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Chemical vs.

Non-chemical Cooling Water


Treatments – a Side-by-Side Comparison
KEVIN A. KITZMAN, Alcoa, Alcoa Center, PA and EDWARD F. MAZIARZ, Alcoa, Pittsburgh, PA and BOBBY
PADGETT, Alcoa, Goose Creek, SC
CHARLES D. BLUMENSCHEIN, USFilter, Pittsburgh, PA
ALAN SMITH, Consultant, Pittsburgh, PA

IWC - 03 - 22
KEYWORDS: cooling towers, non-chemical treatment technologies, chemical treatment, scale control, monitoring, micro-
biological control, corrosion control

ABSTRACT: Two non-chemical cooling water treatment technologies, a pulsed power system, and a hydrodynamic
cavitation device, were evaluated against conventional chemical treatment in a detailed six-month study. The comparison
was conducted at Alcoa’s Mt. Holly Works in Goose Creek, SC. Three identical, non-contact, evaporative coolers used to
cool air compressor systems were used as the test sites. The three technologies were installed on the external 600-gpm spray
water loop in these towers. The towers were operated at a range of setpoints representing between 4 – 20 cycles of
concentration. Water quality parameters, corrosion, scaling indices, microbiological (aerobic and anaerobic planktonic and
sessile, Legionella), and aquatic toxicity data/results will be presented for the different operating conditions. Operating cost
comparisons will also be shared. Conclusions and Recommendations will be presented.

serving their air compressor systems, and they were


BACKGROUND interested in evaluating these non-chemical technologies.
With the rising cost of chemical treatment PROJECT OBJECTIVE(S)
additives for cooling water systems, and Alcoa’s
announced goal of reducing water usage and wastewater The objectives of this study were to evaluate the
discharges by 60% by 2008, locations were eager to effectiveness of commercially available
explore alternatives for reducing their water treatment mechanical/electrical treatment devices for controlling
costs and achieving the Company’s conservation goals. corrosion, scale formation, and microbiological growth in
Spurred by the perceived successes of two non-chemical, recirculating cooling water systems, and to substantiate
mechanical/electrical cooling water treatment devices at the following performance claims made by both non-
the Alcoa Corporate Center, and an extrusion plant in chemical treatment suppliers:
Louisiana, other locations were anxious to install their • Eliminates essentially all chemical additives with the
own systems. These devices were reported to associated cost savings
successfully control scaling, corrosion, and • Eliminates most of the employee health, safety, and
microbiological growth in recirculating cooling water environmental issues typically associated with the
systems. Ten more units were installed in 2001, and storage and use of chemicals
approximately the same number installed in 2002. • Reduces water consumption through operation at
These non-chemical devices were being installed at higher cycles of concentration. Blowdown reduced
such a rapid pace, that there was little opportunity to 80% and Makeup by 40% when cycles increase from
gather historical performance data beyond the claims and 2 to 6
testimonials provided by the manufacturers. Because of • Reduces or eliminates the toxicity of blowdown to
the great interest in these technologies corporate-wide and aquatic life in receiving streams
the potential for significant cost savings and • Degrades and removes old scale encrustations and
environmental benefits, it was decided to perform a side- bio-film from wetted pipes and tower surfaces
by-side evaluation of two technologies. These were an • Overall lower operating costs including savings in
electromagnetic pulsed power system (herein after called water and sewer charges, maintenance, chemicals,
PP), and a hydrodynamic cavitation unit (herein after and labor.
called HDC). Both were compared to conventional
chemical treatment.
Mt. Holly Works was selected for the test site
because they had three identical, but segregated (i.e.
separate influent and effluent water lines with no
interconnection between the basins) cooling towers

1
PROJECT APPROACH Molybdate = 2.0 – 5.0 mg/l
A corrosion/scale inhibitor is continuously fed to
A. MT. HOLLY’S COOLING TOWERS. maintain molybdate levels in the desired control range. In
Mt. Holly has three, Baltimore Aircoil (BAC) addition to sodium molybdate and a phosphate compound
Model F1463 – PR evaporative coolers serving their air for mild steel corrosion control, the corrosion inhibitor
compressor system (see Figure 1). A closed internal loop contains a triazole for copper corrosion protection, and an
cools the main air compressors and air dryers. The acrylic polymer for scale control. Chemical treatment
internal loop is comprised of 10 pass cooling coils. Each also includes two non-oxidizing biocides, isothiazolin and
coil is a 1.05 in. external diameter tube with 2 in. spacing glutaraldehyde, on an alternating, batch dosage basis to
between the coils. Hot internal loop water from the maintain microbiological control in the three towers.
combined compressor system is returned and distributed Under this control program the towers normally operate at
across the three segregated, independently functioning, 3 to 5 cycles of concentration with a typical discharge
BAC towers. (blowdown) rate of 3,200 – 6,400 gallons per day.
As part of this investigation the middle tower was
Figure 1. BAC Towers (back)
left on the chemical treatment program while the West
and East towers were converted to the
mechanical/electrical treatment approaches. The
performance of the two non-chemically treated towers
was measured against that of the conventional, chemically
treated middle tower.
Pulsed Power. The pulsed power (PP) system was
installed on the West tower (see Figure 2). The PP
imparts a pulsed, high frequency (100,000 hz)
electromagnetic energy into the circulating water by
inducing varying magnetic fields 60 times per second.
The system is normally sized according to the pipe
diameter of the recirculating cooling water. The coils
operate at a low voltage of less than 45 volts rms1.
Figure 2. 3” PP with Insulated Cyclonic Separator

