COOLING TOWER SEMINAR

AGENDA

1. Types Of Cooling Systems.

2. Types Of Cooling Towers

3. Cooling Towers Definitions & Calculation.

4. Basic Cooling Water Treatment principles.

5. Microbiological Contamination.

6. Veolia Water Approach To Control Legionella.

 1. TYPES OF COOLING SYSTEM

X 3 kinds of cooling systems..

9 Once-Through.

9 Closed Loop.
9 Cooling Towers ( Open Circuit).
 ONCE – THROUGH – BLOCK DIAGRAM

HOT
Process Gas/
Liquid

Sea Water Cooling IN Sea Water Cooling OUT

Heat
Exchanger

Drain

COOL
Process Gas/
Liquid
CLOSED LOOP
 COOLING TOWERS ( OPEN CIRCUIT)

>PRINCIPLE : EVAPORATION

T2 Hot Water

APPOINT
MAKE UP
EXCHANGERS

Circulation
T1 Cold Water
BLOW DOWN

¾ Water cooled after having cooled the process on an

atmospheric cooling agent.
¾ Air is the cooling agent.
X Definition of a Cooling Tower

•“A device which provides optimum

air/water contact in order to cool that
water by evaporation”.
 2. TYPES OF COOLING TOWERS

Cooling Principle
¾Water Evaporation, Enhanced With High
Contact Surface : THE FILL
¾Air flow generation methods :
1. Natural Draft.(Flowrate Depends on Atmospheric Condition)

2. Mechanical Draft. (Constant Flowrate)

Rule of Thumb...

1 BTU will raise the

temperature of 1
pound of water 1
degree Fahrenheit.
 TYPES OF COOLING TOWERS

1. NATURAL DRAFT :

¾ Tall chimney with hyperbolic shape.

¾ Warm, moist air naturally rises due to

the density differential to the dry, cooler
outside air. This produces a current of
air through the tower.

Applications :

¾ Refinaries.
¾ Power Plants.
¾ Petrochemicals.
 TYPES OF COOLING TOWERS

2. MECHANICAL DRAFT COOLING TOWERS

which uses power driven fan motors to force or draw air through the tower.

Three types……

A. Forced draft.
B. Induced draft cross flow.
C. Induced draft counter flow.
 TYPES OF
MECHANICAL DRAFT COOLING TOWERS

A. Forced Draft Cooling Towers …

¾ Water distributed via spray nozzles

¾ Air blown through tower by centrifugal fan at air inlet.
 TYPES OF
MECHANICAL DRAFT COOLING TOWERS

B. Induced Draft Counter Flow CT……

¾ Hot water enters at the top.

¾ Air enters at bottom and exits at top.
¾ Uses forced and induced draft fans.
 TYPES OF
MECHANICAL DRAFT COOLING TOWERS

C. Induced Draft Cross Flow CT

¾ Water enters top and passes over fill

¾ Air enters on one side or opposite sides
¾ Induced draft fan draws air across fill

Module 1.1.0.4
 TYPES OF
MECHANICAL DRAFT COOLING TOWERS

Water Flow Diagram - Induced Draft Cross Flow C.Towers

 3. COOLING TOWERS

DEFINITIONS & CALCULATIONS

 Cooling Water Mass Balance

X Water is recirculated over a cooling tower

and cooled. Makeup replaces water losses.

X Loss of water occurs from:

• Evaporation
• Blowdown
• Windage
 PARAMETERS FOR
WATER CALCULATIONS

9 MAKE UP WATER.
9 RE-CIRCULATION RATE.
9 TEMPERATURE DIFFERENTIAL (∆T)
9 EVAPORATION RATE.
9 BLOW DOWN RATE.
9 WINDAGE RATE
 MAKE UP WATER

Evaporation

Hot Water Out T1

Process to be cooled

Cold Water In T2
Windage Blowdown

Cold Water Basin

Makeup

Re-Circulation Pump

Makeup = Evaporation + Blow-down + Windage

 RECIRCULATION RATE (R.R)

It is the Flow of cooling water being pumped

through the entire plant cooling loop.
 Temperature Differential (∆T)

‰WET BULB TEMPERATUE OF AIR :

Wet bulb temperature indicates how much
water can evaporate into the surrounding air.

