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Cooling System
Chatchawan Boonchoo
Senior Power Plant Chemistry Specialist
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Content
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Water Balance In An Open Evaporative Cooling
Water System
Windage Loss (W) Evaporative Loss (E)
Environment:
Health & Safety Recirculating Cooling Water (R)
Heat Exchanger
MAKEUP
(M) Heat Exchanger
Efficiency
Holding Water
Volume (H)
Quality
Availability & Environment:
Cost Chemical
BLOWDOWN
(B)
Discharge
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Terms & Symbols Related To Water Balance In Open
Evaporative Cooling Water Systems
Recirculating Water R, m3/hr total cooling water circulated by pumps per hour
Quantity
Holding Water V, m3 total water volume held in cooling water system including piping
Volume and cooling water tower basin
Evaporative Lossess E, m3/hr water lost by evaporation per hour
Windage Loss W, m3/hr water lost by windage + drift
Blowdown Water B, m3/hr water quantity discharged per hour in order to control
concentration
Make Up Water M, m3/hr water supplied to the cooling system to maintain system water
volume
Temperature Drop T, °C difference of cooling water temperature between the cooling
Through Cooling tower inlet and outlet
Tower
Concentration Factor CF concentration of dissolved solids in circulating water compared
(Cycles of to makeup water
Concentration)
Retention Time TR time required for water to make one trip around the circulating
loop
Holding Time Index, HTI represents the time required to dilute an added chemical to
or Half Life 50% of its concentration
time required to concentrate makeup solids by a factor of 2
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an important factor for establishing effective biofouling, scale
& corrosion control programme
Calculations
Makeup M = E + B + W
Concentration Factor (or cycles of concentration)
CF = [X] Circulating Water
[X] Makeup Water
Evaporative Losses E = Rx T
H
As a rule of thumb
H = Latent heat of water evaporation,
E = 1.4% x R if T = 10°C
E = 0.8% x R if T = 10°F Approx 578 kcal/kg at 40°C
Blowdown B = E ,
(CF -1)
ANSWERS
1) Evaporative Losses (E) = R x T = 55 m3/hr
578
System Volume
(By adding NaCl and Ciculating when reached steady state(around 2-3 hrs))
Chemical Consumtion
Continious Feed.
Consump.(Kg./Hr)=ppm.in circulating water x (MU/CC) x (100/%of AI)x(1/1000)
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Problems in Cooling Water Systems
Efficiency drop in
heat exchangers
Plugging of
Corrosion heat exchangers Microbiological
(mild steel, (algae, fungi
yellow metal) Leakage from & bacteria)
heat exchangers
Reduction of
materials strength
Increased pump
pressure and reduction
Scale of flow rate
(Calcium carbonate Sludge
calcium phosphate (general deposits)
Acceleration of
Silicates and sulphates)
corrosion
Dirty Appearance
These problems occur most frequently in open evaporative cooling water systems since the
dissolved solids are concentrated in the cooling9 water by evaporation.
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Water Treatment Concerns
Biofouling
Corrosion Products
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Langelier Saturation Index (LSI)
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Langelier Saturation Index (LSI)
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LSI&RI Calculation
CC
1.Estimate water quality MU 3 4 5 6 MU
pH 7.39 8.24 8.45 8.62 8.76 pH=1.35*logM-Alk+5.36 7.943649
EC. 360 1080 1440 1800 2160 ** pH=1.7177*log M-Alk.+4.1333 7.420658
M-Alk. 82 246 328 410 492 pH=1.465*log M-Alk.+4.54 7.343737
T-H 108 324 432 540 648
Ca-H 73 219 292 365 438
Mg-H 43 129 172 215 258
SiO2 10 30 40 50 60
Cl 50 150 200 250 300
SO4 20 60 80 100 120
Temp.(oC) 60 60 60 60 60
Acid Feed
By reducing pH in cooling water, the equation
LSI = pH ‐ pHs
means that LSI will be reduced, therefore calcium carbonate scaling
potential is reduced
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Methods of Treatment for High LSI#2
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Cooling Water Treatment
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Cooling Water Treatment(cont.)
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Evauating the cooling system
Component Consideration
• Mild Steel Susceptible to corrosion from high TDS , SS , • Chemical water treatment minimizes this
Biomass , Scale & heavy metal. potential
• Increased flow rates and periodic
flushing of heat exchangers minimizes
this potentials.
• Galvanized Iron Susceptible to corrosion from high TDS and • Reduce CC.
(Cu & Zn coating) pH level belows 6.5or above 8.5 • Adjust pH with chemical treatment.