Water in each 1,200 gallon basin is recirculated to


the top of the tower at 610 gpm, distributed through a
piping manifold, and then sprayed through a series of
nozzles over the closed loop coils. Fans (3) at the base of
each tower, blow air upwards against the falling spray
water. Drift eliminators placed above the pipe manifold
trap water droplets and return them to the tower basin.
This comprises the outer loop cooling circuit, and the
chemical characteristics and microbiological content of
this spray water was the subject of this six-month study.
The towers were installed in 1996, with design
specifications to cool 343 gpm of internal loop water from
116 0F to 90 0F at an 80 0F wet bulb. Each tower has a
design heat load of 4.45 MM BTU/hr. or approximately
297 Tons of cooling. At design conditions of a 26-degree
change in temperature, and 343 gpm flow rate the
estimated evaporation rate of the recirculated water is
approximately 12,800 gpd. Design drift loss is 0.001% or
0.006 gpm (~9.0 gpd). The basins of all three towers The PP supplier prefers to size their units to turn
were flushed and thoroughly cleaned before the test over the system volume once every 15 minutes for good
program began. microbiological control. The initial 110 gpm flow rate
B. TREATMENT ALTERNATIVES. through the 3 in. unit created a 10-minute turnover
Chemical Treatment. Chemical treatment is presently frequency. When a larger 6-inch unit was installed, the
used in the external loop spray water in all three towers. turnover frequency increased to once every 2 minutes.
The following control ranges for the chemical treatment A centrifugal pump draws water from a 3 in. drain
program are maintained: connection on the bottom of the tower, and directs it
pH = 6.5 – 9.0 through the 3 inch PP unit, and then to a cyclonic
Conductivity = 400 – 1,000 umhos separator for solids removal before returning the treated

2
water back to the tower basin. The reason for installing • Corrosion was measured using a rack that contained
the separator was to achieve results that could be slots for five (0.5 in. x 3.0 in.) coupons. A mild steel
compared to the hydrodynamic cavitation system coupon occupied one slot, an aluminum coupon
(discussed next). The hydrodynamic cavitation system another, and a steel electrode used in conjunction
typically is installed with a solids separation device. with a Corrater®3 meter a third. Corrater® readings
Hydrodynamic Cavitation. The hydro-dynamic were taken once per week.
cavitation (HDC) system was installed on the East tower. • Microbiological analysis included a variety of
The HDC unit is based on the principle of controlled techniques to measure planktonic and sessile
hydrodynamic cavitation. Cavitation is the dynamic organisms, both aerobic and anaerobic. Two
process of the formation, growth, and collapse of micro- perforated steel coupons were used to provide a
sized bubbles in a fluid. Studies have shown that when a growth substrate for sessile organisms.
liquid moves fast enough, gas bubbles will form and • Aquatic Toxicity of the tower blowdowns was also
collapse creating a process called cavitation. In turbulent measured during the study.
liquid flows, and notably at high velocity, hydrodynamic D. OPERATING SET POINTS
cavitation will occur2. Before the trial, the three towers were operating
Figure 3. HDC System with Bag Filters and between 3-5 cycles of concentration as determined by
Cyclonic Separator comparing the conductivities of the water in the
recirculating spray loop with that of the makeup water.
The intent of the trial was to operate the three
towers at increasingly higher cycles of concentration to
see how the different treatment technologies would
perform under increasing scale-forming potentials.
Corrosion rates and microbiological control for both
planktonic and sessile organisms were also measured
during these different operating periods. The different
operating settings were controlled by adjusting the
conductivity setpoint on the continuous conductivity
monitor in each tower. When the conductivity of the
recirculating spray water reached the setpoint, the
conductivity controlled blowdown valve would
automatically open and some high conductivity water
would be purged from the tower, and sent to drain. Since
the blowdown setpoint (based on conductivity) was set
the same for all three towers, it was considered an
A 20 gpm unit was sized and selected by the independent variable of this test.
supplier for Mt. Holly. HDC units are sized to treat the Conductivity controllers were initially set at 1,000
entire system volume seven times a day plus an allowance umhos to approximate 5.0 cycles of concentration. The
for makeup water. Based on the size of this tower and following table lists the dates and setpoints for the
expected heat load this would have calculated to a 15 gpm operating periods used during this study.
unit, but the HDC supplier elected to increase to the next
larger size in their product line, a 20 gpm unit, rather than Table 1. Conductivity Setpoints
use their smallest 10 gpm model. Dates Conductivity Intended Cycles
The HDC unit was installed with 2 process loops. 2002 Setpoint (umhos) of Concentration
One circuit draws water from the tower basin through a 3 6/24 – 8/4 1,000 5.0
in. strainer, and pumps it through a cyclonic separator and 8/5 – 8/26 1,250 6.0
then through duplex bag filters before returning it through 8/27 – 9/12 1,650 8.0
a piping manifold into the bottom of the tower basin. The 9/13 – 9/23 2,150 8.0
second process water loop draws water from the tower 9/24 – 12/5 2,7501 10.0
basin through a 2-in. strainer before entering the HDC 12/6 – 12/20 4,0002 16.0
unit. 12/21 2,150 Test over
C. SAMPLING AND MONITORING. Notes:
The following parameters were monitored: 1. The Chemical tower was set back to 2,150 umhos on
• Water meter readings were recorded at least 5 times November 1, due to excessive buildup of suspended
per week and included make-up and blowdown. solids in the recirculating spray water loop.
• Water temperatures were monitored continuously 2. Only the PP and HDC non-chemical towers were
from various points in each tower. operated at 4,000 umhos
• pH and conductivity were measured from makeup
supply, and outer loop spray water from all three
towers on a daily basis.

