COOLING WATER TREATMENT

Jayanta Chakraborty

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 Cooling tower - an introduction
 Industries Generate Tremendous Waste Heat
 This Waste Heat is transferred to cooling water.
 From cooling water the heat is dissipated into
the atmosphere by COOLING TOWERS

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 Principle of cooling Tower operation
In COOLING TOWER
 Water is split up into small droplets & brought into
intimate contact with air.
 In doing so a small quantity of water is evaporated .
 The EVAPORATION brings about the 75 % of the
cooling effect.
 Balance 25 % of the cooling is due to sensible heat
transfer .

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 Types of Cooling Towers
Cooling Towers

Natural Draft Mechanical Draft

Design of Cooling tower is

such that cold air of the Forced Draft Induced Draft
bottom of tower push the
warmer air out from top. Air is pushed in Air is pulled in
the tower with a cooling tower by
fan at the side. a fan at the top

Counter Flow Cross Flow

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 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.

3. Drift / Windage loss : (D)

Some water droplets escape alongwith air and water vapours. A usual drift loss in
conventional cooling towers is in the range of about 0.05 -0.2% of the recirculation rate.

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 Contd.
4. Evaporation Losses : (E)
• Water lost to the atmosphere in the cooling process is evaporation.
The rate of evaporation depends upon the temperature differential
1% of the circulation rate evaporates for each 5.6 Delta T.
Actual evaporation 0.85 % of calculated

5. System Losses : (S)

Circulating water is lost in the plant through
pumps, valves or leakage’s in plant etc.

6. Concentration Cycle : (C) MakeupWater requirementsvs. cyclesof

concentration
12.0

Mg or Silica in cooling water 10.0

C =
8.0

-------------------------------------------

%MAKEUPWATER ( basedon circulation)

6.0
50FDROP

Mg or Silica in make up water 4.0

Blowdown E
25FDROP

2.0
10FDROP

& Windage losses = ----- 0

0 1 2 3 4 5 6
CYCLEOFCONCENTRATION
7 8 9 10

C-1
where E = Evaporation rate.
C = Cycle of Concentration.
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 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
8. Holding Time Index :

Time required to reduce the concentration

of any constituent in cooling water to half.

0.693 x (Hold up capacity )

HTI =
Blowdown + Windage loss

Each programme has maximum allowable HTI beyond which chemical lose its
effective.

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 Contd…

9. Approach :

Indicate efficiency of cooling tower.

Lesser is approach better is cooling tower efficiency.

Approach = Supply C. W. temperature - Wet bulb temperature

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 Assessment of Cooling Towers
Measured Parameters

 Wet bulb temperature of air- The temp. of saturated air.

At 100 % humidity the wet bulb temp. equals the dry
bulb temp
 Dry bulb temperature of air- Ambient temp. of air
 Cooling tower inlet water temperature
 Cooling tower outlet water temperature
 Exhaust air temperature
 Electrical readings of pump and fan motors
 Water flow rate
 Air flow rate

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 Assessment of Cooling Towers

Performance Parameters
 Range
 Approach
 Effectiveness
 Cooling capacity
 Evaporation loss
 Cycles of concentration
 Blow down losses
 Liquid / Gas ratio

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 Assessment of Cooling Towers

Range
 Difference between
cooling water inlet and
outlet temperature:

 Range (°C) = CW inlet

temp – CW outlet temp

 High range = good

performance

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Approach
 Difference between
cooling tower outlet cold
water temperature and
ambient wet bulb
temperature:

 Approach (°C) =
 CW outlet temp – Wet
bulb temp

 Low approach = good

performance

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Effectiveness
 Effectiveness in %
 = Range / (Range +
Approach)
 = 100 x (CW temp –
CW out temp) / (CW in
temp – Wet bulb temp)
 High effectiveness =
good performance

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Cooling capacity
 Heat rejected in kCal/hr or tons of
refrigeration (TR)
 = mass flow rate of water X specific heat
X temperature difference
 High cooling capacity = good
performance

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Evaporation loss
 Water quantity (m3/hr) evaporated for cooling
duty
 = theoretically, 1.8 m3 for every 10,000,000
kCal heat rejected

 = 0.00085 x 1.8 x circulation rate (m3/hr) x (T1-

T2)

 T1-T2 = Temp. difference between inlet and

outlet water

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COC
Ratio of dissolved solids in circulating water to the
dissolved solids in make up water

Blow down
 Depend on cycles of concentration and the
evaporation losses

 Blow Down =
 Evaporation Loss / (C.O.C. – 1)

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 FUNDAMENTALS

OF

COOLING WATER TREATMENT

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Cooling water treatment- All about !!!

