A-Z LITE®

Overall Program Application:

Corrosion Control:

The A-Z LITE® program uses a combination of ortho-phosphate, zinc, and tolyl-
triazole to provide corrosion protection for mild steel and yellow metals (copper
containing alloys). Additional corrosion protection is provided by a phosphonate
(PBTC) which also inhibits calcium carbonate deposition. Application is at
moderately alkaline pH in most cases, the exception being waters with low calcium
(< 100 ppm), where the pH may be near 9.

As in all robust programs, a combination of anodic and cathodic inhibitors are used
in the program. Anodic corrosion inhibition is accomplished by ortho-phosphate
from two possible sources: product feed and make-up water. At the anodic site,
ortho-phosphate can be thought of as a plugging inhibitor by direct reaction with
the soluble iron generated at the corrosion site. All metal loss occurs at the anodic
site with formation of an iron phosphate plug. This film is self limiting because as
less iron is generated from the corrosion process, less phosphate will precipitate.
Because the pH is higher in this program, less corrosion potential exists and
maintaining ortho phosphate levels above 5 ppm soluble will provide adequate
corrosion protection. More detail is shown in the CPP. Local plant conditions may
dictate that higher or lower residuals be maintained to obtain the desired results.

Cathodic corrosion protection is controlled by several mechanisms. With the

infusion of oxygen in water, an electrochemical reaction occurs at the cathode
where hydroxyl ions are formed causing a localized high pH condition. When this
occurs, a zinc hydroxide film forms at the cathode. In addition, a calcium
organophosphate (PBTC) film will form under these alkaline conditions. A
controlled zinc phosphate and calcium phosphate film is the third reaction which
completes the cathodic corrosion inhibition.

With the low levels of zinc (0.5 - 2 ppm) used in this program, protection of yellow
metals cannot be assured when conductivity exceeds 2000 mS/cm. Under these
circumstances, tolyl-triazole (TT) should be applied as part of the program. Even if
there are no yellow metal heat exchangers, brass valves, bearings, or valve trim
could allow copper to solubilize into the water and redeposit on mild steel. This
would cause mild steel pitting by galvanic mechanisms.

Phosphate and zinc residuals are expressed as soluble. This means that the
phosphates and zinc are analyzed after filtration through a 0.45 m filter. In addition
to maintaining proper soluble residuals, splits (the difference between filtered and
unfiltered analyses) should be maintained at less than 1 ppm for optimum results.
Deposition / Fouling Control:

When a cooling water program is operated under alkaline conditions in the

presence of calcium, calcium carbonate can become a potential scalant. To prevent
this from occurring, an effective calcium carbonate inhibitor such as PBTC must
be employed. Polymer dispersants are used in cooling water systems to control two
types of fouling. To insure adequate corrosion protection, adequate levels of zinc
and phosphate must be present in the system. Thus, the solubility products of
calcium phosphate, zinc phosphate, zinc hydroxide, and iron phosphate are
exceeded. By preventing these components from precipitating in the bulk water,
they are kept in the soluble form and available for controlled chemical / physical
reactions at the highly active anodic and cathodic sites at the metal surfaces.
Polymer dispersants keep the very small particles from agglomerating into larger
particles and forming troublesome deposits. Dispersants also keep miscellaneous
small suspended solids present in the system from agglomerating and forming
deposits, especially in low flow areas.

High stress conditions consist of high temperature, high calcium level, high iron
level, long holding time index, and high aluminum level. Since the species
responsible for corrosion protection (zinc hydroxide, zinc phosphate, and calcium
phosphate) encountered in the AZ-Lite program exhibit reverse temperature
solubility, high temperature increases the supersaturation level of these species.
High temperature also increases the kinetic driving force for particle growth and
deposition. High calcium level increase the supersaturation of calcium phosphate.
High iron level, in addition to increasing the supersaturation of iron phosphate,
tends to deactivate polymers by adsorbing on their surfaces. Polymers have a
tendency to deactivate with time so a system with a long holding time index will
tend to put a stress on a polymer. In addition to forming aluminum phosphate,
which is a foulant, aluminum also tends to deactivate polymers in the same

Manner as iron.