3
Figure 4. History of Makeup Conductivity

Makeup Conductivity History


Operating Periods (umhos)
Startup 1250 1650 2150 2750 4000
330

310

290
umhos

270

250

230

210

190
7/3 8/2 9/1 10/1 10/31 11/30 12/30

In early September, the conductivity of the makeup water Note that potassium values from the Chemical tower were
increased dramatically as shown in Figure 4 necessitating not used in the calculation on Figure 5 since potassium
an increase in the conductivity setpoints of the three was a component of the chemical additives used in this
towers on September 13, in order to maintain 8.0 cycles tower.
of concentration. The 2,750 umhos operating period The quick and easy method of using the ratio of
lasted the longest - 73 days – as a variety of tests and conductivities was not appropriate for calculating cycles,
observations were made during that time frame. The last particularly as the test program moved into potentially
operating period was used to try to “stress” the non- higher scaling regimes. It was determined that for all of
Chemical towers to see how they would perform under the operating periods starting with 1,250 umhos that
high scaling conditions. cycles based on magnesium, potassium (not including
Chemical tower), sodium, and sulfate were the most
representative of the true operating concentration factors
TECHNICAL RESULTS OR FINDINGS
in the towers.
A. CYCLES OF CONCENTRATION. Note that as the conductivity settings are increased
Cycles initially based on water meter readings were in later operating periods, the cycles determined from the
calculated by dividing the makeup water by the constituent values increase progressively higher than the
blowdown + solids separator purge + drift losses. Only conductivity values. This was taken as an indication that
the PP and HDC towers had solids separators, which calcium carbonate and other compounds were
contributed small daily purges of 26 and 73 gpd precipitating at higher chemical saturation levels, thereby
respectively. Drift losses were calculated as 9 gpd for all lowering conductivity values, and yielding lower than
towers, which was the designed drift loss specified by the actual cycles of concentration determinations. This
manufacturer. While it was initially thought that cycles precipitation might have been via nucleation in the
based on water meter readings would be the most recirculating water as the non-chemical vendors claim, or
accurate, unmeasured leakage and observed drift losses simply scaling on the heat exchangers. Additional
that appeared higher than calculated likely contributed to discussion on scale is provided later in this text. Two
higher values using this method. values are plotted for the Chemical Tower during the
When the conductivity settings were moved to 2,150 umhos operating period. As was mentioned
1,250 umhos during the next operating period, cycles previously, the Chemical Tower was only operated at the
based on magnesium, sodium, sulfate, and potassium 2,750 umhos setpoint for a limited time, and was dropped
concentrations were also calculated and compared against back to 2,150 umhos on November 1.
cycles based on conductivity for each of the operating B. WATER METER READINGS.
periods. These are plotted in Figure 5. The similarity Figure 6 shows the average daily blowdowns for
amongst towers of cycles based on salts verified that this each of the three towers during the various operating
was the best way to measure true cycles during this test. periods. This blowdown includes discharge from the

4
solids separator devices from the non-chemical units. The control during this time period so some anomaly during
only statistical difference (95% confidence) was between startup caused the difference. Similarly there was no
the PP and HDC tower during the startup period. It is not statistical difference in make-up water usage between the
clear why this might have occurred, however it can be three towers.
assumed that the three towers were not completely in
Figure 5. Cycles of Concentration History

Cycles of Concentration
Average of Na, SO4, Mg, K
vs Conductivity
Note: Potassium Cycles were not used for Chem Tower

23.7
25

22.8
Average Cycles of Concentration

20

16.0
15.4
14.9
14.2
15

11.18

10.0
8.7
10
8

7.1
6.9

6.8
6.7

6.7

6.3
6.2
5.8
5.7

0
1250 1650 2150 2750 4000
Operating Periods (umhos)

PP Chem I HDC Chem II Hand Conductivity

Figure 6. Average Daily Blowdowns

Average Daily Blowdown for Three Towers


1,500
1,359

1,600
1,318

1,141

1,400
Average Blowdown

1,066
1,009

1,200
943

883
885

1,000
692
745
(gpd)

716

800
426

600
346

339

400
173

181

200
0
Startup 1250 1650 2150 2750 4000
Conductivity Periods (umhos)

PP Chem HDC

5
C. WATER QUALITY DATA. over 70 NTU. After five weeks of operation at these
In a further attempt to identify any performance elevated cycles (~14), the chemical supplier
differences between the three towers, water samples were recommended reducing the setpoint back to 2,150 umhos
taken an average of twice per week from the makeup so that their chemical treatment program would not be
source as well as the three towers and the following compromised. Within days of returning to this lower
parameters were measured: alkalinity, total dissolved setpoint, the affect of larger volume blowdowns
solids (TDS), total hardness, calcium hardness, and successfully reduced turbidity levels below 20 NTU
turbidity. where they stayed for the remainder of the study. The
The average values for all parameters showed a ambient air scrubbing affect of the cooling towers, and the
steady increase across the operating periods as the cycles close proximity of the three towers to a carbon silo may
of concentration were raised. TDS, total alkalinity, total have exaggerated the high turbidity levels observed in the
hardness, calcium hardness and conductivity were Chemical tower due to lack of side stream filtration on
scrutinized statistically and generally showed no this unit.
difference between all three towers for each operating D. CORROSION CONTROL.
period respectively. A few exceptions are as follows. Weekly Corrater® readings were used to
First, during the 2,750 umhos time frame the alkalinity for supplement the corrosion results determined by weight
the Chemical tower was higher than that of either non- loss of the mild steel coupons. The mild steel coupons
chemical tower. The reason for this is likely due to the were removed and replaced three times at various
scale inhibitors keeping scale forming elements in intervals during the study period. The aluminum coupons
solution for the Chemical tower, while scale or other were only removed once, after 77 days in the rack.
precipitates were forming in the non-chemical towers. Unfortunately, the last set of coupons, steel and
Second, while the turbidity levels track fairly aluminum, were lost in transit and never recovered.
closely across the towers at average values below 10 NTU Figure 7 is a graphical presentation of all of the
over the first two periods, the Chemical tower began to corrosion rate data obtained during the study. The
show some elevated spikes during the 1,650 umhos Chemical tower exhibited excellent control averaging
period. As the conductivity controlled blowdown < 1.3 mils/year over the entire study period based on
volumes continued to decrease with increasing cycles, the Corrater® readings. The rate exhibited a gradual decline
adverse affect of not having a sidestream solids separator from approximately 1.3 mils/year at the start of the study
became more pronounced in the Chemical tower. Finally to < 0.8 mils/year during the final month. This
at the 2,750 umhos control point while both non-chemical extraordinary rate was partly attributable to the fact that
towers were still operating below 10 NTU, the Chemical the chemical supplier did not adjust the feed rate of their
tower recorded spikes above 120 NTU with an average