‰ Wet Bulb temperature can be measured by

using a thermometer with the bulb wrapped in
wet muslin.

‰ Performance of cooling tower is dependent

on the wet bulb temperature. Lower wet bulb
temperatures means more evaporation.
 Temperature Differential (∆T)

Wet bulb % Capacity

¾ As wet bulb temperature Temperature Available
changes , Performance of
85 0F 10
cooling tower changes. 80 0F 82
79 0F 91
78 0F Standard Rating 100
77 0F 107
76 0F 112
75 0F 120
74 0F 126
73 0F 131
72 0F 138
71 0F 142
70 0F 148
65 0F 170
60 0F 182
 Temperature Differential (∆T)

Hot Water Tem.to Tower (in)

85 0F
Cooling Range :

Difference between cooling water

Cooling Range
inlet and outlet temperature:
Heat Load

Range (°C) = CW inlet temp – CW outlet temp

High range = good performance Cold Water Temp. From Tower (out)
70 0F

Approach

Wet Bulb Temperature (Ambient)

65 0F
 Temperature Differential (∆T)

Hot Water Tem.to Tower (in)

85 0F

Approach :

Cooling Range
Difference between cooling tower
outlet cold water temperature and Heat Load
ambient wet bulb temperature:
Approach (°C) = CW outlet temp – Wet bulb temp

70 0F Cold Water Temp. From Tower (out)

Approach

Wet Bulb Temperature (Ambient)

65 0F
 Temperature Differential (∆T)

Hot Water Tem.to Tower (in)

85 0F

Effectiveness :

Cooling Range
Effectiveness %
Heat Load
= 100 x (Range / (Range+Approach))

Cold Water Tem. From Tower (out)

High effectiveness = Good Performance 70 0F

Approach

Wet Bulb Temperature (Ambient)

65 0F
 EVAPORATION RATE (LOSS) – E.R

Definition :

Water quantity (GPM) evaporated (Loss) to atmosphere for cooling

duty.

As a rule of thumb …….

For each 10ºF(5.60C) that the re-circulated water needs to be cooled, 1% of
the cooling water is evaporated in the cooling tower.

Evaporation Rate (GPM) = R.R X (∆T/1000)

 BLOW-DOWN RATE – B.R

Definition :
The portion of the concentrated cooling tower water
intentionally discharged from the cooling tower to maintain
an acceptable water quality in the cooling tower.

Evaporation Rate
Blow-Down Rate (GPM) =
Cycle of Concentration -1
 CYCLE OF CONCENTRATON – C.C

Definition :
The number of times the T.D.S content of the cooling water
is increased in multiples of itself.
The cycles of concentration can be estimated by measuring the
T.D.S or conductivity or some specific ion in both the recirculating
water (CW) and the makeup water (MU) and dividing the makeup
number into the tower water number.

Cycles Of Concentration = TDS CW / TDS MU

 CYCLE OF CONCENTRATON – C.C

Before Evaporation After Evaporation More Evaporation

Volume:1000 liter. Volume: 500 liter. Volume: 250 liter.
TDS: 100 ppm TDS: 200 ppm TDS: 400 ppm
Conc. Factor: 0 Conc. Factor: 2 Conc. Factor: 4
 CYCLE OF CONCENTRATON – C.C

3.5

WHY CYCLE?
3

With E = 1 m3/h
High cycles of Concentration Means : 2.5

M a k e u p w a t e r ( m 3 /h )
9 Low makeup Rate. 2

1.5

9 Low blow-down Rate.

1

9 Cutting total operating cost. 0.5

0 1 2 3 4 5 6 7
Concentration
 WINDAGE

Definition :
The droplets of cooling water carried by the wind and lost
from the system.

¾ Windage is commonly calculated using the following equation.

Windage = Re-Circulation Rate x 0.001

 EXAMPLE…

A cooling tower system currently circulates water at the rate of 10,000 GPM
and the cooling tower needs to cool the warmed water exiting the heat
exchanger from 90ºF to 80ºF degrees (or reduce the temperature of the water
by 10ºF), TDS of make up water is 100 ppm and cooling water 500 ppm.