A recent advance in polymer technology, the new High Stress Polymer molecule,
allows operation at higher stress levels than was previously possible. With High
Stress Polymer it is now possible to operate systems at the following stress
conditions:

Condition Prism limit High Stress Polymer limit

Temperature ( oF) 135 180

Calcium (ppm as CaCO3 ) 750 1200

Iron (ppm) 2 8
Holding time index (hr) 72 225

Aluminum (ppm) 0.5 2

In some cases, it would be possible to operate above the Prism limits while still
using the Prism dispersant. The High Stress Polymer will give better results at
these conditions. While the High Stress Polymer is superior to regular Prism for
control of calcium, zinc, and iron phosphate based scale, the goal of this program is
not to minimize polymer dosage but to ensure program success. Therefore we do
not suggest a reduction of polymer feed when switching from on polymer to the
other but to maintain the active polymer feed rate consistently.

Determining Program Dosage:

Calcium

The AZ-Lite program is operable over a wide range of calcium levels, from 15 to
1200 ppm (as CaCO3). Guidelines are shown in the accompanying charts. In
general, 4 ppm of polymer active is necessary for satisfactory operation, no matter
how low the calcium is. As calcium and/or alkalinity increase, the amount of
polymer needs to be increased to adequately control the tendency of calcium and
zinc phosphate to precipitate. As calcium levels increase above 750 ppm, Super
Prism should be substituted for Prism. In some cases, it would be possible to
operate above the Prism limits while still using the Prism dispersant. The High
Stress Polymer will give better results at these conditions.

Phosphate

Soluble phosphate levels as a function of calcium and alkalinity are given in the
program guidelines. The goal in the AZ-Lite program is to maintain soluble
phosphate residuals in the range that gives optimal corrosion protection without
contributing to deposit formation. The phosphates should be analyzed on filtered
samples using a 0.45 m filter when possible. Splits (difference between filtered and
unfiltered results) should be maintained at <1 ppm. If splits are greater than this
and the soluble phosphate is in the right range, dispersant feed should be increased.

Zinc

Since very low levels of zinc are being used, it is important to maintain a minimum
of 0.5 ppm of soluble zinc. If the zinc splits (unfiltered minus filtered) are > 1 ppm,
indicating precipitation, the dispersant dose must by increased. Other possible
reasons for low soluble zinc are excessive phosphate, high pH, sulfide leaks, or
other high stress conditions.

Iron
As in any program containing inorganic phosphate, high iron levels from the make
up water or mild steel corrosion will increase the chance of iron phosphate
precipitation. Iron levels up to 2 ppm call for increased polymer dosages (1 ppm
active polymer per ppm iron). Above 2 ppm iron, High Stress Polymer should be
substituted for Prism and an additional 1 ppm active polymer per ppm iron should
be added to the program..

If the iron is from the make up water, iron removal prior to introduction into the
cooling system is the best option to allow optimum program results. If the high
iron levels are from corrosion, higher zinc levels are needed to reduce mild steel
corrosion. Higher than normal blowdown should also be initiated until iron levels
return to normal.

Silica

Silica should be maintained below 180 ppm. The use of Nalco 7304 (silica
stabilizer) is recommended if higher levels are expected in the tower water.
Magnesium silicate may also be a problem in alkaline programs. The CPP will
give the

maximum pH that can be maintained without magnesium silicate precipitation as a

function of temperature, magnesium, and silica concentration.

Holding time index

Long holding time index increases the consumption of polymer and causes some
degradation of inhibitor species. If ortho-phosphate levels are too high (and ortho-
phosphate is not being fed), additional polymer will have to be fed to control
calcium phosphate deposition. A general guideline is to feed an additional 5%
dispersant for each ppm of phosphate above the maximum recommended level in
the CPP. In addition, since the High Stress Polymer dispersant is more stable than
the Prism dispersant, High Stress Polymer should be fed if the holding time index
is greater than 72 hours. It should be possible to treat systems with holding time
indexes up to 225 hours.

Temperature

Temperature is a significant stress factor for any program. While maximum heat
exchanger water exit temperatures of 180 oF (82.2 C) have been tested in the field,
these should be approached with caution and careful monitoring or system
performance. The dispersant doses in the CPP are adequate for temperatures up to
120 oF (48.9 C). Above 120 oF (48.9 C), the dispersant dose should be increased
by 1.67% for each 1 oF (0.56 C) rise in temperature. High Stress Polymer should
be substituted for Prism at temperatures greater than 135 oF (57.2 C). In some
cases, it would be possible to operate above the Prism limits while still using the
Prism dispersant. The High Stress Polymer will give better results at these
conditions.

