COOLING TOWERS

PRADEEP RAWAT

PURPOSE OF COOLING SYSTEM

THE NEED TO REMOVE UNDESIRABLE HEAT IS A COMMON OCCURRENCE IN INDUSTRIES. UNLESS DESIGN TEMP. AND PRESSURE ARE MAINTAINED, MANY PROCESSES AND AIR CONDITIONING SYSTEMS WILL NOT WORK EFFECTIVELY OR EFFICIENTLY. THE PURPOSE OF A COOLING SYSTEM IS TO REMOVE UNDESIRABLE HEAT SO THAT OPTIMUM TEMPS. AND PRESSURES ARE MAINTAINED.

COOLING TOWER FUNDAMENTALS

THE BASIC PRINCIPAL BRINGING ABOUT THE COOLING IN A COOLING TOWER IS THE MECHANISM OF EVAPORATIVE COOLING AND THE EXCHANGE OF SENSIBLE HEAT

EVAPORATIVE COOLING
THE AIR - WATER MIXTURE RELEASES LATENT HEAT OF VAPORISATION ( THE WATER IS EXPOSED TO COOLING AIR STREAMS, EVAPORATES AS THE WATER CHANGES TO VAPOR, THE HEAT IS TAKEN FROM THE WATER THAT REMAINS BY LOWERING ITS TEMP.)

EXCHANGE OF SENSIBLE HEAT

THE SENSIBLE HEAT THAT CHANGES TEMP. IS ALSO RESPONSIBLE FOR PART OF THE COOLING TOWERS OPERATION ( WHEN WATER IS WARMER THAN THE AIR, THE AIR TAKES THE SENSIBLE HEAT OF WATER AND BECOMES HOTTER AND WATER BECOMES COLDER)

COOLING TOWER FUNDAMENTALS

COOLING TAKES PLACE 75 % - DUE TO EVAPORATIVE EFFECT OF THE RELEASE OF LATENT HEAT OF VAPORISATION 25 % - DUE TO SENSIBLE HEAT TRANSFER

COOLING TOWER
A COOLING TOWER IS A SPECIALIZED HEAT EXCHANGER IN WHICH TWO FLUIDS (AIR AND WATER) ARE BROUGHT INTO DIRECT CONTACT WITH EACH OTHER TO AFFECT THE TRANSFER OF HEAT. IGNORING ANY NEGLIGIBLE AMOUNT OF HEAT EXCHANGE THAT MAY OCCUR THROUGH THE WALLS (CASING) OF THE TOWER, THE HEAT GAINED BY AIR MUST EQUAL THE HEAT LOST BY THE WATER.

COOLING TOWER
WITHIN THE AIR STREAM, THE RATE OF HEAT GAIN IS IDENTIFIED BY THE EXPRESSION G(h2-h1) where : G = Mass flow of dry air through the tower -lb/min. h1 = Enthalpy (total heat content) of entering air - Btu/lb of dry h2 = Enthalpy of leaving air - Btu/lb of dry air

COOLING TOWER
WITHIN THE WATER STREAM, THE RATE OF HEAT LOSS IS IDENTIFIED BY THE EXPRESSION L(t1-t2) where : L = Mass flow of water entering the tower -lb/min. t1 = Hot water temp. entering the tower - F t2 = Cold water temp. leaving the tower - F

COOLING TOWER
THIS DERIVES FROM THE FACT THAT A Btu (British thermal unit) IS THE AMOUNT OF HEAT GAIN OR LOSS NECESSARY TO CHANGE THE TEMPERATURE OF 1 POUND OF WATER BY 1F.

COOLING TOWER HEAT LOAD

Hot Water F Temp. Water Flow L lb/min of water LOAD HEAT =L X R LOAD L lb/min of water

Range RF Cold Water F Approach F Wet-Bulb F

EFFECT OF VARIABLES ON COOLING TOWER SIZE

THERE ARE SEVERAL PARAMETERS WHICH WILL AFFECT THE SIZE OF A TOWER IN TERMS OF 1) HEAT LOAD; 2) RANGE; 3) APPROACH; AND 4) WET-BULB TEMPERATURE. IF THREE OF THESE PARAMETERS ARE HELD CONSTANT, CHANGING THE FOURTH WILL AFFECT THE TOWER SIZE AS FOLLOWS :

EFFECT OF VARIABLES ON COOLING TOWER SIZE

TOWER SIZE VARIES DIRECTLY AND LINEARLY WITH HEAD LOAD.
Constants : 7 Range 6 Approach 5 Wet-bulb 4 3 2 1 1 2 3 4 5 6 HEAT LOAD FACTOR 7 TOWER SIZE FACTOR

EFFECT OF VARIABLES ON COOLING TOWER SIZE

TOWER SIZE VARIES INVERSELY WITH RANGE.
1.3 1.2 1.1 1.0 0.9 0.8 0.7 0.6
Constants : Heat Load Approach Wet-bulb