Figure 7. Corrater Corrosion History

6
corrosion inhibitor for most of the study. Thus as E. SCALE CONTROL.
blowdown volumes decreased, the concentration of Precipitated solids form both soft and hard scale
corrosion inhibitor increased. While the stated control deposits on the heat transfer surfaces, which increases the
range was 3-5 mg/l of molybdate, they ranged from 3.0 – resistance to heat transfer, thereby decreasing the thermal
18.5 mg/l concentration with an average of 8.5 mg/l. efficiency of the equipment. One of the claims of the
Corrater® readings for the two non-chemical non-chemical water treatment manufacturers is that their
towers also exhibited an overall decrease over the study devices prevent the formation of scale on heat transfer
period, although the decline was not as consistent. Initial surfaces, allowing the dissolved solids (calcium
readings were at the 3.7 to 3.6 mils/year for the PP and carbonate) to be precipitated in the bulk water, and then
HDC towers respectively, and they dropped to 1.4 and 1.9 purged from the systems via blowdown or in sidestream
mils/year respectively at the conclusion of the study. solids removal devices. To be effective from the
However, the HDC tower spiked to almost 5.0 mils/year standpoint of corrosion control, and in some cases
for two weeks midway through the study. The overall microbiological control too, non-chemical cooling water
decrease in corrosion rates could be attributed to either or treatment systems must operate in an alkaline pH range,
both of two mechanisms: 1) further passivation from which encourages scale formation.
operation in moderate to severe calcium carbonate scaling A convenient place to start when evaluating scale
regimes over the course of the study, and 2) cycling up of is a scaling index. For purposes of this paper, only the
the ortho-phosphate levels in the makeup water which Practical Scaling Index (PSI4) will be discussed, although
acted as a passivating anodic inhibitor and provided both the Langelier and Ryznar indices were also
another measure of corrosion protection. Corrosion rates calculated and produced similar results as the PSI.
between 1 - 3.0 mils/year for mild steel are considered The PSI showed steady movement into
very good control. Excellent control is < 1.0 mils/year. increasingly severe scaling regimes until about the third
Corrosion coupon results are also shown on the Figure 7. week in October or approximately midway through the
These results are summarized below on Table 2. 2,750 umhos operating period. At this time a change in
direction toward lower scaling conditions is noted (see
Table 2 – Corrosion Coupon Results Figure 8). This shift could be somewhat explainable for
PP Chem HDC the Chemical tower, because that operating setpoint was
Mild steel 1.84 0.72 0.83 reduced back to 2,150 umhos on November 1st due to
@ 28 days high turbidity resulting from reduced blowdown rates as
Mild steel 1.50 0.22 1.71 described above. Lower operating cycles of concentration
@ 72 days created by this shift, should translate into lower scaling
Note: All results in mils/year indices, but it initially was puzzling why the two non-
chemical towers followed the same pattern.
Figure 8. Practical Scaling Index

7
A possible explanation may be found by looking at carbonate was being formed and remained in the
the alkalinity and calcium hardness levels, which both recirculating water where it would be measured by the
took a dramatic downward turn at the same time. These test for calcium, but not measured in the standard titration
variables are believed to have precipitated the changes in test for alkalinity. The alkalinity test most likely did not
the PSI. Figures 9 and 10 plot the history of alkalinity dissolve all of the calcium carbonate in the recirculating
and calcium hardness levels in the three towers over the water, thus resulting in a lower alkalinity measurement.
study period. The significance of this finding is that it has been
Alkalinity levels in the makeup water remain fairly hypothesized that certain non-chemical treatment devices
steady at 60 mg/l from the middle of September until accelerate the coagulation-flocculation of solid particles
dropping to 50 mg/l after December 5th. Makeup calcium suspended in water, and increase the crystal formation in
hardness peaks on October 24, at 73 mg/l and then begins the bulk solution instead of deposition as scale on heat-
a steady drop to 44 mg/l by the end of the study. These transfer surfaces. 5
changes in the make-up water, particularly for calcium F. TEMPERATURE OBSERVATIONS.
hardness, could partially account for the observed drop in Cooling efficiency is presented in Figure 11, which
their respective concentrations in the tower spray water. plots the Return (to tower) minus the Supply (to process)
Another possible explanation for the drop in these values water temperatures for the study period. This differential
for the spray water in the two non-chemical towers was is a good measure of the cooling efficiency of each tower.
the fact that the treatment devices were turned OFF from All three towers delivered 17-21 degrees of cooling until
November 6 – 21 to determine what, if any, influence late in October when the PP tower started to have a drop-
they were having on the water chemistry in those two off in efficiency. Water supplied back to the compressors
towers. Without any “treatment” from the non-chemical from the PP tower was 3 to 9 degrees warmer compared
devices, and with the recirculating spray water at to the HDC tower, while the Chemical tower remained in
saturation levels for calcium carbonate as determined by the middle of the pack at 2 to 4 degrees warmer than the
the scaling indices, its possible that calcium carbonate HDC tower. In an attempt to correct what we interpreted
may have precipitated from the bulk water onto heat as an indication of scale formation on the heat exchange
transfer surfaces. This is evidenced by a reduction in tubing in the PP tower, a larger (6 inch) PP unit was
carbonate and alkalinity as shown in Figures 9 and 10 installed on the Spray Water loop on November 26.
during the period when the non-chemical devices were Nothing else was done to clean the tubes at that time. The
shut OFF. When the non-chemical devices were turned temperature differential for the PP tower began to
back ON, their respective “treatments” kept the calcium improve, even when the operating setpoint was increased
carbonate in solution and the levels of alkalinity and to 4,000 umhos. Water temperature monitoring was
calcium hardness began to increase slightly again for the continued after the test program was concluded, and a
PP and HDC towers. However when the towers were noticeable although somewhat erratic improvement for
increased to the 4,000 umhos operating mode, the calcium the PP tower continued. This could be construed that the
levels increased substantially while the alkalinity levels larger, greater powered PP unit removed some of the
remained steady (Figure 9). This indicates that calcium previously formed scale on the heat exchange surfaces.
Figure 9. Alkalinity History

