Water Loss Less Than 1 % / Day.

No Atmospheric Contamination.

Accurate temperature Control Possible.

Economic Operation < Sub-Zero Temp.

NON Very High / Low temp. Cooling Possible.

EVAPORATIVE
COOLING
ADVANTAGES
 CLOSED SYSTEMS
Chilled Water Hot Water

Chillers Brine Cooling DG Sets Internal Cooling Steel Manufacture

Refrigeration Units Gas Cooling Hood, Stack Cooling

Mould & Machine Lance, Camera, Tyre

Cooling Cooling

All closed loop systems are linked to secondary cooling systems,

Generally with plate Heat Exchanger
 M
SY ULT E D
O2, CO2,
Copper ST IM OLV
Aluminium EM ET SS ES: NH3,
I
MS, etc. S: AL D S Process.
GA
CORROSION
BIOFOULING
FOULING TE
R : FO MP
E UL .
AT AN
F W
O TS
RE Soft SS, Oil :
TU
A Hard Corrosion Products
N
DM Biological
CORROSION CAUSES: A SUMMARY
OXYGEN / DISSOLVED GASES:
Ingress through:
Open tanks
Make-up

OTHERS:
Multimetal system (galvanic Corrosion).
Stagnation / low flow (Local cell conc.)
Temp. differentials, Interfering ions etc.

pH :
Due to make-up.
Process Ingress.
Corrosion itself!
 CORROSION: PROBLEMS

DAMAGE TO PRODUCTION
SYSTEM PROBLEMS

Pipe Thinning / Cracks. Ingress of water in Product. (OR)

Excessive water loss. Ingress of Product in Water.
Staining / Surface Corrosion Deposit. of Corrosion products -
Mechanical Seal Damage. Improper mould finish.

Flow blockage by
Corrosion Products.
Oxygen Attack ! Desired temp. not attained.
Unscheduled maintenance.
 METAL CORROSION
ANODE +VE “MICROGALVANIC CELL” CATHODE -VE
DELECTRONATION ELECTRONATION
Fe
E +VE Fe++ + 2e- ELECTTRON TRANSFER
Cu Cu++ + 2e- FLOW OF CURRENT

Fe++ + 2OH- Fe(OH)2

OXIDATION

Fe(OH)3 Fe3O4 (Corrosion Protective Film)

Fe2O3 (Ferric Oxide or RED RUST)

REDUCTION

NEUTRAL/ALKALINE pH IN ACID pH H2 EVOLUTION METAL DEPOSITION

O2 + 2H20 + 4e = 4OH
- -
O2 + 4H + 4e - =
2H20 2H + 2e
+ -
= H2 M++ + 2e-
 TYPES OF CORROSION
GENERAL (SURFACE) CORROSION:

Anodes & Cathodes Alternate, UNIT MEASUREMENT OF

Uniform Layers of Ferric Oxide CORROSION::
1 MPY = 1/1000 INCH /YEAR,
PITTING CORROSION: OR 0.0253 mm/YEAR LOSS.

Small Anode, Large Cathode: - GOOD: < 3 MPY

Pits Formed. ACCEPTABLE: 3 - 5 MPY
NEEDS
CREVICE, GALVANIC, STRESS,
CORRECTION: 5 -7 MPY
EROSION, ABRASION,
BAD: > 7 MPY
WATER-LINE CORROSION etc.
 PITTING CORROSION:
AIR (OXYGEN) GAS PHASE
WATER (OXYGEN) LIQUID PHASE
H+
H+
O2
O2 Fe(OH)3
H+
HIGH O2 H+ H+ HIGH O2

OH- OH- Fe3O4 OH- OH-

CATHODE + Fe(OH)2 CATHODE +

CRATER
Fe2+

H2 H2

ANODE: IRON SOLID PHASE:

 pH: A MAJOR CULPRIT

ls
C

eta
O
R

ic m
R
O

ter
S
I

pho
O
N Am
Iron
R
A
T Acid soluble metals
E
Noble metals
4 9 14
pH
Representative graph.
 OXYGEN & WATER

16
Dissolved O2 ppm

14
12
10
8
6
4
2

-5.0 5.0 15.0 25.0 35.0 45.0 55.0 65.0 75.0 85.0 95.0

Temperature Deg. C
 CORROSION & INDIVIDUAL IONS

40 SULPHATES

33
MPY

25 CHLORIDES

17
MAX.
10 SOLUBILITY OF
50 225 420 610 810 1000 CaSO4
Concentration ppm. AT R.T:
2400 ppm
 CLOSED LOOP INHIBITORS

Disadvantages Additives Advantages

Risk of spot corrosion with low Nitrite Low cost. Good efficiency, if
dose. Reversion. Borate dose is controlled.
Tendency to attack Zinc & Hx
with Large soft solder surfaces. Chromates Good efficiency. Reasonable
price. Available. Protect all
Spot Corrosion with low conc. Silicates metals.
Injurious to skin, toxic! Stains
surfaces. Degradedproducts Organic Inhibitors Harmless to handle. Non-toxic.
damage mech. seals
Molybdate Combinations Not toxic. No TDS build-up.
Limited Suitability Spot corrosion
witn low conc. Inactive with
velocity >2 m/s Likelyhood for Non-toxic, harmless to handle.
fouling. Does not revert. Insensitive to
temp, stable. Broad pH
Heavily expensive. High tolerance.
residuals. New technology.