• 304-SS • Susceptible to corrosion from chlorides • Chemical water treatment minimizes this
when deposit-formingconditions exit. potential
• Biomass deposits can cause rapid pitting.
• Corrodes at chloride levels of 200 mg/L • Maintaining a positive oxidant level will
when deposit-ferming condition exist. benefit the intergrity of the protective
• Tolerates chlorides levels of 1000 mg./L oxide film on SS and will reduce biomass
on clean surface accumulation.
• Nitrates,which occur in higher levels in
recycled water,are known to reduce SS
corrosion.
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Evaluating the cooling system
Component Consideration
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Evaluating the water quality constituents
Impact of water quality parameters on
cooling system
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Evaluating the water quality constituents
Impact of water quality parameters on
cooling system
Water Quality Parameters Impact on Cooling water system
Biological Oxygen Demand (BOD) • Reflects the organic content and associated demand for oxidizing
biocide.
Nitrates and Nitrites • Can provide additional mild steel corrosion control at level above
300 mg/l.
• Can contribute to reductions in stainless steel cracking and
pitting erosion
• Nitrates do not attack copper alloys or protect them from
corrosion.
Zinc • Can assist phosphates and nitrates in reducing mild steel
corrosion rates and pitting tendencies
• Levels in cooling water above 0.5 mg/l are benificial, but levels
above 3.0 mg/l can contribute to deposits.
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Evaluating the water quality constituents
Impact of water quality parameters on
cooling system
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Cooling Tower - Water Qualities Parameter
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Evaluating Water Treatment Option
Chemical Treatment for Corrosion Control
Corrosion
o Electrochemical process
o Metal are oxidized by transferring electrons from anodic site to cathodic site
Cathodic Inhibitors
o Reduce the amount of cathodic surface available
Anodic Inhibitors
o Reduce the amount of anodic surface available
Sometime both types of inhibitors are needed to prevent corrosion
Mild steel corrosion inhibitor
o Phosphates, Zinc salts, Molybdates, Polysilicates
Copper alloy corrosion inhibitor
o Organic nitrogen-based compounds(azole)
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Evaluating Water Treatment Option
Chemical Treatment for Deposition Control
Deposition
o Several type of deposit
o Necessitating different approaches
Depositional Inhibitor Control
o Solubilizing agent (Threshold effect)
o Crystal modifier
Dispersants and Surfactants
o Mutual repulsion
o Keeps solids as smaller particles.
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Precipitation of Scale
Treatment Chemical
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Crystal Formation of Scale
Treatment Chemical
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Completely of Scale Inhibition Mechanism
Treatment Chemical
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Completely of Scale Inhibition Mechanism
Threshold
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Completely of Scale Inhibition Mechanism
Crystal Modification
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Completely of Scale Inhibition Mechanism
Dispersancy of Crystal
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How Polymeric Scale Inhibitor Work
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Kinds of Scale Inhibitor
Polyphosphate
Phosphonates
Aminotrimethylene phosphonate (ATMP).
(1-hydroxyetylidene) diphosphoric acid (HEDP)
2-Phosphonobutane-1,2,4-tricarboxylic acid(PBTC)
Polymer
Acrylic acid homopolymer,
Maleic-anhydride coplymer , Polymaleic acid (PMA)
AA/AMPS Co-Polymer
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Microbiological Growth Control
Oxidizing Biocides
Chlorine based
Not as effective above pH 7.5
Sodium hypochlorite
• “Bleach” available at 14%
Calcium hypochlorite powder, rapid dissolving
Chlorine isocyanurate tablets
• Organic chlorine rapid dissolving tablets
Chlorine dioxide
• Combination of acid and hypochlorite
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Microbiological Growth Control
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Microbiological Growth Control
Non-Oxidizing Biocides
Liquid biocides used to supplement an oxidizing biocide program
Fed via pumps on 7 day timer
Acts as a poison to kill bacteria/algae/fungi/mold
Carbamate ‐ bacteria, sulfate reducers, fungi
MBT ‐bacteria, sulfate reducers, fungi
Terbuthylazine ‐ algae
Isothiazoline ‐ bacteria, sulfate reducers, fungi
DBNPA ‐ bacteria
Glutaraldehyde ‐ bacteria, sulfate reducers, fungi
Thione ‐ bacteria, fungi
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Establishing the treatment and operational regime for the
system
Conditioning Chemical Function Recommended Maximum
Concentration
Organophosphate Control Scale for Steel 20 mg/l as PO4
(phosphonate)
Orthophosphate, Inhibit Corrosion & Control 20 mg/l as PO4
Polyphosphate Scaling
Sodium Silicate Inhibit Corrosion 100 mg/l as SiO2
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Question &Answer
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