For low flow, shell side exchangers, a combination of mechanical methods and
increased polymer dosages should be used. Mechanical cleanings like air rumbling
or reverse exchanger flow along with increased polymer levels will increase the
life of the exchanger but will not keep it clean forever.

Velocity

The guidelines for this program have been specified for typical heat exchanger
velocities of 3 ft/sec (0.914 m/s). Lower velocity exchangers can effectively be
treated but an increase in polymer dosage is required. Typically exchangers
operating at 3 ft/sec (0.914 m/s) have a tube wall (skin) temperature of 15-20 oF
(8.33 - 11.11 C) above the exit water temperature. At 1 ft/sec (0.305 m/s), this
differential may increase to as much as 40 oF (22.2 C). In addition, the diffusion of
corrosion inhibitor to the metal surface is not as fast at the lower velocities. This
increases the driving force for corrosion and fouling to occur. Increasing the
polymer level will help offset this problem. At 2 ft/sec (0.61 m/s), the dispersant
feed should be increased by 20 %; at 1 ft/sec (0.305 m/s), the dispersant feed
should be increased by 40 %. At low flow rates additional mechanical aids such as
air rumbling will aid in keeping the system clean. For low flow, shell side
exchangers, a combination of mechanical methods and increased polymer dosages
should be used. Mechanical cleanings like air rumbling or reverse exchanger flow
along with increased polymer levels will increase the life of the exchanger but will
not keep it clean forever.

Conductivity

Increased conductivity will increase the corrosivity of the water. High chloride
levels are worse than high sulfate levels. A combination of both chloride and
sulfate are the most corrosive. Generally, chloride levels about 500 - 750 ppm and
sulfate about 750 - 1000 ppm can be tolerated. Above this range, an increase in the
zinc level should be considered to prevent higher corrosion. Conductivity levels up
to 10,000 mS/cm have been encountered with good control. Above 5,000 mS/cm,
High Stress Polymer should be substituted for Prism dispersant. In some cases, it
would be possible to operate above the Prism limits while still using the Prism
dispersant. The High Stress Polymer will give better results at these conditions.
Zinc levels should be increased by 10-30 %, with a corresponding increase in
dispersant level.

Suspended Solids

Suspended solids will cause dispersant consumption by adsorbing on the polymer

and deactivating it. Typical suspended solids level of 20-40 ppm do not typically
cause a major impact on polymer consumption. Suspended solids level of 50 -75
ppm will increase polymer demand by approximately 10%. Above this level,
polymer dosages should be increased by 1 ppm active for every 10-20 ppm
increase in suspended solids.

It is important to differentiate the measurement of suspended solids by weight or

by turbidity (light scattering). Small particles will have a high turbidity per unit
weight because of their high surface area which scatters light. Large particles

will not scatter as much light. Polymer consumption is strongly a function of

surface area; thus turbidity is generally a better means of determining the potential
effect of suspended solids.

Aluminum

Aluminum is a difficult problem for any cooling water treatment program which
contains phosphate. The most common source is a poorly operated water treatment
plant. While the lower levels of phosphate in this program make this less of a
problem, aluminum phosphate will still form which will cause polymer
deactivation and can be difficult to disperse. If the level of aluminum is above 0.5
ppm, High Stress Polymer should be substituted for Prism, since it is much more
resistant to deactivation by aluminum. Dispersant dose should also be increased by
2 ppm active polymer per ppm of aluminum. An absolute limit of 2 ppm aluminum
should be observed.

Microbiological Control

All cooling water programs require good microbiological control to achieve

satisfactory results. AZ-Lite is no different. It can tolerate free halogen (Cl2 or
Br2) levels of 0.5 to 1.0 ppm, although 0.2 - 0.5 ppm will generally give
satisfactory microbiological control. The program components are tolerant of
typical free halogen levels. The use of chlorine gas, bleach, ActiBrom, or
STABREX are all compatible with this program. This information is provided by
BioManage training. The polymer is also halogen resistant.

Halogen should be fed to a supply header at the back of the basin to allow the
biocide to sweep the basin limiting microbio growth in basin deposits. Make up
water should be used as the drive water. If Tower water is used to drive the
halogenation process, severe degradation of all program actives will occur. This is
true for any program even the "Dianodic Plus" programs from Hercules
BetzDearborn.