CW TREATMENT

(CORROSION AND SCALE)

BY
P.SRIVASTAVA
SR. MANAGER(CHEM.)
11/13/15

COOLING WATER
Cooling of water is an essential process at
power-generation and industrial plants.
The most important uses of cooling water
includes condensing turbine exhaust
steam, cooling process fluids and
protecting high pressure pump bearings.
Control of cooling water chemistry is very
critical in preventing corrosion and fouling.
11/13/15

COOLING WATER SYSTEMS

Type of cooling water system most suitable
for process depends upon:1.
2.
3.
4.

Process operation
Flow requirements
Availability and quality of water
Environment requirements regarding
discharge
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Types of cooling system

1. Closed Recirculating
2. Once-through
3. Open Recirculating (Evaporative
cooling towers)

11/13/15

Closed Recirculating System

Water circulates in a closed cycle
Alternate cooling and heating without air
contact
Heat absorbed by the water in closed
system is transferred by a water to water
exchange to the recirculating water of an
open recirculating system from which the
heat can be lost to atmosphere.
11/13/15

Once Through System

Water makes one pass through the heat
exchanger equipment and discharged to waste.
Large quantity of water is needed.
Once-through system have advantage of not
concentrating water during its passage through
system, thus reducing scaling and corrosion
potential of water.
Water is returned to source at higher
temperature, thus cause thermal and chemical
pollution of water bodies.
6
Highly 11/13/15
prone to biological fouling.

Open Recirculating( Evaporative

cooling Towers)
Water circulates through the condenser or heat
exchanger to a cooling tower and then returned
to exchanger.
Same high volume flow rate as a once through
system, but with less water discharge.
Cooling of water is by evaporation process,
water loss by evaporation and drift.
The evaporated water is very pure and the
minerals are left behind to concentrate.
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Cooling Water Balance

Evaporation and drift

CW Make up

Condenser

Blow Down
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Cooling Water Balance

Evaporation , blow down, drift and make up
constitute the water balance around the cooling
tower.
MU (flow)
BD Cl- or BD Mg+2 Conc.
C=
=
BD (flow)
MU Cl- or MU Mg+2 Conc.

BD+ D = E/C - 1
MU = E + BD + D
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Types of Cooling Towers

FORCED DRAFT COOLING TOWERS
NATURAL DRAFT COOLING TOWERS

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10

TERMS ASSOCIATED WITH

COOLING TOWER
Evaporation : Approx. amount of evaporation that
occurs in a cooling tower can be calculated
using the following formula.
E = (f X R X T) / 1000
E = Evaporation rate
R = Recirculation rate of cooling tower
T = Temperature diff. between hot and cool
circulting water
f = The correction factor for evaporation
1000 =11/13/15
Approx. latent heat
11

TERMS ASSOCIATED WITH

COOLING TOWER
Cycle of concentration ( C ) : Number of times
the circulating is concentrated in cooling tower
is known as Cycle of concentration. The
maximum C depends upon the effectiveness of
corrosion and scale inhibitor programs and on
the quality of make up water.
Blow Down ( BD ) : Some water must be
continually removed from cooling water system
to prevent excessive build up of the dissolved
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solids. 11/13/15
This is known as blow down.

TERMS ASSOCIATED WITH

COOLING TOWER
Drift ( D ) : Drift is a form of blow down that occurs
due to entrainment of water droplets in the air
leaving the cooling tower. Drift typically ranges
from about 0.3% to 0.05% of the recirculation
rate depending upon the type and efficiency of
the cooling tower.
Make up ( MU ): Water added to Circulating water
system to replace water lost from the system by
evaporation, drift, blown down, and leakage.
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13

Cooling Water Associated

Problems
Due to waters ability to dissolve most
substances to some extent, and its ability
to support biological life every cooling
water system is subjected to potential
operational problems. These are:
1. Corrosion
2. Scaling
3. Fouling ( Chemical an biological)
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14

Corrosion
A natural phenomenon of returning processed
metals to a stable oxide state.
Corrosion of metal Fe
Fe ++ + 2eReduction of water 2H2O + 2eH2 + 2OHWater (electrolyte)

Cations

Anions

Corrosion product
deposits

CATHODE
Electron path
11/13/15

ANODE

CORROSION CELL

15

TYPES OF CORROSION
Corrosion falls into three basic categories
1. GENERAL CORROSION
2. LOCALISED PITTING CORROSION
3. GALVANIC CORROSION
General corrosion takes place over the entire
metal surface while localised pitting takes
place at a small anode and because of smaller
area is typically more severe.
Galvanic corrosion occurs when one metal
sacrifices itself to protect another. This would
occur when two dissimilar metals are in
contact.
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16

Factors affecting Corrosion

Dissolved Oxygen
Dissolved and suspended solids
Acidity Alkalinity
Water velocity
Temperature
Microbiological Growth
The pH or alkalinity of the water is extremely
important as it affects corrosion significantly.
As a general rule corrosion potential decreases
when pH increases, but as the pH increase so
17
does 11/13/15
the potential for scale.

