Documente Academic
Documente Profesional
Documente Cultură
Outline
Cooling Tower Water Quality Water Borne Problems Improvement Areas Case Studies Conclusion
Cooling Tower
Industrial utility Provides Cooling water stream at ambient temperatures Insights CW air evaporative heat transfer interactions Discharge of unwanted process heat to the atmosphere Challenges Qualitative and quantitative maintenance Minimizing energy and water consumptions
3
Water flow
Enven
Type
Flow Rate No of Cells CWR T CWS T Wet Bulb Heat Load 48000 m3/hr 13 + 1 44 C 34 C 29 C 4836 MM k cal/h
Corrosion
CT chemistry includes:
Scaling
7
Challenges
Microbial Growth
Parameter
pH Conductivity Total hardness Ca hardness Max 600 Mg hardness P-alkalinity 0 M-alkalinity 50 120 Chloride < 120 Ortho Phosphate 3.0 4.8 Total phosphate Organic Phosphate 1.0 1.5 Zinc 0.6 1.5 Dissolved Fe <2 Total Fe Silica TDS < 1200 -1500 Suspended solids Max 25 Turbidity Max 30 Ammonia < 10 Nitrites Nil Nitrates Nil Sulphate Max 600 Free Chlorine 0.5 1.0
Water Quality
Units microS/cm ppm CaCO3 ppm CaCO3 ppm CaCO3 ppm CaCO3 ppm CaCO3 ppm Clppm PO43ppm PO43ppm PO43ppm as Zn ppm Fe2+ ppm Fe2+ ppm SiO22ppm ppm NTU ppm ppm NO3ppm NO2ppm SO42ppm Cl2 Make up 7.80 416 175 120 55 0 166 16 0.07 CWR 8.10 1503 520 350 170 0 88 107 3.56 4.96 1.40 0.73 0.41
250 1 3 48
Salt concentrations should remain within given ranges for: Inhibiting corrosion, microbial growth & scaling Efficient heat transfer Optimum COC and operation
Effluents
NEQS limits the disposal of effluents above the permissible ranges without treatment Required chemical treatment before disposal is done
Parameters Permissible Range
pH 69 Ammonia 40 ppm TSS 200 ppm TDS 3500 ppm COD 150 ppm Grease & Oil 10 ppm Chloride 1000 ppm BOD 80 ppm Iron 8.0 ppm Zinc 5.0 ppm Sulphate 600 ppm Chromium 1.0 ppm Conductivity 2500 micro S/cm2 Temperature increase 3C
9
10
Corrosion
Chemistry Return of metal to its original state due to an electrochemical potential between cathode and anode sites Metal ions e.g. Fe
++
Ionic migration
Cathode
Electron migration
Anode
Control: Inhibitors passivation film prevents O2 diffusion to metal site Chemisorption; protective filming; reaction
11
Corrosion
Dosing Zinc and inorganic phosphate (BULAB 9063)
Both anodic and cathodic corrosion protection
Chromates, Orthophosphates Zinc, Polyphosphates,
12
Control
Metabolic poisons; acts rapidly against active cells Surfactants; rupture the cell walls Oxidizing agents; oxidize cell components (Cl, Br)
13
Microbial Growth
Mineral salts may concentrate six
Hypochlorite
14
Microbial Growth
Scaling
Chemistry Deposits
Mineral scales Corrosion products Particular matter Microbiological mass
Types
Waterborne salts Waterborne foulants Airborne foulants
15
Scaling
Dosing Biodispersant (BULAB 8006)
Designed to inhibit slime build up; enhances the effectiveness of microorganism control
Improving Performance
17
Performance Improvement
Reducing:
Water consumption Chemical dosage
Benefits:
Eco efficient Cost effective Easy operation
18
Water Conservation
19
Water Consumption
Reducing blow down Increasing COC Reusing blow down Avoiding water losses
Leaks Splashes Drift losses
20
Water Consumption
21
For deviated condensate recycle from (PCT of Ammonia-3, PCT of Urea-3) conductivities; the effluent must be routed to CT-4 basin rather than in effluent network Any steam condensate must be recovered in tower basin rather than in effluent system
22
Civil repair at CT-4 is required on immediate basis. About 35 m3 /h of Water is being lost due to losses from the leakages Water loss causes:
Dosing wastage More chemical dosing
23
Chemicals Conservation
24
Chemicals Conservation
Chemical free platforms saves money Alternatives:
1. UV radiation 2. Hydrocavitation 3. Radio frequencies
25
Installing UV lights at different headers of CW Network UV will kill most of the microbial entities and substantially reduce the quantity of Hypo dosing in the system Reduced hypo dosing will assist in
Lesser chlorides Less blow down Lesser chemical consumption Reduced load on effluent treatment
26
Golden Circle saves water and dollars per year through technology switch. The project has ensured:
Reduced chemical consumption Reduced waste water treatment requirements Water savings more that
8 7 6 5 4 3
8 ML / year
2 1 0
Nasa Marshal Space Flight Center utilizes radio frequencies to alter the waters scaling tendencies
Increase cycles of concentration to improve water efficiency. Eliminate scale and bio-fouling in the cooling system. Eliminate condenser-side chemicals to reduce operating costs and environmental impacts.
MSFC
28
Summary
Reducing Tower Leakages Reducing chemical dosing and moving to chemical free platforms is profitable and environment friendly Project study and technology switch analysis should be initiated for improved performance Potential Outcome Reduced operational cost Eco efficiency Regional leadership in emerging CT technologies
29
30
NUST School of Chemical and Materials Engineering
A school of excellence acting as a precursor for research and development within public and private sector. Offers undergraduate programmes in twin disciplines of chemical and materials engineering. Graduate and post graduate programmes in energetics materials and materials and surface engineering. Key research areas include alternate energy, propulsion systems, smart materials, bio materials, polymers and composites.
31