8
Figure 10. Calcium Hardness History

Figure 11. Return – Supply Water Temperature Differential

9
The HDC tower consistently had the best cooling Figure 14. Chemical Tower – Scale on Sidewall
performance across the entire study, and their differential
increased to 20 – 22 degrees during the last six weeks.
G. SCALE OBSERVATIONS.
After the test program was completed, the towers
were opened to observe the presence of any scale
accumulation. Both the PP and HDC towers appear to
have more tube scale than the Chemical tower, perhaps an
indication that the scale inhibitor in the chemical
treatment program was performing as intended.
Alternatively this could be due to the fact that the non-
chemical towers were operated in severe scaling regimes
for longer time periods. However, close scrutiny of the
sidewall scale shows distinctive differences between the
three towers. The sidewall scale in both the PP and HDC
towers had a sparkling, crystalline appearance compared
to the dull, flat white scale in the Chemical tower. See
figures 12, 13, and 14.
Mt. Holly Maintenance cleaned the towers shortly
Figure 12. PP Tower – Scale in Sidewall. after the test, and an effort was made to qualify the
cleaning procedures required to remove the scale in the
three towers. The entire top layer and some of the bottom
layer of “sparkling – crystalline” scale in the PP and HDC
towers were removable by water under “garden hose”
pressure. However, there were some spots of tenacious
scale that required “water blast” pressure for removal and
not all scale was accessible for removal. The Chemical
tower didn’t have as much scale, but it was more difficult
to remove and required water blasting. The smaller
amount of scale in this tower was expected, due to both
the scale inhibitor included in the chemical treatment
additive, and the fact that this tower did not operate at the
length and severity of the scaling regimes selected for the
PP and HDC towers. No acid cleaning was done on any
of the towers, and according to plant maintenance staff,
some scale had been present on the heat exchanger tubes
and sidewalls of all three towers before the study began
(although all three towers where cleaned and flushed prior
Figure 13. HDC Tower – Scale on Sidewall to the study).
Samples of scale were obtained from both of the
non-chemical towers and analyzed by X-ray diffraction
(XRD) at the Alcoa Technical Center. The results show
that the majority of scale was calcite, which is a typical
form of calcium carbonate in cooling water. Calcite is
characterized by its crystal formation rather than chemical
composition. There was a significant amount of carbon in
the sample, which was confirmed visually by its blackish-
gray color. It’s possible that carbon was part of the
particulate that was “trapped” in the scale matrix.
H. MICROBIOLOGICAL CONTROL.
Cooling water systems, particularly open
recirculating systems, provide a favorable environment
for the growth of microorganisms. Microbial growth on
wetted surfaces leads to the formation of biofilms. If
uncontrolled, such films cause biofouling, which can
adversely affect equipment performance (i.e. increased
pump pressures, heat transfer problems, etc.), promote
metal corrosion (i.e. microbial induced corrosion or MIC),
accelerate wood deterioration, and cause pathogen

10
concerns (e.g. Legionella). There have also been cooling loop coil pack to encourage sessile growth. The
increasing federal and state regulatory restrictions coupons were routinely removed, after approximately
regarding chemical use in cooling towers, aimed at four weeks of exposure to the flowing spray water and
reducing the aquatic toxicity of effluent discharges to shipped to an independent laboratory. Upon receipt by
receiving waters. This has made microbiological control the laboratory, both sides of the coupon were swabbed
in cooling towers more difficult, and encouraged searches and the swabs returned to the buffer solution used for
for alternatives to current treatment methods. shipment. A vortex mixer was used to remove the
As was mentioned earlier, the PP and HDC organisms from the swabs. This “inoculated” solution was
technologies claim different mechanisms for controlling then tested using Standard Methods procedure for
microbiological growth. Both technologies were Heterotrophic Plate Count. The results were expressed as
compared against a conventional chemical approach CFU/cm2. The sessile samples were also analyzed for
involving alternating two non-oxidizing biocides - sulfate-reducing bacteria with their presence reported as a
isothiazolin and glutaraldehyde. simple Positive or Negative result.
Analytical Methods. There are a variety of Planktonic Results. Figure 15 provides a graphic
techniques available for measuring microbiological summary of the planktonic aerobic results for all three
activity in cooling towers. For this investigation the bulk towers over the course of the study.
recirculating spray water was analyzed for aerobic free The chemical supplier was alternating two non-
floating or planktonic organisms by an FDA approved oxidizing biocides (isothiazolin and glutaraldehyde) each
procedure (FDA Bacteriological Analytical Manual, 8th week. Note that both non-chemical towers were able to
Ed. Chapter 3) which utilizes "Standard Plate Count control aerobic planktonic organisms with PP averaging
Agar," with a 48 hr. incubation period @ 35C. Anaerobic approximately 65,000 CFU/ml and HDC averaging
planktonic bacteria were also measured using Standard approximately 95,500 CFU/ml. Plate counts < 100,000
Methods “Standard Plate Count Agar” with a 48 hr. CFU/ml are considered good control. In contrast the
incubation period in an anaerobic environment, @ 35C. Chemical tower suffered through swings in aerobic
All results were reported in colony forming units per counts, ranging from a low of 7 CFU/ml to a high of
milliliter (CFU/ ml). Planktonic samples were generally 8,000,000 CFU/ml. The average count for the Chemical
taken every two weeks. tower was approximately 1,270,000 CFU/ml. The type
Attached, slime forming, or sessile organisms and dosage of chemical biocides is also recorded on
colonize wetted surfaces and are primarily responsible for Figure 15. The chemical supplier applied some extremely
biofouling. While some information was available on the high dosages (>1,200 mg/l) in an effort to get the tower
effectiveness of non-chemical treatment devices against under control, but the correlation of plate counts with
planktonic organisms, very little information had been biocide doses was mixed. Generally, one would expect to
collected on their ability to control sessile organisms. see lower counts shortly after biocide addition. However,
Perforated steel coupons were included in the coupon isothiazolin is a slow acting product,
racks and one additional coupon was hung inside the
Figure 15. Planktonic Counts – Aerobic History

Planktonic - Aerobic
8,000,000
3,000,000 1400

2,500,000 1200
Biocide Dosage (mg/L)

1000
2,000,000
CFU/ml

800
1,500,000
600
1,000,000
400

500,000 200

0 0
8/2 8/22 9/11 10/1 10/21 11/10 11/30 12/20

PP Chem
HDC Biosperse
Isothiazolin250 - Isothiazolin
Biosperse 254 - Glutaraldehyde
Glutaraldehyde

11
and a significant bacterium kill usually required 16-20 Table 3 - Average Turbidity and Planktonic Values
hours of contact. Glutaraldehyde is a faster acting @ 2,750 umhos Operating Setpoint
product, and will provide a significant reduction in the
bacteria population within 2-6 hours. So sampling time Tower Turbidity Planktonic
relative to specific microbiocide addition has a significant (NTU) Aerobes
impact on the measured results. It is important to (CFU/ml)
alternate non-oxidizing biocides as the organisms can PP 10.7 70,000
develop immunity to a single product over time. Chemical 71.1 2,600,000
Note that all of these results were cultured from HDC 14.7 80,000
unfiltered samples, which put the Chemical tower at
somewhat of a disadvantage, because their higher With conditions in the Chemical tower steadily
turbidity levels due to lack of a sidestream solids removal worsening, the decision was made to drop the control
device. These particulates gave bacteria a place to “hide- point back to 2,150 umhos to increase the blowdown rates
out” as neither of the biocides are considered to be and help purge the tower. Conditions showed a steady
effective to penetrate the interstices of the particles. This improvement from that point to the end of the study, but
certainly became more evident as cycles of concentration this experience served to emphasize the importance of a
were increased with a concurrent reduction in blowdown sidestream solids removal device for maintaining tower
rates. Shortly after the operating set point was increased cleanliness.
to 2,750 umhos on September 24, equivalent to Figure 16 shows a similar history for planktonic
approximately 14 cycles in the Chemical tower, turbidity anaerobic results. Once again the non-chemical towers
levels steadily increased to over 100 NTU while provided more consistent control averaging 85 and 87
planktonic counts soared reaching a peak of 8,000,000 CFU/ml respectively for the PP and HDC towers. The
CFU/ml on October 28. The following table compares Chemical tower exhibited wide swings for anaerobes
the average turbidity levels with average planktonic ranging from <1 to 1,200 CFU/ml with an average of 290
counts during the 2,750 umhos operating period for the CFU/ml for the study period.
three towers.