Expensive than toxic additives.

Synergy works best. 100 - 400
ppm residual needed.
SCALING & FOULING: CAUSES
Velocity, Dead Zones
Process Leakages,
Construction Organic and
EM Biological
S T
S Y Scrubbing
ENVIRONMENT Open tanks, mud
W Seepages,
AT Equipment itself.
ER

High and low pH, Fe/corrosion products,

Water quality, Biological growth, Incorrect treatment.
 FOULING: A PURVIEW

• SCALE/FOULING: • Poor cooling.

• Flow restriction.
• Underdeposit
corrosion
• Improper mould
finish
• Higher utility
consumption.
 SCALE AND DEPOSIT CONTROL

THRESHHOLD INHIBITOR
CRYSTAL MODIFIER
D
pH IS
PE
/AL R
W TR SA
O
L EU N
N TS

NEVER USED DI IMPART LIKE CHARGE

CR ST T
IN CLOSED CA Y OR U P E E TO FOULANTS. KEPT
R
SYSTEMS. TI STA T ISR TIC TU IN SUSPENSION DUE
CORROSIVE! O L D AT UC TO CHARGE REPULSION
NS S L R
O
F ST
 GROWTH ENVIRONMENT
• No MATERIAL / COATING Available Which Can withstand
MICROBIAL COLONISATION
•RATE OF MULTIPLICATION: ONCE EVERY 20 MINUTES.
PRESSURE: 0 - > 1400 BAR SALINITY: Distilled Water to rED
TEMP: ( - 12 TO > 110 Deg.C in Bacteria in SALTERNS.
HYDROTHERMAL VENTS.

TOLERANCE
pH:
0 - 4 Thiobacillus sp. CHEMICALS:
9-13 Plectonema nostocorum, PHENOLS TOXINS,
Pseudomonas sp. BIOCIDES, METALS -
HCN, ... Ag, Cu, SALTS
 MICROBIOLOGY of CLOSED LOOPS:

• Survivors in extreme
environment (Very high /
Very Low temperature) SULPHATE
REDUCING
ANAEROBIC
MICROORGANISMS
• Stagnation/low flow: BACTERIA Mainly Pitting Corrosion

Facultatives/anaerobes SLIME Psychrophiles ,

survive. FORMERS (Temp. Tolerance)
Halophiles, etc.
• Normally occuring algae (Salt tolerance)

etc. stay OUT! OTHERS NITRIFYING BACTERIA

IRON BACTERIA
• Normal TVC from
make-up / tanks etc.
 BIOFOULING: PROBLEMS
CORROSION

PITTING ACID PRODUCTION DIRECT ATTACK

BY PRODUCTION ORGANIC ACIDS IRON
OF H2S BY SRB CATHODIC DEPOLARISATION BACTERIA, O2
PRODUCTION

FOULING W/m Deg. C

CaCO3: 2.26 - 2.93
CaSO4: 2.31

THERMAL COND.
Ca3(PO4)2 : 2.60
BIOGROWTH SPL..ALGAE Fe2O3 : 2.88
PHYSICAL CHOKING OF
IMPROPER SPLASHING: BIOFILM: 0.63
FILS, Hx, PIPING
REDUCED DELTA T,
REDUCED / TURBULENT
PROVIDE FOOD FOR THICKNESS
FLOW
OTHER MICROBES. APPROX.
BIOACCUMULATION OF SS
100 MICRONS.
 CONTROL
BIOCIDES

OXIDISING: NON-OXIDISING
Not Used!

CHLOROPHENOLS SULFUR CONTAINING OTHERS

SPCP Carbamates Non-foamers
Dichlorophenol MBT Glutraldehyde
o-phenyl phenol Isothiazolines DBNPA, BNPD.
 COOLING WATER TREATMENT PROGRAMME
EXPECTED RESULTS:
SCALE
FREE
PLANT

COST EFFECTIVE
EFFECTIVE
PROGRAMME:
CUSTOMER BIOCONTROL:
EASE OF OPERATION EXPECTATIONS: TVC < 3 * 105 Ml
PRODUCT- QUALITY
SRB < 100 / 100 Ml
PERFORMANCE.
MS < 3 - 5 MPY
Cu-ALLOY< 0.5 MPY

CORROSION
CONTROL