TOWER SIZE FACTOR

60

80

100 120 140 160 Range Variance - %

180 200

EFFECT OF VARIABLES ON COOLING TOWER SIZE

TOWER SIZE VARIES INVERSELY WITH APPROACH.
2.5 TOWER SIZE FACTOR 2.0 1.5 1.0 5 10 15 Approach - % 20 25
Constants : Heat Load Range Wet-bulb

0.05

EFFECT OF VARIABLES ON COOLING TOWER SIZE

TOWER SIZE VARIES INVERSELY WITH WET-BULB TEMP.
2.5 TOWER SIZE FACTOR 2.0 1.5 1.0 55 60 65 Wet - Bulb (F) 70 75
Constants : Heat Load Range Approach

0.05

 WATER IS MOST COMMONLY USED MEDIUM FOR REMOVING UNWANTED HEAT BECAUSE IT IS READILY AVAILABLE EASILY HANDLED CAPABLE OF REMOVING LARGE QUANTITIES OF HEAT COST EFFECTIVELY WATER IS AN EXCELLENT SOLVENT AND CARRIES MANY IMPURITIES WITH IT IN FACT, WATER IS REFERRED TO AS THE * UNIVERSAL SOLVENT * SINCE IT CAN DISSOLVE VITUALLY EVERYTHING IT COMES IN CONTACT WITH

 IT DISSOLVES MATTER IT CONTACTS IN THE AIR ON THE EARTHS SURFACE AS IT PERCOLATES DOWN THROUGH THE EARTHS CRUST NATURAL WATER CONTAIN IMPURITIES IN THE FORM OF DISSOLVED GASES DISSOLVED SOLIDS SUSPENDED SOLIDS BECAUSE OF THIS , MOST NATURAL WATERS ARE EITHER CORROSIVE OR SCALEFORMING

 WHEN LEFT UNTREATED, NATURAL WATERS CAN LEAD TO THE CORROSION OF METAL THE FORMATION OF DEPOSITS THE GROWTH OF HARMFUL MICROORGANISMS THE RESULT IS REDUCED OPERATING EFFICIENCY OF COOLING TOWERS & HEAT EXCHANGERS REDUCED PRODUCTION CAPACITY INCREASED MAINTENANCE COST DOWNTIME LOSSES

COOLING TOWERS ARE DESIGNED TO EVAPORATE WATER BY INTIMATE CONTACT OF WATER WITH AIR. COOLING TOWERS ARE CLASSIFIED BY THE METHOD USED TO 1 AIR FLOW NATURAL DRAFT MECHANICAL DRAFT (INDUCED DRAFT OR FORCED DRAFT) 2 DIRECTION OF AIR FLOW (COUNTER FLOW OR CROSS FLOW RELATIVE TO DOWNWARD FLOW OF WATER)

 NATURAL DRAFT COOLING TOWERS : # AIR FLOW DEPENDS ON THE DIFFERENCE IN DENSITIES BETWEEN THE WARMER AIR INSIDE THE TOWER AND THE EXTERNAL ATMOSPHERE # WIND VELOCITY ALSO AFFECTS THE PERFORMANCE # ARE OF HYPERBOLIC DESIGN # PROVIDE COOLING WITHOUT FAN POWER # MINIMIZE PLUME PROBLEMS AND DRIFT

 MECHANICAL DRAFT COOLING TOWERS : # USE FANS TO MOVE AIR INSTEAD OF DEPENDING ON NATURAL DRAFT OR WIND # INCREASES THE EFFICIENCY OF THE TOWER BY INCREASING THE AIR VELOCITY OVER DROPLETS OF WATER FALLING THROUGH THE TOWER # EVAPORATE MUCH MORE WATER THAN NATURAL DRAFT TOWERS OF THE SAME SIZE

# TWO DESIGNS OF MECHANICAL DRAFT COOLING TOWERS : 1 FORCED DRAFT 2 INDUCED DRAFT FORCED DRAFT COOLING TOWERS : # FANS MOUNTED ON THE SIDE OF THE TOWER FORCE AIR THROUGH THE TOWER PACKING, PRODUCING INTIMATE MIXING OF AIR WITH THE FALLING WATER

INDUCED DRAFT COOLING TOWERS: # ARE EITHER COUNTER FLOW OR CROSS FLOW WITH FANS ON TOP PULLING AIR THROUGH OR HORIZONTALLY ACROSS THE FALLING WATER # AVOID RECIRCULATION OF THE WARM AIR DISCHARGE, WHICH WOULD REDUCE TOWER PERFORMANCE # THE MAIN ADVANTAGE OF A COUNTER FLOW TOWER IS THAT THE COLDEST WATER CONTACTS THE DRIEST AIR, PROVIDING THE MOST EFFICIENT EVAPORATION SEQUENCE.

