Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Over view
Closed Recirculating Cooling System
In this system:
• Water is reused continuously
• water loss is very low.
• There is also no evaporation loss.
Example :
Chilled water system, Engine Jacket Cooling System.
Process
Air/ C.W. Cooled
Warmed water
Cooled water
water
HOT WATER
COLD WATER
Blowdown
Types of Cooling Towers
Cooling Towers
HEAT EXCHANGER
Side Stream
MAKE UP Filter Process fluid in
WATER
COLD WATER
Blowdown
Cooling water treatment- All about !!!
Scaling Fouling
Corrosion Deposition
Normal Terminology used in
Open recirculating cooling water system
1. Hold up Capacity of the system : (V)
Hold up capacity of the system = water contained in basin
+
sump of cooling tower
+
water contained in piping and equipments.
2. Blowdown : (B)
•Due to evaporation, concentration of Impurities / dissolved solids takes place.
•Part of water is removed from system as a blowdown to control concentration of
impurities / dissolved solids in water.
Blowdown E 4.0
C-1
10F DROP
0
0 1 2 3 4 5 6 7 8 9 10
C = Cycle of Concentration.
Contd.
7. Make-up Water : (M)
This is the water which is to be added to replace the water lost by evaporation, blow down, drift and
leakage.
M=E+B+D+S
Each programme has maximum allowable HTI beyond which chemical lose its effective.
Contd…
9. Approach :
SiO2 Scale
Contd.
Impurity Effect
Mg.-SiO2 Scale
Cathodic Reaction
O2 + 2H2O + 4e- 4OH- (2)
Overall Reaction
O2 Fe2O3 (Rust)
Water / Electrolyte
O2
Fe (OH)3 OH-
Fe ++ H2O
Fe (OH)2
ANODE
ELECTRON FLOW CATHOD
Most Common Types of Corrosion
In Cooling Water Systems.
1. General Type:
Uniform in nature.
Less dangerous
2. Pitting:
Most destructive
Caused by Localized Deposition & Differential Oxygen cells.
4. Galvanised Corrosion :
It is caused due to the presence of Dissimilar metals.
Contd.…
Tube sheet
6. Crevice Corrosion:
7. Erosion Corrosion:
• Normally restricted to copper based alloys.
• High water velocity, High suspended solids, Turbulence accelerates.
Factors Influencing Corrosion
Water Quality
Soft water–More corrosive (LSI– negative)
Hard water– Deposition– under deposit corrosion potential
Chloride– Accelerates corrosion and stress corrosion cracking
pH & M Alkalinity– Affects corrosion/ fouling potential
Suspended solids– Promotes under deposit corrosion
Bacterial Growth – Promotes MIC
Materials of Construction
Dissimilar metals–
Galvanic corrosion
Design Aspects– Vertical Exchanger
Selection of proper
metallurgy
Sacrificial anodes
Coatings
Corrosion inhibitor
programs are most
economical when used
with other means of
prevention
Corrosion inhibitor
The commonly used corrosion inhibitors in an Open Recirculating System are :
Selection criteria
Fe2+ + H PO - FeH PO +
2 4 2 4
Cl-
FePO42H2O
Fe2O3 anode
PIT
Ortho-Phosphate Film Formation
Dissolution of
Metal Ions (Fe2+)
Ionic Migration
Reduction of Ions
and Oxygen
Ca-Fe Phosphate
Complex
3Zn(OH)2 - 2ZnCO3
FePO42H2O Zn (OH)2
280
240
200 pH = 7.5
ppm TDS = 500
3
160
120
80
40
0
60 80 100 120 140 160 180
TEMPERATURE
OF
Water
• High temperatures.
• High hardness of water.
• High pH of cooling water.
• High M-Alkalinity
Types of Indices
Langalier Saturation Index :
L. S. I. = pHa - pHs
Where, pHa = Actual pH of cooling water and pHs = Saturation pH is the function of
the Total solids, Temperature, Calcium & Total alkalinity
When L.S.I. is positive, it denotes scale forming; and When L.I. is negative, it
denotes corrosion tendency of water.
Stability Index [Ryznar Stability Index]
R. S. I. = 2pHs - pHa
Water Tendency :
Index Tendency of water
LSI RSI
•Dispersion:
Change charge of particulates so they repel each other and do not have an
opportunity to agglomerate.
•Threshold Inhibition:
Stabilization of super saturated solution for longer time / Temporary increasing
solubility of Ca / Mg at very low concentration of inhibitor.