Figure 16. Planktonic Counts – Anaerobic History

12
Sessile Results. The following table summarizes coupons tested positive for SRBs, no indications of MIC
the sessile aerobic results for all three towers over the were observed. Four of the seven coupons were from the
course of the study. All results are presented as colony Chemical tower.
forming units per square centimeter (CFU/cm2). The area Analyses conducted by Ecole Polytechnique for
of the 0.5” x 3.0” perforated, mild steel coupon used to planktonic, heterotrophic organisms indicated that only a
attract sessile growth was 21.8 cm2 (including both sides moderate level of disinfection was occurring across all of
and edges minus perforations). The coupons designated the towers with a significant proportion of the population
as “cold” were located in the coupon racks with the remaining viable/active. This is consistent with PP claims
corrosion coupons through which a sidestream of that their process is more bacteriostatic than bactericidal.
recirculating spray water (~ 5.0 gpm) was sent. The “hot” However, HDC claim of destroying microbial populations
coupons were suspended approximately mid-way in the by high temperature, pressure, and vacuum is not as
cooling coil pack at the top of the tower. These coupons evident 7,8
were difficult to locate, and toward the end of the study, Seven samples taken from each of the three towers
they were subjected to alternating “wet” and “dry” tested for Legionella. None tested positive (> 1.0 CFU/50
conditions as the spray water pumps and fans turned ml.). However, the study protocols were not specifically
“OFF” and “ON” based on temperature settings during designed to determine the efficacy of these chemical and
cold mornings to minimize potential icing problems. non-chemical technologies toward controlling Legionella
These set points were eventually lowered to permit more organisms9.
continuous water flow, but the “hot” coupons were not Algae Control. Although these Baltimore Aircoil
analyzed during this period. Towers were closed on four sides, the exposed moist drift
The results indicate that with only a few eliminators on the top of the tower afforded a perfect
exceptions, the non-chemical devices provided effective haven for algae growth. The non-oxidizing biocides
biofilm control. The HDC system delivered the best added to the Chemical tower and carried in the drift were
results of all three technologies with all of their coupons effective algaecides as indicated by the stark black color
measuring less than 1x 106 CFU/cm2 (Average = 1.9 x of the drift eliminators on top of the Chemical tower. The
105 CFU/cm2) which is an accepted industry standard for PP and HDC towers on the other hand showed patches of
control of slime forming organisms6. The PP system green algae, with the PP showing the most extensive
performed almost as well with only two coupons coverage. Although neither non-chemical supplier claims
measuring over 106 organisms / cm2. However, the last efficacy for algae control, algae growth will require
sample is difficult to explain, as it is two orders of additional maintenance (e.g. physical cleaning or
magnitude higher than another coupon removed from the periodic use of an algaecide).
same rack after an identical four-week exposure period. I. WHOLE EFFLUENT TOXICITY (WET) TESTS.
The average results for the PP tower with and without the As effluent discharge limits become more
last sample were 2.7 x 106 and 5.9 x 105 CFU/cm2 stringent, and facilities strive toward greater water
respectively. By contrast the majority (62%) of the conservation on the way to “zero liquid discharge” the
coupons from the Chemical tower were above the target quality of our cooling tower blowdown waters will play a
1x 106 CFU/cm2 control point with a calculated average = more significant role in attaining “zero non-compliance.”
2.5 x 106 CFU/cm2. One of the anticipated advantages of using non-chemical
All coupons were tested for sulfate reducing cooling water treatments is the elimination of aquatic
bacteria (SRBs). The presence of SRBs is an indication toxicity concerns, and a test program was developed to
of anaerobic conditions, which can promote corrosion of validate this premise.
fouled metal surfaces. As shown in the above table, seven
Table 4 – Summary of Sessile Results
Date PP Chemical HDC
Removed Cold Hot Cold Hot Cold Hot
7/9 9.5x104 1x103 8x104
8/5 2.6x105 4.1x105 1.8x105
4 5**
9/5 8x10 2x10 1.6x104
5 5 6 5
9/23 6.8x10 1.2x10 1x10 9x10 1.6x105 1.5x105
6 6 5**
10/21 2x10 1.1x10 7.5x10
10/28 4.5x105 1.3x104 2.1x106** 1.6x105 1.3x105 7x104
5** 6** 5
11/25 4.5x10 8.1x10 1.4x10
11/25 1.7x107 6.8x106** 8.6x104**
Concentration < 1x106 = Biofilm Control - EFFECTIVE
1x106 < Conc.< 1x107 = Biofilm Control - CONSIDER MODIFICATION for IMPROVEMENT
Concentration > 1x107 = Biofilm Control - IMPROVEMENT REQUIRED
** Sulfate Reducing Bacteria tested positive in these samples

