treatment program:


 Maintain optimum heat transfer in process equipment and heat
exchangers
 Insure equipment reliability and availability
 Minimize operating costs
 Provide predictive treatment recommendations for system operating
changes and tower contamination
 Maintain healthy environment in moist areas around perimeter of tower
 Assure system circulation to keep all areas with fresh flow on a regular
basis

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Cooling Water Treatment(cont.)

 Major concern areas:


 Scale: Formation of insoluble deposits on heat transfer surfaces, usually
hardness salts on the most critical (or hottest) areas
o High potential with high temperatures, high pH, excessive alkalinity, high
dissolved solids, and high hardness
 Corrosion: Loss of metal by reaction with the environment
 Formation at the anode or cathode setting up an “electrical circuit”, or
oxidation of base metal
 Fouling: Microbiological and suspended solids deposition
 Algae, fungi, or bacteria depending upon location in system, can act as
“the glue that holds deposits together”

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Evauating the cooling system
Component Consideration

Material Water quality effect Management Consideration

• Wood N/A Protect from decay or chemical attack

• Mild Steel Susceptible to corrosion from high TDS , SS , • Chemical water treatment minimizes this
Biomass , Scale & heavy metal. potential
• Increased flow rates and periodic
flushing of heat exchangers minimizes
this potentials.

• Galvanized Iron Susceptible to corrosion from high TDS and • Reduce CC.
(Cu & Zn coating) pH level belows 6.5or above 8.5 • Adjust pH with chemical treatment.
• 304-SS • Susceptible to corrosion from chlorides • Chemical water treatment minimizes this
when deposit-formingconditions exit. potential
• Biomass deposits can cause rapid pitting.
• Corrodes at chloride levels of 200 mg/L • Maintaining a positive oxidant level will
when deposit-ferming condition exist. benefit the intergrity of the protective
• Tolerates chlorides levels of 1000 mg./L oxide film on SS and will reduce biomass
on clean surface accumulation.
• Nitrates,which occur in higher levels in
recycled water,are known to reduce SS
corrosion.
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Evaluating the cooling system
Component Consideration

Material Water quality effect Management Consideration


• 316-SS • Similar to 304-SS with higher chloride Similar to 304-SS
tolerances.
• Tolerates chloride levels of 5,000 mg/L
when deposit-forming condition exist.
• Tolerates chlorides levels up to 30,000
mg./L on clean surface
• Copper alloys • Susceptible to corrosion from ammonia • Chemical water treatment can minimizes
and high TDS. this potential
• Ammonia >0.5 mg/L as NH3 can cause • Copper corrosion inhibitors such as TTA
cracking and corrosion and contributes to (Tolytriazole) or BZT(benzotriazole) and
biomass that can cause corrosion to copper BBT (Butylbenzotriazole) reduce but do
alloy under deposits. not totally eliminate cracking. BBT is
• Cu-Ni (90/10 & 70/30) are resistant to most effective
cracking
• Plastics • Keep clean and free of deposits to
prevent clogging.
• Keep plastic film free of biomass
buildup.

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Evaluating the water quality constituents
Impact of water quality parameters on
cooling system

Water Quality Parameters Impact on Cooling water system

Hardness • Contribute to scale.


Ca & Mg • Ca salts exhibit invers solubility which increases precipitation
with water temp.
• Mg is troublesome when Silica levels are also high and can result
in MgSiO2 scale in heat exchanger.
Alkalinity • Alkalinity is an important means of predicting CaCO3 scale
potential.
Silica • Can produce difficult to remove scale deposits.
• Pre-treatment or side stream filtration is often required if silica
leve>150 ppm.as SiO2
TSS • Can enter the system with makeup water and can be generated in
(consists of undissolved material such the system from corrosion and scale byproducts or from
as , silt ,sand , fine clay and vegetation) air/water contact.
• SS can adhere to biofilms and cause under-deposit corrosion.
• TSS can be controlled through pretreatment, sidestream
filtration or through use of deposit control agents.

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Evaluating the water quality constituents
Impact of water quality parameters on
cooling system
Water Quality Parameters Impact on Cooling water system

Ammonia • Promotes biofilm development in the heat exchangers and


cooling tower fill
• Corrosive to copper alloys at concentrations as low as 2.0 ppm.
• Combines with chlorine to form chloramines which can negate
the disinfecting effect of chlorine and some non-oxidizing
biocides such as glutaradehyde.
• Bromine is more cost-effective biocide if ammonia is present.