Scaling Fouling

Corrosion Deposition

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 Important Water Parameters
 pH
 Hardness
 Chlorides
 Silica
 Metal ions
 Turbidity
 Conductivity / TDS
 Alkalinity
 Phosphates
 Oil & Organics
 Dissolved gases

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 ChembondDrewtreat Limited

Water Impurities and it’s effect

Impurity Effect
Total Hardness Scale formation
(Calcium + Magnesium)

M-Alkalinity/ pH Corrosion - Low Alk.

Scale / Deposition - High Alk.

Chlorides Corrosion / SCC of SS

Suspended Solids Deposition

Sulphate Corrosion / Scale formation

SiO 2 Scale

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 ChembondDrewtreat Limited

Contd.
Impurity Effect

Mg.-SiO 2 Scale

Organic Matters Fouling

Iron and Manganese Deposition

Micro-Organisms Fouling / Corrosion

Ammonia Nitrifying bacteria / fouling

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 CORROSION

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 Corrosion
Corrosion is an electrochemical

phenomenon

by which a metal reverts to its natural

state.

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 CORROSION CELL
O O
OH

Fe OH

Oxidizes O O
OH

Fe OH

OH-
Fe++ OH

OH- O O
Fe2O3
e-
RUSTFe e-
Anode Cathode

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 Corrosion Factors affecting
Requires corrosion
 Anode
pH

 Cathode
Oxygen & Dissolved gases

 Electrolyte
Dissolved & Suspended solids

 Electron
Velocityflow

 Temperature

 Microbial Growth

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 EFFECT OF pH ON CORROSION RATE
CORROSION
RATE

4 10
pH
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 Why Corrosion Control ?

Corrosion Leads To -
– Leakage of Exchangers
– Unscheduled Shut Down
– Loss of Production
– High Equipment
replacement Cost.

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 Corrosion Prevention

 Selection of proper
metallurgy
 Sacrificial anodes
 Coatings

Corrosion inhibitor
programs are most
economical when
used with other
means of
prevention
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 Corrosion Inhibition

Gen. Inh
Cathodic Inh Anodic Inh

Cathode No Electron Migration Anode

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 MAIN CORROSION INHIBITORS

Orthophosphates
Organophosphonates
Polyphosphates
Nitrites / Nitrates
Silicates
Zinc
Molybdates
Azoles

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 Selection criteria of inhibitor
 Make up water analysis
 Cycle of concentration
 MOC of exchangers
 Water velocity in exchangers
 process parameters – Temperatures
 Environmental restrictions

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 SCALING

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 What happens when water
evaporates !!!!

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 + -
+ - + -

+ - + -

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 + - + -
+ - + -
+ - + -
+ - + -

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 + - + - + -
+ - + - + -
+ - + - + -

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 SCALING :
Precipitation of
the water soluble
salts occurs once
their saturation
levels are
exceeded.

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 Common Scales

Calcium Carbonate

Calcium Sulphate

Silicate

Magnesium salts

Calcium orthophosphate

Iron salts

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 Factors affecting Scaling:
• pH
• Temperature
• Alkalinity
• Solubility
• Velocity

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 MINERAL SCALES
Temperature - Major Impact on Solubility

SOLUBILITY

TEMPERATURE

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EFFECT OF SCALE ON HEAT TRANSFER
100
% Reduction in U-Coefficient

SiO2
90
80 Clay (Kaolin)
70
60 CaSO4
50
40 CaCO3
30
20
10 Al 2O3
0
0.001 0.010 0.100
1/7/20
Scale Thickness (inches)
Jayanta Chakraborty 41
 Why Scale Control ?