AIR FLOW DISTRIBUTION

CROSSFLOW : HAVE A FILL CONFIGURATION
THROUGH WHICH AIR FLOWS HORIZONTALLY ACROSS THE DOWNWARD FLOW OF WATER

COUNTERFLOW: THE AIR MOVEMENT IS

VERTICALLY UPWARD THROUGH THE FILL, COUNTER TO THE DOWNWARD FALL OF THE WATER

TYPES OF COOLING SYSTEMS

THREE BASIC TYPES OF COOLING SYSTEMS ARE USED IN INDUSTRY : 1 ONCE - THROUGH SYSTEMS 2 CLOSED RECIRCULATING SYSTEMS 3 OPEN RECIRCULATING SYSTEMS

 ONCE THROUGH SYSTEMS : IN THESE SYSTEMS COOLING WATER IS PASSES FROM ITS SOURCE THROUGH HEAT EXCHANGER EQUIPMENT AND IS THEN DISCHARGED COOLING WATER IS NOT RECYCLED SO PROBLEMS THAT MAY DEVELOP ARE LARGLY DETERMINED BY THE COMPOSITION OF THE WATER SOURCE
HEAT EXCHANGER WATER SOURCE

 CLOSED RECIRCULATING SYSTEMS : A CLOSED SYSTEM IS ACTUALLY TWO INTERRELATED SYSTEMS : A COMPLETELY SEALED RECIRCULATING WATER SYSTEM & A HEAT EXCHANGER WHICH REMOVES HEAT FROM THE SEALED SYSTEM THE SAME WATER IS CONTINUOUSLY RECIRCULATED AND ONLY A MINIMAL AMOUNT IS LOST DUE TO LEAKING PUMP SEALS OR DRAINAGE DUE TO REPAIRS THEREFORE, CLOSED SYSTEMS REQUIRE VERY LITTLE WATER TO MAKE UP

 OPEN RECIRCULATING SYSTEMS (EVAPORATIVE COOLING TOWERS) : MOST UNWANTED INDUSTRIAL HEAT IS REMOVED IN OPEN RECIRCULATING COOLING SYSTEMS COOLING TOWERS PRIMARY PURPOSE IS TO REMOVE HEAT WHILE MINIMIZING WATER CONSUMPTION IN OPEN SYSTEMS, WATER IS COOLED IN TWO WAYS OR HEAT IS TRANSFERRED BY TWO MECHANISMS : SENSIBLE HEAT TRANSFER LATENT HEAT TRANSFER(EVAPORATION)

 SENSIBLE HEAT TRANSFER : IN WHICH HEAT IS TRANSFERRED WITHOUT PHASE CHANGE i.e HEAT IS TRANSFERRED FROM THE WATER TO HEAT EXCHANGER LATENT HEAT TRANSFER : AS WARM WATER COMES IN CONTACT WITH DRY AIR SOME OF THE WATER CONVERTS TO VAPOUR. THIS IS KNOWN AS EVAPORATION WATER IS BROKEN DOWN INTO FINE PARTICLES THROUGH THE USE OF SPRAYS, TRAYS AND CASCADING OVER FILL

 THIS INCREASE THE SURFACE AREA OF THE WATER AND MAKES PROCESS OF EVAPORATION EASIER AND FASTER THE EVAPORATED WATER MIXES AIR AND LATENT HEAT IS GIVEN DURING PHASE CHANGE LATENT HEAT ACCOUNTS FOR 75 % OF THE TOTAL HEAT EXCHANGE. ONLY 25 % IS THE RESULT OF SENSIBLE HEAT TRANSFER AS THE WATER FLOWS THROUGH THE SYSTEM IT PICKS UP HEAT AND RETURNS TO TOWER FOR COOLING AND THE CYCLE IS REPEATED

 IN EACH CYCLE SOME WATER IS EVAPORATED. THE EVAPORATED WATER IS VERY PURE AND THE MINERALS ARE LEFT BEHIND TO CONCENTRATE.

EVAPORATION & DRIFT MAKE-UP

BLOWDOWN

COOLING SYSTEM EQUIPMENT & COMPONENTS

1 2 3 4 5 6 7 8 ELECTRIC MOTOR FAN DISTRIBUTION DECK DISTRIBUTION PIPING MIST ELIMINATORS FILL LOUVERS BASIN

COOLING SYSTEM EQUIPMENT & COMPONENTS

1 ELECTRIC MOTOR : - PROVIDES POWER FOR THE FAN TO PULL AIR THROUGH THE LOUVERS TO MEET THE FALLING WATER DROPLETS. 2 FAN : - PULLS AIR THROUGH THE COOLING TOWER SO THAT MAXIMUM COOLING CAN BE OBTAINED. - UNBLANCED BLADES CAUSE IMPROPER FLOW. EXCESSIVE NOISE OR VIBRATION SHOULD BE CORRECTED IMMEDIATELY.