13
Whole effluent toxicity (WET) procedures were Another important aspect of this study, in addition
run using static acute definitive toxicity tests (96 hours for to a performance evaluation of the three technologies, was
Pimephales promelas, and 48 hours for Ceriodaphnia to determine the costs to install, operate, and maintain
dubia) at the following concentrations of blowdown: them. A number of cost categories were established to
6.25%, 12.5%, 25%, 50%, and 100%. With the Chemical provide a basis for comparison. These included:
tower the time of sampling relative to the time of biocide depreciation, supplies, makeup water, blowdown water
application has a great impact on blowdown toxicity. (assuming treatment / surcharge costs), power
Three samples were sent for testing. Two were taken on consumption, R&M materials, labor charges (i.e. O/M,
the same day after biocide addition (isothiazolin), and the supervisory, contracted services, and administrative
last one six days after biocide addition (glutaraldehyde). oversight), and costs to address toxic blowdown. Table 6
The first sampling event was corrupted for the PP tower. below summarizes the results of the net costs (+) or
The results of the last two tests are summarized in Table 5 savings (-) to operate the two non-chemical devices
below. compared to conventional chemical treatment, all at 4
Note that both non-chemical treatment systems cycles of concentration.
were shut down during the last sample taken on A few notes on the tables. Recall that this study
November 19, and had been off since November 6. This involved a 1,600-gallon system. At this size, in this
is not expected to impact the results of blowdown location, neither non-chemical device is competitive with
toxicity. Blowdowns from all three towers exhibited chemical treatment, because the capital costs for the
toxicity to Ceriodaphnia in all three samples. This can be chemical system were fully depreciated. For the
explained by the effect of salinity on freshwater extrapolations starting at a 2,500-gallon system, capital
organisms. The improved survival of Pimephales costs for all three systems are included and depreciated
Promelas (i.e. fathead minnow) from the Chemical tower over a 10-year period. All costs for the extrapolation
is evident on the last test. This is due to taking the sample were based on this study except that capital costs were
6-days after biocide addition, compared to taking the based on vendor input. Installation costs were
sample right after addition on October 28th. A value of extrapolated from the cost of the Mt. Holly system based
>100.0 means that all organisms survived at all blowdown on six-tenths rule applied to the ratio of model sizes (e.g.
concentrations. square of diameters for PP and flow rates for HDC).
J. OPERATING AND MAINTENANCE COST Comparison was made for oxidizing and non-oxidizing
COMPARISONS. biocides in order to capture costs or savings based on this

Table 5 – Summary of Toxicity Test


% of blowdown corresponding to 50% mortality (LC50)
October 28, 2002 November 19, 2002
2,750 umhos 2,750 2,150 2,750
umhos umhos umhos
PP Chemical HDC PP Chemical HDC
Pimephales Promelas >100.0 70.8 >100.0 >100.0 >100.0 >100.0
(96 hour LC 50)
Ceriodaphnia 36.6 11.3 35.4 29.0 9.5 21.0
Dubia
(48 hour LC50)
Table 6 – Cost Comparison at 4 Cycles of Concentration
Chemical
Size System System Pulsed Power HDC
(gallons) Comparison
Annual Simple Payback Annual
Cost (+) or Savings (-) (yrs) Cost (+)
2,500 gal Oxidizing $161 NA $3,049
2,500 gal Non-Oxidizing -$114 295 $2,774
10,000 gal Oxidizing -$1,749 24 $2,754
10,000 gal Non-Oxidizing -$2,851 15 $1,652
50,000 gal. Oxidizing -$5,432 12 $10,904
50,000 gal. Non-Oxidizing -$10,931 6 $14,567
100,000 gal. Oxidizing -$10,884 7 $21,541
100,000 gal. Non-Oxidizing -$21,899 4 $10,525

14
variable. It must be noted however that although HDC system during this trial, while difficult to quantify,
oxidizing biocides (such as bleach) are generally cheaper, could also favorably impact their overall operating costs.
they require much more containment, ventilation and
controls. The costs for this infrastructure were included SUMMARY AND CONCLUSIONS
in the comparison. Finally maintenance labor and
materials costs for the HDC unit for this test were high Based upon the results and findings of this twenty-
due to the presence of the carbon particles and their effect six week study we offer the following conclusions:
on the pumps and the HDC hardware. Subsequent to our A general observation was that fugitive dusts
field trial, the HDC manufacturer made improvements to emanating from a nearby carbon silo were readily drawn
their design, which eliminated the need for one of their into the three cooling towers by the air scrubbing action
high maintenance filtration devices. For the cost analysis of the tower fans. While the abrasive carbon fines caused
above, essentially similar maintenance costs were used for some operating difficulties for pumps associated with the
both non-chemical systems. A significant portion of the PP and HDC systems, the lack of a sidestream solids
maintenance expenses for the chemical system was removal device severely compromised operation of the
assumed to be included in the unit cost of the chemicals. Chemical tower at elevated cycles creating unacceptable
Non-chemical suppliers claim they can run at 6 to 8 (>120 NTU) turbidity levels.
cycles of concentration, which this study shows is The make-up (MU) and blowdown (BD) volumes
feasible. The chemical systems typically run at 3 to 5 across all three towers were statistically the same (95%
cycles, which was where the chemically treated towers CI) at all setpoints. This is expected, as conductivity
where running prior to this test. Cost comparison at 8 setpoints were the same across all three towers.
cycles for non-chemical and 4 cycles for chemical treated Conductivity is not reflective of true cycles of
systems is shown in Table 7. Recall from Figure 6 that concentration in higher cycles (greater than 7 cycles at
going from 8 to 4 cycles for these towers resulted in an this site). Additionally, make-up and blowdown in this
approximate 50% blowdown reduction. study proved to be an inaccurate measure of cycles of
As shown on the tables, the HDC does not seem to concentration due to possible unquantified leaks and drift
have the economies of scale that the PP unit does. This is loss. The best way to track cycles of concentration at
due to the significant capital cost increases required by higher cycles is by comparing salt (Mg, Na, K, SO4, etc)
the HDC suppliers to move into the larger systems. In contents of the make-up and blowdown.
addition to capital cost, the power costs are also higher for TDS, total alkalinity, total hardness, calcium
the HDC units to run the extra pumps required. Both non- hardness and conductivity were scrutinized statistically,
chemical systems would compare even more favorably if and showed no difference between all three towers for
consideration was given to potential fines levied for each operating period respectively, with a couple
violations of WET test standards associated with toxic exceptions. During the 2,750 umhos time frame the
blowdowns discharged from chemically treated cooling alkalinity for the Chemical tower was higher than that of
towers. Another potential benefit of non-chemical either non-chemical tower. The reason for this is likely
treatment is a reduction in amount of reportable chemicals due to the scale inhibitors keeping scale forming elements
into the environment as reported in the annual Toxic in solution for the Chemical tower, while scale or other
Release Inventory (TRI) report (e.g.chlorine from bleach). precipitates were forming in the non-chemical towers.
Lastly, the better heat transfer results exhibited by the Turbidity was higher in the Chemical tower at higher
cycles due to the lack of a solids separation device.
Table 7 – Cost Comparison at 8 Cycles for Non-Chemical and 4 Cycles for Chemical Treated Systems
Size System Chemical Pulsed Power HDC
(gallons) System
Comparison
Annual Simple Payback Annual Simple Payback
Cost (+) or Savings (-) (yrs) Cost (+) or Savings (-) (yrs)
2,500 gal Oxidizing -$8,168 4 -$5,280 9
2,500 gal Non-Oxidizing -$8,443 4 -$5,556 8
10,000 gal Oxidizing -$22,253 2 -$17,750 4
10,000 gal Non-Oxidizing -$23,354 2 -$18,851 4
50,000 gal. Oxidizing -$34,897 2 -$18,570 9
50,000 gal. Non-Oxidizing -$40,404 2 -$24,078 7
100,000 gal. Oxidizing -$49,328 2 -$16,903 17
100,000 gal. Non-Oxidizing -$60,343 1 -$27,919 10

