Improvement Opportunities of Cooling System Practices in the Refining and Petrochemical Industries

Kamran Saeed
AJCL and Eastern Technologies

Outline
Types of Cooling Systems
Objectives of Cooling Treatment Program Monitoring Methods Types of Chemical Treatments Conclusion

TYPES OF COOLING SYSTEMS

Once-Through
Open Recirculating

Closed

ONCE THROUGH COOLING

Process

Body of Water

OPEN RECIRCULATING COOLING

Process

Cooling Tower

Makeup Water

Blowdown

CLOSED COOLING
Makeup Water Process

Surge Tank

Cools Circulating Water

OBJECTIVES OF COOLING WATER TREATMENT

Minimize Corrosion
Minimize Scale

Minimize Microbial Fouling

Energy Conservation

COOLING WATER PROBLEMS

Corrosion

Biological

Fouling
Scale Deposition

DEPOSIT FORMATION & CONTROL

Deposit that occur in cooling water systems is usually divided into two categories:
Fouling
Scaling

FOULING
Scale
Crystalline

Deposition
Amorphous Solids form away From Surface Deposits may form due to low velocity or adhesive binder

Forms on Surfaces
Most Common on Heat Transfer Surfaces

SCALE
A crystalline material formed inplace. Scale precipitates and grows on surfaces.

DEPOSITION
Deposition is the accumulation of material that has formed elsewhere and has migrated to the place where it adheres.

MONITORING METHODS
Scale coupons
Heat transfer monitor

Critical exchanger monitoring

MICROBIOLOGICAL OVERVIEW
Principle cause of water problems
If not controlled, MB will increase
Corrosion rates Fouling rates

Effective control is essential for a successful cooling water program

PHYSICAL CONDITION REQUIREMENTS

Temperature

Most 750F - 1400F, Optimum 1000F

pH Optimum pH is 6.5 to 9.5 Oxygen Requirements vary drastically Aerobic bacteria require free Oxygen Anaerobic grow in the absence of Oxygen

MICROORGANISM FOUND IN COOLING WATER SYSTEMS

Aerobic slime formers
Anaerobic corrosive Iron depositing

Nitrifiers
Fungi Mold Yeast Algae

CRITICAL MB CONTROL FACTORS

Prevention is the key
Proper selection of the biocides Proper and Consistent dosage with sufficient time to kill
Like antibiotics, take the whole course

Monitor to ensure the results are achieved Proper registration for the biocide in use Process leaks should be detected and stopped as soon as possible

TYPES OF CHEMICAL TREATMENT

Oxidizing biocides Non-oxidizing biocides

OXIDIZING BIOCIDES
Chlorine Chlorine gas Chlorine liquid (bleach) Bromine Sodium Bromide Liquid Solid Bromine Source Chlorine Dioxide Generated on site Ozone

NON-OXIDIZING BIOCIDES
nIsothiazolin n2,2-dibromo-3-nitrilopropionamide (DBNPA) nGlutaraldehyde nTerbuthylazine (TBZ)

MICROBIOLOGICAL MONITORING METHODS

Oxidative/Reductive Potential (ORP) of water
Inspection of deck and coupons Chlorine residual and consumption

Heat transfer coefficients

Heat transfer monitors Inspection of water RW Sampler Bio test results

MICROBIOLOGICAL CONTROL TIPS

Establish good chlorination/bromination practices
Keep the tower deck free of algae Detect anaerobic bacteria growth as soon as possible

Apply non - oxidizing biocide based on accurate system volumes

Alternate biocides if possible

Process leaks should be detected and stopped as soon as possible

CORROSION
Electrochemical reaction
Metal returns to its natural state

CONTROL OF CORROSION
Form a protective film of calcium carbonate on the metal surface using the natural calcium and alkalinity in the water Remove the corrosive oxygen from the water, either by mechanical or chemical deaeration Add corrosion inhibitors

CORROSION INHIBITORS FOR FERROUS METALS Anodic Inhibitors:

High chromate High nitrite Soluble silica Molybdate
Expensive Often reduces pitting

MONITORING METHODS
Corrosion coupons
Corraters

Water analysis

COOLING WATER CONTROL LIMITS

Total Hardness < 350 ppm Alkalinity < 250 ppm Free Chlorine Residual 0.2-0.5 ppm Cond < 1000 umhos pH 8.0 8.8

Phosphate 3-5 ppm

Zinc 1-3 ppm BPC 67375 60 90 ppm As product BPC 68095 30 50 ppm As product

Silica < 150

Turbidity < 20 NTU

MONITORING ACTIVITY

COOLING WATER TREATMENT CHEMICALS

Biocides
Corrosion Inhibitors Scale Inhibitors Antifoams Bio-dispersants Pre-Commission Cleaners

Biocides
Stabilised Bromine, Activated

Effective for the removal of microbiological growth and bio-films

Microbiocide

Effective for the control of bacteria and algae in cooling water and related systems
Biodegradable Biocide Effective for the control of microbiological growths in cooling water systems

Biocides
Surfactant for Hypochlorite

Used to improve bio-film cleaning and removal properties

Bronopol 10%

Used for controlling bacterial growth in industrial process systems such as industrial process waters, re-circulating water cooling towers and evaporative condensers, oil production and transport, and pulp and paper production

Biocides
Chlorine Dioxide Is an effective water disinfectant that can be applied anywhere that contamination from micro-organisms occurs. It is also a powerful oxidizing agent that is used as a superior and cost-effective treatment for the following: Drinking water disinfection THM reduction in drinking water Fe and Mn removal Cooling tower biocide Pulp Bleaching

Biocides (Chlorine Dioxide)

Rendering scrubbers Odor control Ethanol production Wastewater Treatment Phenol, cyanide, H2S destruction Paper machine and slime control

Corrosion Inhibitors
Silicate Based Corrosion Inhibitor
Inhibits both ferrous and non ferrous metal corrosion and also exhibits excellent deposit control Molybdate/Phosphonate Corrosion Inhibitor, Closed Systems It prevents corrosion and deposits in closed and aerated cooling water systems

Corrosion Inhibitors
Corrosion Inhibitor & Antifoulant for Aluminium Cooling & Closed Circuits
Is a superior corrosion inhibitor developed for use in closed water circulating systems containing aluminium

Corrosion Inhibitor/Antifoulant
Is a superior corrosion inhibitor developed to protect steel, copper and other non-ferrous metals Supplementary Corrosion Inhibitor Creates an insoluble polymeric surface complex on copper and its alloys

Scale Inhibitors
Combined Scale Control/Antifoulant
To inhibit scale formation and fouling in cooling water systems

Scale Dispersant/Sludge Conditioner

Is a blended mixture of polymeric sludge conditioners developed for use in steam boilers and cooling water systems

Antifoams
Hydrocarbon Based Multi-Purpose
Multi-Purpose Antifoam Glycol Based Antifoam Water Based Antifoam

These are developed to prevent and control foam

Bio-dispersants & Pre-Commission Cleaners

Bio-Dispersant
Improves the performance of cooling water systems, where fouling by microbiological slimes is reducing efficiency Pre-Commission Cleaner Is a chealant and polymer based cleaning agent developed specifically to remove iron and scale deposits

Conclusion
Importance of controlling cooling system problems (corrosion, scaling, and microbiological fouling)
Controlling microbiological fouling is key to the overall success of the cooling water system

Introduced effective technology to combat cooling water problems

Thank You