Phosphate • At concentration of 4.0 mg/L or less and pH is controlled between


7.0 and 7.5 phosphate may provide corrosion protection because
it is an anionic inhibitor.
• At concentration greater than 20 mg/l, combined with calcium
greater than 1,000 mg/l, there is a potential for calcium
phosphate scaling
• Act as nutrient for biofilm.
Chloride • Corrosive to most metal.
• Limit concentration to 300 ppm for SS: up to 1,000 ppm for other
metals.
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Evaluating the water quality constituents
Impact of water quality parameters on
cooling system
Water Quality Parameters Impact on Cooling water system

Iron • Can combine with phosphate to form foulants.


• May deactivate specialized polymers used to inhibit calcium
phosphate scaling.
• Recycled water has concentrations over 0.1 mg/l of iron and
specialized treatment for iron may be required.

Biological Oxygen Demand (BOD) • Reflects the organic content and associated demand for oxidizing
biocide.
Nitrates and Nitrites • Can provide additional mild steel corrosion control at level above
300 mg/l.
• Can contribute to reductions in stainless steel cracking and
pitting erosion
• Nitrates do not attack copper alloys or protect them from
corrosion.
Zinc • Can assist phosphates and nitrates in reducing mild steel
corrosion rates and pitting tendencies
• Levels in cooling water above 0.5 mg/l are benificial, but levels
above 3.0 mg/l can contribute to deposits.

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Evaluating the water quality constituents
Impact of water quality parameters on
cooling system

Water Quality Parameters Impact on Cooling water system

Organics • Acts as fertilizer for micro-organisms.

• Water-soluble cationic polymers can react with some anionic


treatment biocides, as well as some scale and corrosion
inhibitors.
Fluoride • At 10 ppm or more can combine with calcium to cause scale
formation.
Heavy Metals • Copper and Nickel can plate out on steel, causing localized
(e.g.: Cu, Ni,and Pb.) galvanic corrosion that can rapidly penetrate thin steel heat
exchanger tubes.

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Cooling Tower - Water Qualities Parameter

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Evaluating Water Treatment Option
Chemical Treatment for Corrosion Control

 Corrosion
o Electrochemical process
o Metal are oxidized by transferring electrons from anodic site to cathodic site
 Cathodic Inhibitors
o Reduce the amount of cathodic surface available
 Anodic Inhibitors
o Reduce the amount of anodic surface available
 Sometime both types of inhibitors are needed to prevent corrosion
 Mild steel corrosion inhibitor
o Phosphates, Zinc salts, Molybdates, Polysilicates
 Copper alloy corrosion inhibitor
o Organic nitrogen-based compounds(azole)

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Evaluating Water Treatment Option
Chemical Treatment for Deposition Control

 Deposition
o Several type of deposit
o Necessitating different approaches
 Depositional Inhibitor Control
o Solubilizing agent (Threshold effect)
o Crystal modifier
 Dispersants and Surfactants
o Mutual repulsion
o Keeps solids as smaller particles.

 Typical mineral scale inhibitors


o Acid (H2SO4)
o Phosphonates (HEDP, PBTC,etc.)
o Water-Soluble Polymer (AA, AA/AMPS Co-polymer, etc.)

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Precipitation of Scale
Treatment Chemical

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Crystal Formation of Scale
Treatment Chemical

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Completely of Scale Inhibition Mechanism
Treatment Chemical

(1) Threshold Inhibition


(2) Crystal Modification (Distortion)
(3) Dispersion

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Completely of Scale Inhibition Mechanism
Threshold

 กลไกการทางานแบบ Threshold นี้ จะใช้ปริมาณเคมีภณั ฑ์นอ้ ย เพราะจะไม่เข้าทาปฏิกิริยากับตะกรัน


แบบ Stoichiometry แต่จะเป็ นการเข้าไปขัดขวางการรวมตัวของไอออนบวกและลบที่จะจับตัวเป็ น
ตะกรัน ลาดับขัน้ ที่ใช้ดว้ ยกลไกนี้จะเกิดขึ้นก่อนการเป็ น Nuclei

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Completely of Scale Inhibition Mechanism
Crystal Modification