3 DISTRIBUTION DECK : - DISTRIBUTES COOLING WATER THROUGHOUT THE TOWER SO THAT ENTIRE TOWER IS USED. - DEPOSITS CAN PLUG DECK ORIFICES. IF ONLY A FEW ARE PLUGGED, WATER CHANNELING WILL RESULT. MORE SEVERE PLUGGING WILL CAUSE THE DECK TO OVERFLOW CAUSING THE HOT RETURN WATER TO BYPASS THE TOWER FILL AND RETURN TO THE BASIN WITHOUT COOLING. 4 DISTRIBUTION PIPING : - CARRIES COOLING WATER TO THE DISTRIBUTION DECK, OR SPRAPS WATER

- DIRECTLY OVER THE FILL. - DEPOSITS WILL CLOG NOZZLES AND CAUSE WATER CHANNELING THROUGH THE TOWER. 5 MIST ELIMINATORS : - USED TO MINIMISE THE AMOUNT OF WATER CARRIED AWAY BY WIND AT THE TOP OF THE TOWER . MIST ELIMINATORS LET WATER VAPOUR PASS THROUGH, WHILE TRAPPING WATER DROPLETS WHICH FALL BACK INTO THE TOWER BASIN. - MISSING ELIMINATOR BOARDS WILL RESULT IN EXCESSIVE WINDAGE LOSSES, AND INCREASED MAKEUP WATER AND TREATMENT CHEMICAL DEMAND.

6 FILL : - WOODEN OR PLASTIC SPLASH PLATES OR FILM DESIGNED TO INCREASE THE AMOUNT OF WATER SURFACE EXPOSED TO THE SURROUNDING AIR. - SPLASH FILL BREAKS THE FALLING WATER INTO FINER DROPLETS - FILM TYPE CAUSES WATER TO FILM ALONG IT - BY INCREASING THE AMOUNT OF WATER SURFACE EXPOSED TO THE SURROUNDING AIR , EVAPORATION IS MAXIMISED - FOULED SPLASH PLATES REDUCE THE EFFICIENCY OF WATER DROPLET

- FORMATION, CAUSING LESS SURFACE AREA TO BE EXPOSED AND A SUBSEQUENT LOSS IN COOLING. - DEPOSITS ON PLASTIC FILM WOULD ALSO PREVENT FINE DROPLETS FORMATION. 7 LOUVERS : - PROVIDE CONTROL OF AIR FLOW INTO THE TOWER, AND ARE USUALLY ANGLED TO MINIMISE DRIFT AND LOSSES DUE TO WATER SPLASHING OUTSIDES OF THE TOWER. - SEVERE FOULING ON LOUVERS CAUSES INSUFFICIENT AIR TO ENTER THE TOWER. - MISSING LOUVERS CAUSES EXCESSIVE AIR

- CHANNELING AND REDUCED COOLING 8 BASIN : - COLLECTS WATER THAT HAS PASSED THROUGH THE TOWER AND IS WAITING TO BE RECYCLED THROUGH THE SYSTEM. - EXCESSIVE SLUDGE BUILDUP IS CAUSED BY THE SETTLING THE FOULANTS. - HIGH LEVEL OF SLUDGE WILL CARRY OVER INTO THE SYSTEM AND COULD CAUSE DEPOSITS IN HEAT EXCHANGERS AND OTHER EQUIPMENT.

TERMS ASSOCIATED WITH COOLING TOWER

1 EVAPORATION : * THE PROCESS OF CONVERTING A LIQUID INTO VAPOUR. AS A SUBSTANCE CHANGES FROM LIQUID TO GAS, IT TAKES HEAT ENERGY WITH IT. * APPROXIMATE AMOUNT OF EVAPORATION THAT OCCURS IN A COOLING TOWER CAN BE CALCULATED USING FOLLOWING FORMULA :
E=(f*R* T ) / 1000

* E = ( f * R* T ) / 1000
E = EVAPORATION RATE R = RECIRCULATION RATE OF COOLING WATER T = TEMP. DIFFERENCE BETWEEN HOT & COOL CIRCULATING WATER f = A COORECTION FACTOR FOR EVAPORATION. IT IS THE RATIO OF THE AMOUNT OF HEAT EXCHANGED BY EVAPORATION VERSUS SENSIBLE HEAT TRANSFER, AND IS A FUNCTION OF WET BULB TEMP. AND RELATIVE HUMIDITY. f ( AVERAGE ) f ( IN SUMMER ) f ( IN WINTER ) = 0.75 = 0.85 = 0.65

1000 = APPROXIMATE LATENT HEAT

2 CYCLE OF CONCENTRATION : * CYCLES ARE EXPRESSED AS A RATIO BETWEEN DISSOLVED SOLIDS IN THE COOLING TOWER WATER AND DISSOLVED SOLIDS IN THE SYSTEMS MAKEUP SUPPLY.
MINERAL IN RECIRCULATIG WATER CYCLE = MINERAL IN MAKEUP

3 DRIFT :

* DRIFT OCCURS DUE TO ENTRAINMENT OF WATER DROPLETS IN THE AIR LEAVING THE TOWER.