15
The Chemical tower provided the best corrosion CFU/cm2, which is considered the standard for effective
control with rates averaging 1.1 mils/year over the entire biofilm control.
study period. Corrosion rates for the non-chemical Seven of thirty (23%) sessile coupons tested
devices were higher, but still within industry standards. positive for sulfate reducing bacteria (SRB), which is an
This may have been due to the action of the non-chemical indicator of anaerobic conditions that can promote
devices in operating in moderate to severe calcium corrosion of fouled metal surfaces. Of these seven
carbonate scaling regimes, or simply cycling up of the positive coupons, four were from the Chemical tower, two
ortho-phosphate levels in the makeup water, which acted were from the HDC and one was from the PP.
as an anodic inhibitor. The non-oxidizing biocides added to the Chemical
Both the PP and HDC towers showed a greater tower appeared to also serve as effective algaecides as
potential for scale formation when these non-chemical evidenced by the stark, black surface of the drift
devices were turned OFF from November 6-21. This is eliminators on this tower. The top of the drift eliminators
inferred from the reduction in both alkalinity and calcium on the PP and HDC towers exhibited scattered patches of
hardness during that time (i.e.presumably scale was green algae with the largest coverage on the PP tower.
forming on the surfaces when the devices were OFF). The results showed a clear cost savings advantage
However when the devices were turned back on and for the PP systems against the other two technologies
moved up to 4,000 umhos calcium hardness increased, across all system sizes.
while alkalinity stayed low. A reasonable explanation of
this result is that calcium carbonate was forming in the RECOMMENDATIONS
water column (very small particulate) as suppliers had
claimed. Additional evidence for scale control could be As locations implement water conservation
inferred by the effect a larger PP unit had on improving measures by operating their cooling towers at higher
heat transfer of its respective tower. cycles of concentration, they should strongly consider
The sidewall scale in both the PP and HDC towers installing side stream solids removal devices to improve
had a sparkling, crystalline appearance compared to the system cleanliness at reduced blowdown levels.
dull white scale of the Chemical tower. The buildup in Locations considering new applications of these
the PP scale may have been an example of the “ripening” non-chemical approaches as a water conservation measure
affect whereby the crystal size of the precipitate increases. should carefully evaluate their source of makeup water
The entire top layer and some of the bottom layer of and the overall system economics. Makeup water with
“sparkling – crystalline” scale in the PP and HDC towers reasonable levels of hardness (40 – 50 mg/l) and ortho-
was removable by water under “garden hose” pressure. phosphate (0.5-1.0 mg/l) will result in better corrosion
However, there were some spots of tenacious scale that control than soft water without any additives. Addition of
required “water blast” pressure to remove. The Chemical a sidestream solids removal device is also highly
tower had less scale accumulation, probably as a result of recommended. In very abrasive environments (i.e. lots of
operating at lower cycles of concentration for extended dust/sand in the air) the standard sidestream removal may
periods, and the affects of the scale inhibitor additive. not be enough to protect mechanical non-chemical
However, this scale was difficult to remove and required treatment devices. Locations currently experiencing algal
water blasting. control problems should be aware that these non-chemical
Both of the non-chemical towers delivered better technologies may not provide effective algal control.
and more consistent microbiological control for both
aerobic and anaerobic planktonic organisms compared to
the Chemical tower. There was no statistical difference in
the microbiological control performance between the PP
and HDC technologies. Despite alternating two non-
oxidizing biocides, microbiological control performance
in the Chemical tower suffered due to higher turbidity
levels created by lack of a sidestream solids removal
device. While there was some correlation between these
high turbidity levels and high microbiological counts, this
does not appear to fully explain all the biological
variability in the Chemical tower.
Microbiological control for slime forming, sessile
organisms was better and more consistent for the non-
chemical systems. There were only a few instances where
the non-chemical treatment systems did not provide
effective control, and both instances occurred in the PP
tower. The HDC technology delivered the best results
with all of their test coupons measuring < 1x106

16
REFERENCES

1. Condenser Water Treatment Results Under Pulsed-


Power Technology by J. Lane (PP Systems), and D.F.
Peck (Hatch Mott MacDonald). Presented at the
Cooling Tower Institute Conference 2002
2. An Innovative and Alternative Method for Cooling
Water Treatment by R. Kelsey, D. Koontz, and W.
Wang (HDC Technologies). Presented at the
International Water Conference, October 2001
3. Rohrback Aquamate Corrater User Manual, Corrater
is a registered trademark™ of Rohrback Cosasco
4. Cooling Water Scale & Scaling Indices: What They
Mean – How to Use Them Effectively – How They
Can Cut Treatment Costs by P. R. Puckorius and G.
R. Loretitsch (Puckorius and Associates, Inc).
Presented at the International Water Conference,
October 1999
5. Physical Water Treatment for the Mitigation of
Mineral Fouling in Cooling-Tower Water
Applications, by Y.I. Cho Ph.D, S. Lee, and W. Kim
presented at ASHRAE Conference January 2003
6. Dr. Benoit Barbeau, Personal Communication, Date
Feb 17, 2003
7. Alternative Methods of Microbiological Control –
Review of Major Rapid Techniques by Petat etal,
STP Pharma Pratiques 6:6, pp. 449-464 1996
8. BacLight: Application of a New Rapid Staining
Method for Direct Enumeration of Viable and Total
Bacteria in Drinking Water by B. Barbeau etal,
Journal of Microbiological Methods, Vol. 37, pp 77-
86, 1999
9. Guideline: Best Practices for Control of Legionella
by Cooling Tower Institute, February 2000.

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