 การทางานด้วยกลไก Crystal Modification หรือ Distortion ด้วยโครงสร้างที่มีหมู่


ฟั งค์ชน่ั ที่เหมาะสมของเคมีภณั ฑ์ โดยการเข้าไปขัดขวางหรือแทรกแซงการเกิดผลึกแบบปกติท่ีมีรปู ทรง
แน่นอน ซึง่ จะเป็ นตะกรันแข็งสามารถเกาะแน่นผิวสัมผัสได้ (Hard Scale) กลายเป็ นตะกรันเบาคล้าย
ฝุ่ นแป้ง (Soft Scale) จึงไม่เกาะติดผิวสัมผัสแน่นเหมือนตะกรันปกติ

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Completely of Scale Inhibition Mechanism
Dispersancy of Crystal

 กลไกนี้ เมื่อเกิดเป็ นผลึกและยังแยกกันอยู่ ( Discrete) และ/หรือผลึกนัน้ มีการขยายตัวโตขึ้น (


Crystal growth) จนถึงระดับมีการรวมตัวเป็ นกลุ่ม Agglomeration) สารเคมีท่ีสามารถ
ทาหน้าที่ Disperse ได้ จะเข้าไปจับที่ ผิวผลึก แต่เนื่องจากสารเคมีกลุ่มนี้มีประจุลบที่โครงสร้าง ทาให้เกิด
การผลักกัน กลุ่มตะกรันดังกล่าวจึงมีการกระจายตัว และแขวนลอยในสารละลายโดยไม่จมตัวสะสมเกาะที่ผวิ
โลหะ ดังนัน้ ด้วยกลไกนี้ สารละลายอาจมีความขุ่นมากกว่าปกติ

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How Polymeric Scale Inhibitor Work

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Kinds of Scale Inhibitor

 Polyphosphate
 Phosphonates
 Aminotrimethylene phosphonate (ATMP).
 (1-hydroxyetylidene) diphosphoric acid (HEDP)
 2-Phosphonobutane-1,2,4-tricarboxylic acid(PBTC)
 Polymer
 Acrylic acid homopolymer,
 Maleic-anhydride coplymer , Polymaleic acid (PMA)
 AA/AMPS Co-Polymer

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Microbiological Growth Control

 Oxidizing Biocides
 Chlorine based
 Not as effective above pH 7.5
 Sodium hypochlorite
• “Bleach” available at 14%
 Calcium hypochlorite powder, rapid dissolving
 Chlorine isocyanurate tablets
• Organic chlorine rapid dissolving tablets
 Chlorine dioxide
• Combination of acid and hypochlorite

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Microbiological Growth Control

 Oxidizing Biocides (cont.)


 Bromine based
 Effective above pH 7.5
 Stabilized bromine
• 14% bromine combined with sodium hypochlorite
 Bromine hydantoin tablets
• Slow dissolving fed via brominator
 Bromine isocyanurate
• Rapid dissolving bromine tablets

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Microbiological Growth Control

 Non-Oxidizing Biocides
 Liquid biocides used to supplement an oxidizing biocide program
 Fed via pumps on 7 day timer
 Acts as a poison to kill bacteria/algae/fungi/mold
 Carbamate ‐ bacteria, sulfate reducers, fungi
 MBT ‐bacteria, sulfate reducers, fungi
 Terbuthylazine ‐ algae
 Isothiazoline ‐ bacteria, sulfate reducers, fungi
 DBNPA ‐ bacteria
 Glutaraldehyde ‐ bacteria, sulfate reducers, fungi
 Thione ‐ bacteria, fungi

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Establishing the treatment and operational regime for the
system
Conditioning Chemical Function Recommended Maximum
Concentration
Organophosphate Control Scale for Steel 20 mg/l as PO4
(phosphonate)
Orthophosphate, Inhibit Corrosion & Control 20 mg/l as PO4
Polyphosphate Scaling
Sodium Silicate Inhibit Corrosion 100 mg/l as SiO2

Aromatic triazole Inhibit Corrosion for Cu Alloy 2-4 mg/l as AI

Non-Oxidizing Biocide such as: Inhibit Biological Control Base on Chemical


Isothiazolone
DBNPA
Quantenary amine

Oxidizing Biocide Inhibit Biological Control Residual 0.5-1 mg./l


-Chlorine
-Bromine

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Question &Answer

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