Deposition / Fouling
Causes :
1. Corrosion Products carryover.
2. Suspended solids in cooling water.
3. Dead algae in cooling tower.
4. Slime produced by microorganisms in water.
5. Low velocity.
6. Process Contaminants - Ammonia, Oil, Hydrocarbons.
Under Deposit
Corrosion
Microbiological Fouling
The major classes of microorganisms which are associated with recirculating Cooling
System are :
•Bacteria - In Cooling Water.
•Algae - On cooling towers structure / distributing deck.
Sessile:
Bacteria attached to surfaces
Over 95% of bacteria in a cooling
system are sessile and live in
BIOFILMS
Why Microbiological Control ?
• Fouling of Exchangers .
• Less Heat Transfer.
• Under Deposit Corrosion.
• Reduction in plant load.
• Microbiological Induced Corrosion (MIC)
-Pitting.
• Unschedule Shutdown.
• Decrease in Cooling Tower Efficiency.
• Damage of Wooden Parts of Cooling Tower.
Slime acts as a insulator
CaCO3 2.6
CaSO4 2.3
Ca3(PO4)2 2.6
Biofilm 0.6
80
Cl2 + H2O - HOCL + HCL 60
HOCl HOBr
Increases
0
4 5 6 7 8 9 10
pH
HOBr and OBr-
are more toxic to bacteria compared to HOCl, OCl-
At pH = 8.5
HOCl / OCl- = 10 / 90
HOCl + OH- = OCl- + H2O HOBr / OBr- = 60 / 40
• Organic Matters
• Ammonia - forms Chloroamines
• Dead Algae, Slime
• Other Oxidizable Substances
•Bromine
-Effective at high pH
-Effective in ammonia contaminates system compare to chlorine
- HOCl + NaBr = HOBr + NaCl HOBr + OH- = OBr- + H2O
- NH3 + Br = Bromoamines
•Ozone
-pH in sensitive
-Produced at site by electrolysis
Chlorine Dioxide
In-Situ Generation of Chlorine Dioxide
Advantages :
Cl2
Cl2 Cl2 Cl2
ClO2
ClO2
ClO2
ClO2
Non-oxidising Biocides
•Methylene Bis Thiocynate ( MBT )
Very effective against SRB and Nitrifying bacteria. It Hydrolizes above7.5 pH
•Quaternary Ammonium Compounds(QAC)
Tendency to foam. Ineffective in highly oil or organic fouled systems. Effective at high pH.
•Glutaraldehyde ( ALD )
Effective over wide pH range. De-activated by ammonia / amines in water.
•Isothiozoline ( THIO )
pH Insensitive
De-activated by sulphite containing compound.
•Dichlorophene (DICH) EFFECTIVENESS
Good algaecide. Bacteria Fungi Algae
Effective over wide pH range.
E = Excellent
•DBNP G = Good
Works quickly. MBT E S S S = Slight
De-activated by strong reducing QAC E G E M =Moderate
agent. ALD E E M
THIO E G S
•Carbamate (CARB)
DBNP E G S
Effective upto pH 8. DICH S E E
Effective against SRB. CARB E M S
Non-Oxidising Biocide
Covering the top of the distributing deck of the cooling tower will
eliminate the sunlight resulting in a reduction in the formation of algae.
Bio-Dispersant
What is Bio-Dispersant ?
Bio-Dispersants are non-ionic type surface active agents alongwith slime solublizing
compound.
Functions :
When Bio-Dispersant is added alongwith oxidizing or non-oxidising biocide, it :
Control:
• Using of Chlorine Dioxide alongwith Chlorine on continuous basis.
• Addition of Non-oxidising biocide – MBT, Carbamet based.
Significance of maintaining instruments for
Treatment Monitoring:
• Corrosion coupon
1. Corrosion :
• Corrator : On line monitoring
JUNCTION BOX
COLD CONDENSATE OUT
Mains Restart Heater
1/2” TUBE
OUTLET
Actual
Set
Ammeter
Ammeter
HOT CONDENSATE IN
ACRYLIC TUBE
BALL VALVE
SENSOR ( t 1)
INLET
Biofouling Monitor
Performance Limits
Good treatment programs should ensure the following results for the parameters :
1. Corrosion rate of <2 mpy on Carbon Steel and absence of under deposit corrosion.
< 0.2 mpy on copper-alloy