X Calculate The Following :

• Evaporation Rate
• Cycle Of Concentration
• Blow-down Rate.
• Windage.
• Makeup Rate
 4. Basic Cooling Water Treatment principles

Water Treatment is the most important factor

affecting the life and energy efficient operation
of cooling towers equipments
COOLING SYSTEM WATER PROBLEMS

FO
E
AL

U LIN
SC

MICRO

G
ORGANISIM

CORROSION
 MINERAL SCALE

™Cooling Water contains many different minerals -- normally

these minerals are dissolved in the water

™Under certain conditions minerals can come out of solution and

form into hard, dense crystals called SCALE.
 COMMON SCALES

ƒ Calcium Carbonate
ƒ Magnesium Silicate
ƒ Calcium Phosphate
ƒ Calcium Sulfate
ƒ Iron Oxide
ƒ Iron Phosphate

Scaled Heat Exchanger Tubes

 SCALING

Why is it so important to control it ?

SCALING

Blockage Of Possibility Of Corrosion

Insulating Film Under Deposit
Tubes & Pipe works

Reduces Reduces
Heat Transfer Flow rate Pitting

Increase in Temperatures
&
Pressures
PARAMETERS AFFECTING THE RATE OF
SCALE FORMATION

™ PH

™ TEMPRATURE.

™ CONCENTRATION OF IONS e.g HCO3- , Ca+2 , Mg+2

™ Total Dissolved Solids.
 PARAMETERS AFFECTING THE RATE OF
SCALE FORMATION

THE SEQUENCE OF EVENTS THAT LEADS TO THE

CRYSTALLISATION OF A SALT MAY BE DEFINED AS :
SCALE

CRYSTAL GROWTH

NUCLEATION

SUPERSATURATION

SOLUBALISATION

Water & Soluble Minerals

 PARAMETERS AFFECTING THE RATE OF
SCALE FORMATION

HYDREXTM ANTISCALANT CHEMICAL ADDITIVES.

(MECHANISM TO CONTROL SCALE DEPOSITION)

1. THRESHOLD EFFECT
Chemicals which , when used is sub-stoichiometric amount is capable of preventing the
precipitation of salts from a supersaturated solution.

2. CRYSTAL GROWTH INHIBITION / CRYSRAL DISTORTION.

Chemical interference to normal crystal growth produces irregular crystal structure with
poor scale forming ability

3. DISPERSANCY :
Chemical which can adsorb onto scale surface causing the particles to remain in suspension.
 METHOD OF CONTROLING
SCALE FORMATION

ordering
+
+ - +
- + - +-- +
+ + - + +- +
+ + - + -
- - - -+ - + - -
+ - +- + -- + -- + -+ - Growth
+ - +
-+-+ - + -+ - +- + - - +
+ - -+ -+
+
- - -+ + -+ +- + - + +- -+ +- +-
+
- - +
- - -+ +- -+ + -+++ -+ - + -
PROTONUCLEI - +-
IONS NUCLEI

CRYSTALS
 METHOD OF CONTROLING
SCALE FORMATION

ordering
+
+ - +
-
+ - + + - +
- + - +
+
- - - -+ - + - - +
+ - + + - + + - +- Growth
+ - +
-+-+ - + - + - +
+ - - + - + - -
+
- - -+ + -+ - + - +- +
+
- + - + -
- - + - ++ - +
+ -
IONS PROTONUCLEI NUCLEI

Distorted crystal Lattice No-Scale

 FOUR STEP CORROSION MODEL

STEP 1
STEP 4 STEP 3

STEP 2

X Step 1: At the anode, pure iron begins to break down in contact with the cooling water.

X Step 2: Electrons travel through the metal to the cathode.

X Step 3: At the cath ode, a chemical reaction occurs between the electrons and oxygen in cooling
water to forms hydroxide.