* DRIFT TYPICALLY RANGES FROM ABOUT 0.3 TO 0.05 % OF RECIRCULATION RATE DEPENDING ON THE TYPE AND EFFICIENCY OF THE COOLING TOWER.

4 BLOW DOWN : * SOME WATER MUST BE CONTINUALLY REMOVED FROM COOLING WATER SYSTEM TO PREVENT EXCESSIVE BUILD UP OF THE DISSOLVED SOLIDS. THIS IS KNOWN AS BLOWDOWN.
Evaporation

* Blowdown =

Cycle of Concentration - 1

Drift Loss

5 MAKE UP : * WATER ADDED TO THE COOLING TOWER TO MAKE UP FOR WATER LOSSES BY DRIFT, EVAPORATION, BLOWDOWN AND LEAKAGE.

* Make-up = Evaporation + Blowdown + Drift

ACT/UCT DETAILS
* COOLING WATER CIRCULATION RATE * HOT WATER TEMP. * COLD WATER TEMP. * DESIGN WET BULB TEMP. * No. OF PUMPS * PUMP CAPACITY * PUMP DISCHARGE PRESS. * FAN CAPACITY * EVAPORATIONRATE(1.74%) * DRIFT LOSS @ 0.1 % = 24000 /12000 M3/ hr = = = = = = = = = 45 DEG. C 35 DEG. C 32 DEG. C 5/3 6000 M3 / hr 5 Kg / cm2 1182960 CFM 418 / 209 M3 / hr 24 / 12 M3 / hr

ACT/UCT DETAILS
* BLEED LOSS AT 6 CYCLES * MAKEUP RATE AT 6 CYCLES * TOTAL HOLD UP VOLUME * CYCLE OF CONCENTRATION * SIDE STREAM FILTRATION ( 2.5 % ) = 59.60 / 29.80 M3 / hr = 501.60 / 250.80 M3 / hr = 14000 / 7400 M3 = 6 = 600 / 300 M3 /hr

QUESTIONAIRE
S.T=32C, R.T=42C,WBT=28C, DBT=35C, R.R=10000M

1 2 3 4 5 6 7 8 9

Calculate heat load Calculate Range Calculate Approach How much is drift loss ? How much is evaporation rate ? How much is side stream filtration ? What is latent heat contribution in a cooling tower ? What is sensible heat contribution in a cooling tower ? Cooling water can be cooled upto which temp.? 10 Write the 4 variables which affects the cooling tower size.

ANSWERS
1 2 3 4 5 6 7 8 9 Heat load = 100 x 10 Kcal/hr Range = 10 C Approach = 4 C Drift loss = 0.1% Evaporation rate =1.74% Side stream filtration =2.5% Latent heat contribution in a cooling tower =75% Sensible heat contribution in a cooling tower =25% Cooling water can be cooled upto =Wet Bulb Temp. 10 Heat Load, Range, Approach, WBT

COOLING TOWER ASSOCIATED PROBLEMS

DUE TO WATERS ABILITY TO DISSOLVE MOST SUBSTANCES TO SOME EXTENT, AND ITS ABILITY TO SUPPORT MICROBIOLOGICAL LIFE, EVERY COOLING WATER SYSTEM IS SUBJECT TO POTENTIAL OPERATIONAL PROBLEMS. ALL PROBLEMS FALL INTO THREE MAIN CATEGORIES : 1 DEPOSIT FORMATION

COOLING TOWER ASSOCIATED PROBLEMS

2 CORROSION 3 BIOLOGICAL DEPOSITION AND CORROSION # DEPOSIT PROBLEMS ARE USUALLY DIVIDED INTO TWO TYPES : FOULING SCALE

COOLING TOWER ASSOCIATED PROBLEMS

FOULING : DUE TO THE PRESENCE OF SUSPENDED SOLIDS IN THE CIRCULATING WATER, IS THE ACCUMULATION OF WATER-SUSPENDED MATERIALS ON HEAT EXCHANGER SURFACES SCALE : IS A DENSE COATING OF PREDOMINANTLY INORGANIC MATERIALS AND RESULTS FROM SUPER SATURATION OF WATER - SOLUBLE MINERALS

CORROSION
CORROSION IS AN ELECTROCHEMICAL PHENOMENON BY WHICH A METAL RETURNS TO ITS NATURAL STATE. BEING AN ELECTROCHEMICAL PROCESS, FOR CORROSION TO OCCUR, A CORROSION CELL CONSISTING OF AN ANODE, A CATHODE AND AN ELECTROLYTE MUST EXIST. AT ANODE, METAL IONS DISSOLVE INTO THE ELECTROLYTE ( WATER ). AS THE METAL IONS GO INTO SOLUTION AT THE