Corrosion Monitoring
System corrosion rates can be measured
with the use of:
Corrosion Coupons
Corrater Readings
Water chemistry tests

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18

Corrosion Control
Corrosion inhibitors are used to control the
corrosion in CW system, which are
Phosphates -When added to the system in
presence of calcium hardness will form a
cathodic inhibitor.
Chromates : Anodic inhibitor
Zinc : Cathodic inhibitor, which provides
excellent pitting corrosion protection.
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19

Corrosion Control
Tiazoles : An anodic inhibitor that
specifically protects system yellow metals.
Phosphonates : Cathodic inhibitor which
that lays down monomolecular film on
metal surfaces.
Molybdates : A non toxic heavy metal that
is excellent anodic inhibitor.

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20

SCALE
As the water cycles in cooling system, the
concentration of the dissolved ions
increases until the solubility of one or
more of the constituents is exceeded.
When this happens, the material
precipitates, or becomes a solid in water,
and is available to become a deposit.

11/13/15

21

Factors Affecting Scale formation

Water temperature
Alkalinity
Concentration of scale forming material in the
water
Scale occurring in cooling water system
Most Common
Less Frequent
Calcium Carbonate
Magnesium Silicates
Calcium Sulphate
Zinc Phosphate
Calcium Phosphate
Calcium Floride
Iron oxide
Iron Carbonate
Silica 11/13/15
22

Effects of Scale
Scale forms an insulating barrier and restricts
heat transfer thus decreasing cooling
efficiency.
Flow restriction through tubes
High operation cost
Process down time costs money and loss in
production
Unsafe process condition due to pressure,
temperature etc.
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23

Scale Monitoring
Calcium carbonate is the most common
frequently encountered scale in cooling
water system. It forms when Calcium and
carbonate alkalinity exceed the saturation
level and began to precipitate as calcium
carbonate.
Langelier Saturation Index (LSI)
Ryzner Stability Index (RSI)
Are very useful indices for determining scale
and scale tendencies of make up water.
11/13/15

24

Scale Monitoring
To predict corrosive or scale forming tendency of
water following indices are used.

Langlier Saturation Index

LSI = pH - pHs
pHs = (9.3 + A +B) - (C + D)
A -Total Dissolved Solid Factor
B - Temperature Factor
C - Calcium Hardness Factor
11/13/15 of Cooling Water
D - Alkalinity

25

Scale Monitoring
Ryzner Stability Index
RSI = 2pHs -pH
LSI - +ve
LSI - -ve

Scaling
Corrosive

RSI - Above 6.0 Corrosive

RSI 11/13/15
- Below 6.0 Scaling

26

Scale Control Program

Acid Feed
Sulfuric acid addition reduce bicarbonate
alkalinity as follows
H2SO4 + Ca(HCO3)2

Ca2SO4 + CO2 + 2H2O

Alkaline Treatment Method

Alkaline treatment programs are designed to
either keep calcium in solution or to modify the
crystalline structure of calcium precipitate so that
a sludge like product, which can be blow down.
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27

Scale Control Program

Scale stabilising chemical include
Phosphate and Polyacrylates
Crystal Modifier are
Copolymers and Terpolymers

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28

Fouling
Fouling is deposition of suspended solids
or buildup of microbiological organisms
within heat exchanger and cooling tower
fill.
Warm water, aeration nutrients and
sunlight transform a cooling tower into an
efficient bio-reactor.

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29

Types of fouling
General Fouling
Fouling by corrosion products
Microbiological Fouling
Biocides are used to control microbiological
fouling and organic fouling in cooling water.
Continuous chlorine dosing is being done for
better bio-fouling control at NTPC,Dadri.
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30

Types of Biocides
Oxidising Biocides
Non-oxidising Biocides
Oxidising biocides are capable of
undergoing oxidative reactions with
organic molecules.They kill
microorganisms on contact and dissipate
to form harmless, non-toxic products.
However their activity is short and require
frequent and continuous dosing. Also high
dosages cause delignification of lumber
31
and 11/13/15
metallic corrosion.

Oxidising Biocides
Various Oxidising Biocides used in cooling
water system are as follows:A. Chlorine and its various products
B. Bromine
C. Chlorine oxide
D. Ozone
E. Hydrogen Peroxide
F. Halogen Donors / Halogen Releasing
compounds
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32

C W Treatment
Circulating Water chemistry is maintained
primarily to control
-- Corrosion
-- Inhibit scale formation
-- To minimize micro-organism growth in
condenser tube or in cooling water system.