 Scale Formation Leads To -

– Reduction in Water Flow

– Poor Heat Transfer
– Reduction in Plant Load
– Chemical Cleaning
– Unscheduled Shut Down
– Shorten the Life of
Equipments

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 FOULING

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 FOULING:

Air Borne Water Borne

Under deposit
corrosion

Choking of tubes > Microbial growth

Blockage of water passage Induces Scaling
& Corrosion

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 Common Foulants

Dirt and Silt

Sand

Corrosion Products

Natural organics

Microbial matter

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 Common Foulants

Dirt and Silt

Sand

Corrosion Products

Natural organics

Microbial matter

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 Factors Affecting Fouling:

Suspended solids
Turbidity
Temperature
Velocity
Oils
Microbial Slime
Corrosion products

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Jayanta Chakraborty
 MICROBIAL GROWTH

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 CT- the ideal Incubator for bacterial growth

 Ideal pH
 Ideal Temperature
 Plenty of sunlight
 Abundance of nutrients

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 Microbial Activity:

ALGAE

FUNGI

BACTERIA

BIOFILMS

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 ALGAE

Requires air, water and sunlight

Found in open areas like distribution decks,

louvers and side walls

Leads to choked pipelines, nozzles,

increased corrosion, slime and
deterioration of certain Inhibitors like
nitrite

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 Fungi

Lack chlorophyll

 Depend on nutrients provided by organic

matter (heteorotrophic)

 Use CT wood as nutrient

 Reproduce by forming spores

 Difficult to kill

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 Bacteria

Pseudomonas

Sulphate reducing bacteria

Iron bacteria

Nitrifying bacteria

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 Pseudomonas

• Generates voluminous slime

• Increases fouling

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Sulphur Reducing Bacteria

o Anaerobic bacteria

o Reduces sulphur to sulphides

4Fe + SO4-2 + 4H2O FeS + 3Fe(OH)2 + 2OH-
Fe + H2S FeS + H2

o Iron sulphide is cathodic with respect to iron

o During chlorination
H2S + Cl2 2HCl + S (can attack concrete basin)

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 H2S

Fresh corrosion

Sulphate Reducing Bacteria

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 Iron Bacteria

- Utilise iron for their growth

4FeCO3 + O2 + 6H2O 4Fe(OH)3 + 4CO2

Produces voluminous deposits that causes

plugging, pitting corrosion and reduced heat
transfer.

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 Nitrifying bacteria

Consists of nitrosomonas and nitrobacter

Converts ammonia to nitrites/nitrates

Reduces pH and leads to corrosion

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Biofilms

Jayanta Chakraborty
WexTech
 CHEMICAL TREATMENT PROGRAMMES

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 Complete Treatment Programme:

Must Address All Potential Problems

simultaneously
Suitable Corrosion Inhibitors
Antiscalants & Antifoulants
Dispersants
Crystal Distorters
Biodispersant
Oxidizing & Non Oxidizing Biocides
pH corrector
AND ABOVE ALL THE CHEMICALS SHOULD
BE ECO FRIENDLY AND NON POLLUTANT

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 Different programmes

Inorganic phosphate based

Metallic & non metallic
All organic
Soft water Molybdate based
Eco friendly microbial
Speciality polymeric dispersants
Crystal distorters
Closed Loop Nitrite/Molybdate

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 Program Targets:

Corrosion Control : < 2 mpy : Long eqpmt.life

Scale Control : < 15mg/dm2/day:Efficient heat tfr
TVC : <1,00,000 org./ml : min.slime,biofilm
SRB : < 25/100ml : No pitting
NRB : Min.causing no pH drop:No alkali addition
COC : highest possible : Water & Ecological
conservation
Sustained & efficient operations for long
duration

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 Success of Cooling Water treatment
programme not only depends on proper
chemicals, but also -

• Regular monitoring of cooling water

parameters
• Regular monitoring of critical
exchangers
• Dosing of chemicals at proper dosage
and at proper point / time.
• Identifying symptom of upsets.
1/7/20 • Adopting best practices
Jayanta Chakraborty (Non-66
 Important points for success for Cooling Water
Treatment
• To know make-up water quality
(i.e. pH, TH,TDS, CaH, M-Alk., TDS, Silica, Suspended Solids, TVC etc.)

• Understanding Circulating Cooling Water analysis and limit of each

constituents.

• Exchanger details, MOC

• Regular addition of chemicals in required quantity for treatment.

• Knowledge of active ingredient in chemicals added in cooling towers.

• Observing monitoring instruments and cooling tower.

• To check contaminants from process and surrounding.