CORROSION
ANODE, ELECTRONS ARE LEFT BEHIND WHICH MIGRATE THROUGH THE METAL TO THE OTHER POINT ( CATHODE ), WHERE THE CATHODIC REACTION TAKES PLACE i.e. THE ELECTRON IS CONSUMED.
Fe ++

CATHODE ANODIC REACTION :

2eFe

ANODE Fe++ + 2 e-

CORROSION
CATHODIC REACTIONS :
1) O2 + 2 H2O + 4e 2) 2H + 2 e 3) O2 + 4H + + 4e 4OH (natural aerated waters) H2 (acidic pH) 2H2O (aerated acidic solutions)

4) Fe +3 + e Fe +2 (acidic, turbulent conditions, iron reducing bacteria) 5) 4H2 + SO4 -2 S -2 + 4H2O ( SRB attack )

CORROSION
CATHODIC REACTIONS :
H2 + 2OH (natural waters) THE HYDROXYL IONS FORMED AT THE CATHODE COMBINE WITH THE FERROUS CATIONS. Fe(OH)2 Fe +2 + 2OH FERROUS HYDROXIDE HAS VERY LOW SOLUBILITY AND PRECIPITATES AS A WHITE FLOC AT THE METAL WATER INTERFACE WHERE IT IS RAPIDLY OXIDISED TO FERRIC HYDROXIDE. FERRIC HYDROXIDE, UNDER COOLING WATER CONDITIONS LOSSES WATER AND PRODUCES THE SO CALLED CORROSION PRODUCT, FERRIC OXIDE. THE NET RESULT OF ALL THIS ACTIVITY IS THE LOSS OF METAL AND OFTEN THE FORMATION OF A DEPOSIT. 6) 2 H2O + 2e -

SOME IMPORTANT FACTORS THAT AFFECT CORROSION

1 pH : * THE RATE OF CORROSION IS DEPENDENT ON THE pH. GENERALLY CORROSION IS MORE SEVERE IN ACIDIC pH AS MOST PROTECTIVE METAL OXIDE FILMS ARE SOLUBLE IN ACIDIC OR SLIGHTLY ALKALINE WATER. 2 OXYGEN AND OTHER DISSOLVED GASES : * OXYGEN DISSOLVED IN THE WATER IS NECESSARY FOR THE CATHODIC REACTION TO TAKE PLACE.

SOME IMPORTANT FACTORS THAT AFFECT CORROSION

# SOME OF THE OTHERS GASES THAT INFLUENCE CORROSION ARE # CO2 : FORMS H2CO3 AND REDUCES THE pH # NH3 : SELECTIVELY CORRODES Cu, PARTICULARLY IN THE PRESENCE OF OXIDISING AGENTS # H2S : (a) LOWERS pH (b) FORMS IRON SULPHIDE WHICH IS CATHODIC TO IRON AND LEADS TO GALVANIC CORROSION # Cl2 : (a) FORMS HOCl + HCl, REDUCES pH

SOME IMPORTANT FACTORS THAT AFFECT CORROSION

(b) RETARDS THE FORMATION OF CERTAIN PROTECTIVE FILMS (C) IN SOME CASES OXIDISES THE CORROSION INHIBITOR FILMS ALREADY FORMED, THIS EXPOSING THE METAL 3 DISSOLVED AND SUSPENDED SOLIDS : # NORMALLY, HIGHER THE DISSOLVED SOLIDS, HIGHER SHOULD BE THE CORROSION DUE TO INCREASED CONDUCTIVITY. # HOWEVER, HARDNESS SALTS AND ALKALINITY RETARD CORROSION BY FORMING CORROSION

SOME IMPORTANT FACTORS THAT AFFECT CORROSION

# INHIBITING FILMS AND THE BENEFIT DUE TO THE PROTECTIVE FILM FORMED DUE TO HIGH HARDNESS GENERALLY OUTWEIGHS THE CORROSION INDUCED BY HIGHER CONDUCTIVITY. # THUS DM WATER IS MORE CORROSIVE THAN SOFT WATER WHICH IN TURN IS MORE CORROSIVE THAN HARD WATER # THE CHLORIDE AND SULPHATE IONS PRESENT IN THE WATER ARE CAPABLE OF PENETRATING PASSIVE FILMS THERBY PROMOTING CORROSION BY SETTING HIGHLY ACTIVE

SOME IMPORTANT FACTORS THAT AFFECT CORROSION

# LOCAL ANODIC SITES. # SUSPENDED SOLIDS INFLUENCE CORROSION BY EROSIVE OR ABRASIVE ACTION. THEY CAN ALSO SETTLE ON METAL SURFACES PRODUCING LOCALISED CORROSION CELLS. 4 MICROBIAL GROWTH : # MICROBIAL GROWTH PROMOTE THE FORMATION OF CORROSION CELLS. # IN ADDITION, THE BY-PRODUCTS OF SOME ORGANISMS ARE CORROSIVE. IRON OXIDISING AND SULPHATE REDUCING BACTERIA ARE PARTICULARLY HARMFUL.