11/13/15

33

Recommended C W Treatment
Acid dosing
Sulphuric acid dosing is done which reduces
pH as well as alkalinity of the system,in turn it
reduces scaling tendency of the system.
Chemical Dosing system
Descalent and corrosion inhibitors are added
to system to avoid scaling and corrosion in
system. Biocides are also added to reduce
biofouling of the system.
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34

C W Treatment
Soft Water as Make up
Use of soft water as make up to CW system
reduces hardness of the system, hence
reduces scaling tendency of cooling water.
In addition chlorine dosing is being done to
reduce bio-fouling of the system.Residual
chlorine is maintained at 0.1 PPM.

11/13/15

35

WHY SOFTENING PLANT IS REQUIRED AT NCPS

-- At

NCPS canal water is not available in plenty.

-- It is available for 10 to11 months of a year

-- 1 to 2 months bore well water is used
-- Bore well water is mixed through replenishment pumps.
-- With pure canal water without softening COC < 1.8
For COC of 1.8 blow down required -- approx.2000 M
11/13/15

36

WHY SOFTENING PLANT IS REQUIRED AT NCPS

-- Calcium & Magnesium ions are replaced by Sodium ions,

-- Soft water in which total hardness (Ca & Mg) < 5 ppm
COC can be increased
-- Most of scales formed at heat transfer zones of
condenser are carbonates, sulphates & silicates of calcium
& magnesium.
-- Anions (sulphates, carbonates, silicates) cannot be
controlled at softening plant, so cations i.e. Calcium &
Magnesium are controlled to control scale formation.
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37

CYCLE OF CONCENTRATION

T.D.S. of Circulating Water

COC =

11/13/15

T.D.S. of Soft Water

38

TYPICAL FILTER WATER ANALYSIS FOR

DIFFERENT TYPES OF WATER
PARAMETERS

pH
CONDUCTIVITY
TOTAL HARDNESS
CALCIUM HARDNESS
MAGNISIUM HARDNESS
SODIUM & POT (BY DIFF)
M ALKALINITY
CHLORIDE
SULPHATE
SILICA
T.D.S

11/13/15

UNIT

US/CM
PPM CACO3
PPM CACO3
PPM CACO3
PPM CACO3
PPM CACO3
PPM CACO3
PPM CACO3
PPM CACO3
PPM CACO3
PPM CACO3

CANAL
WATER
8.00
160.0
90.0
60.0
30.0
10.0
60.0
10.0
30.0
6.0
90.0

75% C.W 50% C.W 25% C.W BORE WELL

25% B.W 50% B.W 75% B.W WATER
7.90
320.0
130.0
70.0
60.0
82.5
157.5
16.5
38.5
7.5
180.0

7.80
480.0
170.0
80.0
90.0
155.0
255.0
23.0
47.0
9.0
270.0

7.70
640.0
210.0
90.0
120.0
227.5
352.5
29.5
55.5
10.5
360.0

7.60
800.0
250.0
100.0
150.0
300.0
450.0
36.0
64.0
12.0
450.0

39

TYPICAL SOFT WATER ANALYSIS FOR

DIFFERENT TYPES OF WATER

11/13/15

40

NATURE OF COOLING WATER IF CANAL WATER IS USED

WITHOUT SOFTENING AT DIFFERENT COC

11/13/15

41

NATURE OF COOLING WATER IF SOFT MADE FROM

CANAL WATER IS USED AT DIFFERENT COC

11/13/15

42

NATURE OF COOLING WATER IF SOFT WATER MADE

FROM 75% CANAL WATER & 25% BOREWELL
WATER IS USED AT DIFFERENT COC

11/13/15

43

NATURE OF COOLING WATER IF SOFT WATER MADE

FROM 50% CANAL WATER & 50% BOREWELL WATER IS
USED AT DIFFERENT COC

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44

NATURE OF COOLING WATER IF SOFT WATER MADE

FROM 25% CANAL WATER & 75% BOREWELL WATER IS
USED AT DIFFERENT COC

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45

NATURE OF COOLING WATER IF SOFT WATER

MADE FROM BORE WELL IS USED AT
DIFFERENT COC

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46

COOLING TOWER DETAILS

EVOPORATION LOSSES [TH] @1.8% OF CIRCULATING WATER.

DRIFT LOSSES [TH] @0.05% OF CIRCULATING WATER.
EVOPORATION LOSSES [GAS] @1.85% OF CIRCULATING WATER.
DRIFT LOSSES [GAS] @0.05% OF CIRCULATING WATER.
OBR IS TAKEN AS 6000 MT IN CASE OF BOREWELL.
OBR IS TAKEN AS 15000 MT IN CASE OF CANAL WATER.