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 Addition of Water Treatment Chemicals to
maintain correct concentration (PPM):
• Normally, corrosion inhibitor, Dispersant & Bio-dispersant are
added
continuously at proper place where mixing takes place away from
chlorinated water, alkali/acid.
• Addition of Biocide as slug dose after a certain interval based on
microbial growth pattern (15 to 30days interval and near circulating
pump sometime on top deck)

• Chlorination / Bromination is added continuously to attain FRC =

0.2 - 0.5 ppm. ( preferably towards back side of the basin in each
cell).
• Chemicals dosage level is necessary to be calculated based on
bleed, windage loss and system volume, Delta T . Regular
analysis to cross-check the phosphate, Zn etc to modify dosage
level,if necessary.
 Addition of Acid away from pump inlet/suction

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 • Deciding cycles of concentration based on make-up
water
quality, Cooling Tower differential temperature and
cost of
make-up water.

• Maintaining cycles of concentration based on

requisite
bleed or stopping loss of water / leakage.

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Contd…..
Circulation Rate (CR) - 10,000 M 3 / Hr
Delta T - 10 oC
Evaporation Rate - 180 M 3 / Hr (For Every 5.6 oC at 1% of
CR)
Windage Loss - 10 M 3 / Hr (0.1 % of CR)
COC Blowdown
2 170 M 3/ Hr
3 80 M 3 / Hr
4 50 M 3 / Hr
5 35 M 3 / Hr
6 26 M 3 / Hr
8 15.7 M 3 / Hr
10 10 M 3 / Hr

• To check pH in every shift and take necessary step to add acid or soda ash in case
variation is too-much. Avoid caustic (NaOH) to increase the pH as it will
precipitated metal hydroxides.

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 Cooling Water Parameters to be
analysed, monitored & its effects:
Parameter Low High
Increases corrosion Increases scaling/deposition
pH • Check MW pH • Check contamination (NH3)
• CO2 contamination • Increase Dispersant, reduce
• excess chlorination PO4
• Add Soda Ash • Add H2SO4
• Increase PO4 /
Corrosion
inhibitor
More than 75000 increases scaling
Mg x Silica • Give blowdown
Increases deposition / fouling
Turbidity a.Check for any leak like oil,
Organics. Plug the leaky tubes etc.
b. Operate side sand stream filter
efficiently.
c. Give blowdown.
increases scaling
Calcium Hardness
a.Give blowdown.
b. Increase antiscalant / dispersant
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 Contd…
Parameter Low High
Inorganic/Ortho phosphateIncreases corrosion Increases scaling / deposition
a. Increase corrosion a. Check & control corrosion
Inhibitor dose. inhibitor dose.

Delta phosphate No Film formation / Phosphate deposition

(Filter – Unfiltered) high pitting corrosion • Increase dispersant dosage
a. Decrease dispersant • > 1.5 ppm
dosage
< 0.5 ppm
Organic phosphate Increases deposition / Very high Org. phosphate
scaling tendency increases Corrosion rate.
a. Increase antiscalant a. Reduce antiscalant
dose dosage.

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 Contd…

Parameter Low High

Accelerate corrosion rate.
Chloride
Leads to SSC in SS metallurgy.
a. Increase blowdown.
b. Check make up water
chloride.
c. Check for excessive
Iron as Fe+++ If Iron pickup in cooling water is
chlorination.
high (>0.5ppm) indicates more
corrosion in the system.
a. Increase blowdown.
b. increase corrosion inhibitor
dose.
c. Check make up Iron.
d. Dose specific Iron dispersant
e. Check iron
Deposition bacteria.
/ Scaling tendency
Conductivity & TDS
increase.
a. Give blowdown to control in
desired range
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 Contd…
Parameter Low High

Increases biological load / biofouling.

COD Increase Chlorine demand.
a. Check for any source of Organic
leak &
attend
b. Increase Biodispersant,
chlorination
c. Add chlorine activator( Chlorine
Dioxide).
• Increases biological load /
Oil & Grease d. Give blowdown.
biofouling.
a. Check for any leak.Isolate leaky
exchanger
b. Plug the leaky tube.
c. Add Oil Dispersant
d. Give heavy blowdown.
e. Give extra dose of biocide
f. Increase chlorination.
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 Cooling System– Best Practice
 Occasional addition of non-oxidising biocide on cooling tower top deck/Covering
of top deck to avoid sunlight exposure.
 Observe the colour of water, top deck, smell of water, tower area for any change,
nature of foam.