SOME IMPORTANT FACTORS THAT AFFECT CORROSION

5 VELOCITY : # IN HIGH VELOCITY AND TURBULENT WATERS, OXYGEN IS RAPIDLY DISTRIBUTED AND REACHES THE METAL SURFACE. # HIGH VELOCITY ALSO REMOVES PASSIVATING LAYER OF CORROSION INHIBITORS.THE NET RESULT IS INCREASED CORROSION. # HIGH VELOCITY CAN ALSO LEAD TO EROSION OF METAL SURFACE, PROTECTIVE FILMS AND OXIDES # LOW VELOCITY CAN LEAD TO DEPOSITION GIVING RISE TO LOCALISED CORROSION CELLS.

SOME IMPORTANT FACTORS THAT AFFECT CORROSION

6 TEMPERATURE : # AS THE TEMPERATURE INCREASES, THE DIFFUSION OF OXYGEN TO THE METAL SURFACE ALSO INCREASES, PROMOTING CORROSION # ABOVE 70 DEG. C THE LOSS OF DISSOLVED OXYGEN EXCEEDS THE AMOUNT MADE AVAILABLE BY DIFFUSION, AND A DECREASE IN CORROSION RATE OCCURS.

CORROSION INHIBITORS
# A COMPLETE PRODUCT FOR CORROSION INHIBITION MUST ADDRESS BOTH THE ANODIC AND CATHODIC SITES OF ALL SYSTEM METALLURGY. THE FOLLOWING MATERIALS ARE ALL CORROSION INHIBITORS THAT HAVE BEEN USED IN THE INDUSTRY. 1 PHOSPHATE : WHEN ADDED TO THE SYSTEM IN THE PRESENCE OF CALCIUM HARDNESS WILL FORM A CATHODIC INHIBITOR. 2 CHROMATE : WAS THE BEST ANODIC INHIBITOR AVAILABLE. UNFORTUNATELY, DUE TO TOXIC NATURE, ITS USE HAS BEEN BANNED IN COOLING SYSTEMS

CORROSION INHIBITORS
3 ZINC : A CATHODIC INHIBITOR, WHICH PROVIDES EXCELLENT PITTING CORROSION PROTECTION. 4 TRIAZOLES : AN ANODIC INHIBITOR THAT SPECIFICALLY PROTECTS SYSTEM YELLOW METALS. 5 PHOSPHONATES : A CATHODIC INHIBITOR THAT LAYS DOWN A MONOMOLECULAR FILM ON METAL SURFACES. 6 MOLYBDATE : A NON-TOXIC HEAVY METAL THAT IS AN EXCELLENT ANODIC INHIBITOR.

SCALING
# SCALING IS THE PRECIPITATION OF HARD AND ADHERENT SALTS OF WATER SOLUBLE CONSTITUENTS, LIKE CALCIUM AND MAGNESIUM, ON THE METAL SURFACE. # THESE SALTS HAVE VERY POOR THERMAL CONDUCTIVITY AND THEIR CONTROL IS THEREFORE ABSOLUTELY ESSENTIAL FOR PROPER HEAT TRANSFER EFFICIENCY. # SOME OF THE COMMON SCALES ARE : 1 CALCIUM CARBONATE 2 CALCIUM SULPHATE 3 SILICATE SCALES 4 CALCIUM ORTHOPHOSPHATE

SCALING
5 MAGNESIUM SALTS 6 IRON SALTS

FACTORS THAT AFFECT SCALING

1 TEMPERATURE : # THE COMMON SCALANTS FOUND IN COOLING WATER, CaCO3 AND CaSO4, EXHIBIT INVERSE SOLUBILITY i.e. THEIR SOLUBILITY DECREASES WITH INCREASING TEMP. # GENERALLY, THE AMOUNT OF SCALE INCREASES WITH INCREASE IN TEMPERATURE. 2 pH OR ALKALINITY : # THE SOLUBILITY OF CACO3 DECREASES WITH INCREASING pH. ALKALINE pH USUALLY INCREASES THE SCALING POTENTIAL

FACTORS THAT AFFECT SCALING

# HOWEVER, SOME MATERIALS LIKE SILICATES ARE MORE SOLUBLE IN THE ALKALINE RANGE. 3 SULUBILITY : # EACH POTENTIAL SCALANT EXHIBITS A DEFINITE SOLUBILITY LIMIT. ONCE THIS LIMIT IS EXCEEDED, THE SOLUTION GETS SUPERSATURATED AND A PRECIPITATE FORMS LEADING TO SCALING. # IN GENERAL, HIGHER THE LEVEL OF SCALE FORMING DISSOLVED SOLIDS, GREATER THE CHANCES OF SCALE FORMATION.