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47

SOFT WATER REQUIREMENT

COC EVOP+DRIFT EVOP+DRIFT BLOW DOWN BLOW DOWN BLOW DOWNBLOW DOWN TOTAL SOFT WTRCAPACITY OF ONE NO. OF STREAMS
LOSSES [TH] LOSSES [GAS] THERMAL GAS
THERMAL GAS
REQUIRED
STREAM PER DAY REQUIRED
PER DAY PER DAY
PER DAY
PER DAY
PER HOUR PER HOUR PER DAY
B.W.
C.W.
B.W.
C.W.
5.0
4.5
4.0
3.5
3.0
2.5
2.0
1.5

44400
44400
44400
44400
44400
44400
44400
44400

23712
23712
23712
23712
23712
23712
23712
23712

11/13/15

11100
12686
14800
17760
22200
29600
44400
88800

5928
6775
7904
9485
11856
15808
23712
47424

463
529
617
740
925
1233
1850
3700

247
282
329
395
494
659
988
1976

85140
87573
90816
95357
102168
113520
136224
204336

13125
13125
13125
13125
13125
13125
13125
13125

15750
15750
15750
15750
15750
15750
15750
15750

6.5
6.7
6.9
7.3
7.8
8.6
10.4
15.6

48

5.4
5.6
5.8
6.1
6.5
7.2
8.6
13.0

DESIGN PARAMTERS OF COOLING TOWER

Drift losses
C.W. Flow

-- 0.05 % of C.W. Flow.

--1,00,000 M3/hour if all 4 units
are in operation at full load.

Drift Quantity

-- 50 M3/hour hours if all 4 units

are in operation at full load

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49

T.D.S. IN CIRCULATING WATER DURING CANAL WATER AT

DIFFERENT COC

COC

T.D.S IN C.W. (PPM)

90

180

270

360

450

SALT QTY. IN DRIFT (KG/DAY)

108

216

324

432

540

SALT QTY. IN DRIFT (KG/MONTH)

3200

6480

9720

12960

16200

11/13/15

50

T.D.S. IN CIRCULATING WATER DURING BORE WELL WATER AT

DIFFERENT COC

COC

T.D.S IN C.W. (PPM)

450

900

1350

1800

2250

SALT QTY. IN DRIFT (KG/DAY)

540

1080

1620

2160

2700

16200

32400

48600

64800

81000

SALT QTY. IN DRIFT (KG/MONTH)

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51

SALT QUANTITY IN DRIFT

Salt quantity through drift can be reduced by using following
methods

A. By reducing drift.
B. By reducing TDS in circulating water.

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52

SALT QUANTITY IN DRIFT

BY REDUCING DRIFT
-- Drift eliminators are used to reduce drift quantity.
-- This can reduce drift from 0.05% to as low as 0.007%.
-- This is mechanical way of reducing drift and requires one time
investment.

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53

SALT QUANTITY IN DRIFT

T.D.S. IN CIRCULATING WATER DURING CANAL WATER AT
DIFFERENT COC WITH DRIFT ELIMINATOR

COC

90

180

270

360

450

SALT QTY. IN DRIFT (KG/DAY)

15.1

30.2

45.4

60.5

75.6

SALT QTY. IN DRIFT (KG/MONTH)

453

906

1359

1812

2265

T.D.S IN C.W. (PPM)

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54

SALT QUANTITY IN DRIFT

T.D.S. IN CIRCULATING WATER DURING BORE WELL WATER
AT DIFFERENT COC WITH DRIFT ELIMINATOR

T.D.S IN C.W. (PPM)

450

900

1350

1800

2250

SALT QTY. IN DRIFT (KG/DAY)

75.6

151.2

226.8

302.6

378

SALT QTY. IN DRIFT (KG/MONTH)

2265

4530

6795

9060

11325

COC

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55

SALT QUANTITY IN DRIFT

BY REDUCING T.D.S. IN CIRCULATING WATER

-- Analysis of soft water & filter water shows that at softening plant
TDS does not change.
-- By softening we are only exchanging Ca & Mg ions by more soluble
Sodium ions.
-- If TDS is to be decreased then we have to go for either
-- partial demineralization process
or
-- convert few softening streams in H+ cycle
i.e. split stream operation

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56

SALT QUANTITY IN DRIFT

-- Water of split stream operation if passed through degasser
alkalinity due to carbonates/bicarbonates can also be decreased.
-- This needs major modifications in the plant but this will also
reduce pH of circulating water and increase the effectiveness of
chlorination.
-- This modification requires initial investment as well as
expenditure on procurement of HCl.
-- Additional annual expenditures will be approx. 20 lakhs if daily
one regeneration with Hydrochloric acid is required in the
softening plant.

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57

11/13/15

58