 Conduct side stream filter efficacy studies at least every 3

months
– Monitor inlet and outlet turbidity or TSS and calculate %
removal
– Clean and sterilize if necessary by adding biocide
– Change out media when efficiency declines
– Synchronizing with back washing of side stream filters to 3 – 5% of circulation
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save rate through sand filter
 Cooling System– Best Practice

 Cooling Tower basin sump cleaning – Atleast once in a two years

 Proper / design cooling tower screen in sump preferably 2 nos. to avoid

extraneous matter going into the system (1st screen – 8 mm & 2nd screen – 4mm).

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 Cooling System– Best Practice

 Cooling water flow measurement in exchangers – Atleast

once
in six months to maintain proper velocity.
 Carefully charging cooling water in empty exchanger with
vent valve
open.
 Check vibration at baffle – Failure of Heat Exchangers tube at
baffle
tube area

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 Don’t pinch back flow in heat exchangers.
• Ideal velocity is >1.5mps in process exchangers and >2.0in
surface condensers.
• Velocities >2.5 mps could cause erosion problems in steel
and copper alloy exchangers.
• By-pass some of process flow to outlet if cooling duty is too
high-don’t throttle cooling water.
Process out
CW out

Heat Exchanger CW out Process out

Heat Exchanger
CW in
Process in

CW in Process in

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 Cooling System– Best Practice

 Proper precleaning / passivation of new carbon steel exchanger

before taking into line.
 For New system proper flushing of pipeline headers, precleaning &
passivation.

 Avoid shell side water as water velocity is low, deposition tendency is

high. If unavoidable, select better material of construction or proper
baffle design (helical).

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 Cooling System– Best Practice

 Avoid vertical heat exchanger as suspended solids tends to settle

at the bottom.
 Avoid stagnant water - leads pitting
Stand by exchangers – preservation
 Avoid using cooling water in chlorinator system. Addition of
chlorinated water at back side in each cell.

• Avoid extended tubes in exchanger to avoid crevice Corrosion.

Tube sheet

Crevice

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 Cooling System– Best Practice

Measure and graph ORP on supply and return

line
– Large  could indicate leak
Leak detection– identifying problem exchanger
– ORP in and out
– FRC in and out
– Turbidity in and out
– Look for gas bubbles in outlet
– Sniffer test
 Target dose individual chemicals (e.g., scale inhibitor, biocides,
etc.) in front of problem exchangers
 Use PO4 test to control dispersants in phosphate programs
– >1 ppm– increase dosage
– <0.3 ppm– decrease dosage
 Regularly run iron tests and perform mass balance
– >0.5 ppm Fe pick up indicates corrosion
– Negative pick up indicates iron fouling

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 Cooling System– Best Practice

• Monitoring COC based on Calcium, Magnesium and

Silica
• COC based on Ca less than Mg / Silica – Ca
precipitation.
Scaling occurring Under control

 SiO2 ratio
 Ca ratio

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 Cooling System– Best Practice

 Use mechanical as well

as chemical means for
improving results
– Backflushing
– Air or N2 bumping

COOL ING WA TER ON SHEL L SIDE COOLING WA TER ON SHELL SIDE

Cooling W ater Out Cooling Water Out

Process Out
Process Out
Air / N 2 Injector
Process In Process In
point

Cooling Water In
To Drain Alternate Air
Cooling W ater In
Injector Point

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 Cooling System– Best Practice
P2
Cooling Water
return header
In case of multi-pass
exchangers, P1
Exchangers in series,
Seal flush cooler Process in
H. E. - B
ensured
return Header
pressure less than
Cooling water outlet
pressure from Process out H. E. - A
Exchangers P1 > P2
Cooling Water in

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 Cooling System– Best Practice
 Use corrosion inhibitor while doing
hydro testing of new exchangers.
Completely dry and preserve the same
properly.
 Flush the SS exchanger with DM water
after hydro testing to avoid
accumulation of chloride.

 Annual shutdown, close inspection of exchangers, analysis

of
deposits & flushing / cleaning of exchangers. Online
precleaning /
passivation of system after shutdown.

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COOLING TOWER COLLAPSE

Collapse of return cooling water raiser (header) due to corrosion.

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 • Occasional Cooling Tower internally inspection, change of
damage
wood, corroded nuts & bolts of support system, testing of
wood.
• Change of nuts & bolts with SS

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