FOULING
# FOULING IS THE DEPOSITION OF SUSPENDED MATTER, INSOLUBLE IN WATER. THEY CAN BE WATER BORNE OR AIR BORNE. # SOME OF THE COMMON FOULANTS ARE : - DIRT AND SILT - SAND - CORROSION PRODUCTS - NATURAL ORGANICS - MICROBIAL MATTER

FACTORS THAT AFFECT FOULING

1 WATER CHARACTERISTICS : * WATER CONTAINING SUSPENDED MATERIAL WILL CAUSE FAULING. 2 TEMPERATURE : * FOULING TENDENCY INCREASES WITH INCREASING TEMPERATURE. 3 VELOCITY : * FOULING IS GREATER IN AREAS OF LOW VELOCITY WHILE IT IS LESS SEVERE IN AREAS OF HIGH VELOCITY.

FACTORS THAT AFFECT FOULING

4 MICROBIAL GROWTH : * MICROORGANISM CAN DEPOSIT ON ANY SURFACE 5 CORROSION PRODUCTS : * INSOLUBLE CORROSION PRODUCTS MIXES WITH OTHER FOULANTS LIKE DEBRIS * IT ALSO SERVES AS A NUTRIENT FOR IRON BACTERIA , PROMOTING THEIR GROWTH.

SCALING AND FOULING CONTROL

$ SCALING AND FOULING CAN BE CONTROLLED IN A NUMBER OF WAYS : * LIMITING THE CYCLE OF CONCENTRATION * SOFTENING THE MAKEUP WATER * ACID FEED TO MAINTAIN THE pH BETWEEN 6.0 TO 6.8 * TREAT WITH CHEMICAL INHIBITORS. THE ANTISCALANTS COMMONLY USED ARE 1 ORGANOPHOSPHONATES 2 POLYPHOSPHATES 3 LOW MOLECULAR WEIGHT ANIONIC POLYMERS

CONTROL OF MICROBIAL FOULING

1 # # # 2 # # # PHYSICAL CONTROL METHOD : SIDE STREAM FILTRATION COOLING TOWER AIR INTAKE FILTERS ELIMINATION OF SUNLIGHT BY SHADING CHEMICAL CONTROL METHOD : OXIDIZING BIOCIDES NON-OXIDIZING BIOCIDES BIODISPERSANTS

OXIDIZING BIOCIDES
1 2 3 4 5 CHLORINE CHLORINE DIOXIDE BROMINE OZONE HALOGEN DONORS

NON-OXIDIZING BIOCIDES
1 CHLOROPHENOLS 2 QUARTER NARY AMMONIUM COMPOUNDS 3 METHYLENE BIS THIOCYNATE 4 CARBAMATES 5 GLUTARALDEHYDE 6 DICHLOROPHENE 7 ISOTHIAZOLINE

BIODISPERSANTS
# THE EFFECTIVENESS OF BIOCIDES IS ENHANCED BY THE USE OF BIODISPERSANTS.

NALCO CHEMICALS
# # # # # # A-5010 CORROSION INHIBITOR 9ppm N-23210 SCALE DISPERSANT 11ppm N-8549 BIO DISPERSANT 3ppm N-8300 IRON DISPERSANT 6ppm N-1338 CHLORINE ACTIVATOR N-73280 CORROSION & SCALE 6ppm INHIBITOR # A-321 NON-OXIDIZING BIOCIDE # N-8088 NON-OXIDIZING BIOCIDE

FORMULA
CONTINUOUS FEED RATE OF PRODUCT (Kgs/Hr) =
ppm Of product x make-up rate (m/hr) cycle of concentration x 1000

FORMULA
SLUG ADDITION OF PRODUCT (Kgs)
ppm Of product x holdup volume (m) 1000

==

QUESTIONAIRE
S.T=32C, R.T=42C,WBT=28C, DBT=35C, R.R=10000M

1 2 3 4 5 6 7 8 9

Write 3 problems associated with cooling water Write two types of deposit problem Due to corrosion metal returns to which state Corrosion is high in 1)acidic pH 2)alkaline pH Scaling is high in 1)acidic pH 2)alkaline pH Soft water is corrosive than DM water1)more2)less Soft water is corrosive than hard water1)more2)less Fouling is more 1)low velocity area 2)high velocity area Write 3 oxidizing biocides 10 Write 2 methods of controlling microbial fouling

ANSWERS
1 2 3 4 5 6 7 8 9 i) corrosion ii) fouling iii) scaling i) fouling ii) scaling Natural state Acidic pH Alkaline pH Less More Low velocity area Chlorine, Bromine, Ozone, Chlorine di-oxide 10 i) Physical control method ii) Chemical control method

THANKS