XStep 4: Dissolved minerals in the cooling water complete the electrochemical circuit back to the anode.
 CORROSION

Corrosion product Corrosion product

Cooling Tower Circulation Pump Cooling Tower Suction Line
 CORROSION

¾ Factors affecting corrosion rate

z Temperature
z pH
z Water velocity
z Product Solubility
z Metallurgy
 CORROSION VS. WATER PH

100
Corrosion Rate, Relative Units

10

0
5 6 7 8 9 10
pH
CORROSION VS. WATER TEMPERATURE

Temperature

In general, for every 18°F in

water temperature, chemical
reaction rates double.
Corrosion Rate
 Corrosion Control

Common corrosion inhibitors for open

cooling water systems:
¾ Molybdate
¾ Zinc
¾ HPA (all organic)
¾ Silicate
¾ Phosphate
¾ Polyphosphates
 Corrosion Inhibition

HPA Zn Si MO PO4 HPA Zn Si MO PO4

Cathode(+) Metal Surface Anode(-)
 METHODS TO CONTROL CORROSION

™ HYDREXTM CORROSION INHIBITOR

ACTIVE MATERIALS FUNCTION

MOLYBDATE Anodic Corrosion Inhibitor

ZINC Cathodic Inhibitor

ORGANIC INHIBITOR Copper Metal Corrosion Inhibitor

 METHODS TO CONTROL CORROSION

Two Types Of Corrosion Inhibitors :

1. ANODIC INHBITOR (MOLYBDATE).
9 Protect bulk of metal surface by forming oxide film.
9 PH control not required.
9 Does not promote bacterial growth.
2. CATHODIC INHIBITOR (ZINC).
9 Stifles the cathodic reaction.
9 Prevents corrosion from proceeding ahead.

Both the cathodic & anodic sites are protected to

ensure low overall corrosion rates
MONITORING TOOLS TO CONTROL CORROSION

Designed By

Metito/Veolia Water Solutions & Technologies

 A. ON LINE CORRATER INSTRUMENT

™ CORROSION RATE SYSTEM DESIGNED FOR COOLING WATER SYSTEMS.

™ MEASURMENT OF CORROSION RATE ( MPY ) ON CONTINOUS BASIS.
™ DATA LOGGING WITH CORRDATA PLUS SOFTWARE
B. CORROSION & DEPOSITE MONITORING SYSTEM

THIS SYSTEM CAN BE USED BY METITO/VEOLIA WATER TO MONITOR AND CONTROL

CORROSION / DEPOSIT IN HEAT EXCHANGER.
 C. CORROSION COUPONS

Plastic rod

Stainless
steel rod

Steel test plate

∆w (g)x 365
C (µm/year)=
Area (mm2) x N(days) x density (g/cm2)
5.0 MICRO-BIOLOGICAL CONTAMINATION

Micro-Organism Contamination caused by…..

¾ BACTERIA (MICROSCOPIC ANIMALS)

ƒ Aerobic
ƒ Anaerobic
¾ ALGAE (MICROSCOPIC PLANTS)
¾ Fungi/yeast (‘timber-eaters’)
 ALGAE

¾ Large quantities of polysaccharides (slime) can be produced during

algal metabolism.

¾ Plug screens, restrict flow and accelerate corrosion.

¾ Provide excellent food source.

¾ Exist between 5 to 65 C and pH 4 to 9.

 FUNGI

¾ Although yeast and some aquatic fungi are normally unicellular, most
fungi are filamentous organisms

¾ Fungi form solid structures which can reach a considerable size.

¾ Fungi require presence of organic energy source.

¾ Exist at between 5 to 38 C and pH 2 to 9 with an optimum of 5 to 6.

 EFFECTS OF
MICROBIAL GROWTH

¾ Fouling of: tower, distribution pipework, heat exchangers

¾ Reduction in heat transfer efficiency
¾ Lost production
¾ Under deposit corrosion
¾ Inactivation/interference with inhibitors
FACTORS CONTRIBUTING TO MICROBIAL GROWTH

¾ Rate of incoming contamination

¾ Amount of nutrient present
¾ pH
¾ Temperature
¾ Sunlight
¾ Availability of oxygen/carbon dioxide
¾ Water velocities
 Closed Systems

Closed loop water systems can be used

to cool or heat an area or process.
CLOSED LOOP
 Closed Systems

¾ Water loss is usually less than 0.5% of the

system volume in a year.
¾ No water loss – no makeup.
¾ No concentration of solids so scale is
generally of no concern.
¾ Corrosion controlled by establishing a good
film barrier.
 Closed Systems
Treatment objectives:
¾ Prevention of deposits from corrosion
by-products
¾ Prevention of microbiological fouling
(glycol can be a nutrient)
 Water Treatment
¾ Corrosion Inhibitors
9 Nitrite-Borate-Triazole
9 Nitrite-Polyphosphate
9 Molybdate-Borate-Triazole
¾ Oxygen Scavenging
¾ Side-Stream Filtration
¾ Microbiological Control
¾ Glycol Systems and pH
 Sodium Nitrite

X NaNO2
X Sodium nitrite is an oxidizing agent which
functions as an anodic inhibitor by forming
an impervious oxide film to protect the
metal from further attack.
X Layer is formed by the combined action of
nitrite and dissolved oxygen and then kept
in repair by the nitrite alone.
 Silicates
X Sodium silicate (CAS Number 1344-09-8) is
the generic name for a series of compounds
derived from soluble silicate glasses and
described as water solutions of sodium oxide
(Na2O) and silicon dioxide (SiO2).
X The ability to change the proportion of silica to
sodium and the solids content provides us
with products of widely different functional
and handling properties.
 Azoles
X The most widely used azole in water treating is
tolyltriazole (TT). Also used are benzotriazole
(BZT) and mercaptobenzo-thiazole (MBT).
X While TT and BZT have roughly equivalent
performance and stability, BZT costs more than TT.
X TT is about three times as effective as MBT and is
much more stable to heat, oxidation, and light.
 Description Make-up Cooling

” Recirculation Rate. pH

” Temp at C.T Top.

TDS
” Temp at C.T Sump.
” Max Skin Temp (Condenser) Total Hardness
” C.T Lood.
” M.U Rate m3/day
Calcium Hardness
” Blow down Rate
” Pre-treatment equipments
Cl-
” Current Treatment
” Current Dosing System
Total Alkalinity
” Current Monitoring
Fe
 CONCENTRATION FACTOR

1 For normal M.U water : Max Lsi 2.5

2 Softned or R/O M.U water : Max S.S is 100
- For Low S.S use C = 10
- For High S.S use C = 5
 COOLING TOWER CALCULATION

Evaporation Rate (E) = 0.01 x ∆T (0C) x R

5.5

Blow Down = E
C-1

Windage = 0.001 x R
M.U = E+B+W
 TREATMENT PROGRAMME

¡ Corrosion control
¡ Scale control
¡ Suspended Solids Control
¡ Microbological Control
 Testing & Monitoring
Cooling Testing - What, Where & Why ?

Sample Analysis Reason

Makeup T.D.S. Hardness Cycle of

Alkalinity Concentration
pH Scaling / Corrosive
Treated water As above To ensure correct
(where applicable) operation of pre-treatment plant
T.D.S. Hardness Cycles of concentration
Recirculating
Alkalinity + scale formation
Water
Treatment reserve High waste
Low reduced protection
Iron levels High corrosion
 What if ? Cooling
START

IF WATER ACCEPT
YES YES BLEED VALVE
MAKEUP LOW CONCENTRATION NO
QUALITY AND CONTROLLER RECITIFY
QUALITY RATIO
CHANGES OPERATION
PERMANANTLY, NO NO
OK
NOTIFY ATCI
CHECK HIGH CONCENTRATION YES CHECK PROBE
PRE-TREATMENT RATIO & CLEAN
PLANT IF
APPLICABLE OR NO
SOURCE OF SUPPLY
LOW CORRECTED* YES CHECK OK INCREASE DOSE
TREATMENT RESERVE PUMP RATE OF INHIBITOR 10%
NO
NO
REPAIR

HIGH CORRECTED* YES REDUCE DOSE

TREATMENT RESERVE RATE OF INHIBITOR 10%

NO

*CORRECTED TREATMENT RESERVE MICROBIAL DOUBLE DOSE

HIGH WHY?
SPECIFIED TDS COUNT BIOCIDE
= MEASURED RESERVE x
ACTUAL TDS
2000 LOW
e.g. 20 x
4000
NO ACTION
= 10 ppm REQUIRED