Description of Operating Problems in Cooling Towers and Chemical Dosing System for
Cooling Tower System
1. Details of the Cooling Water System
- Cooling tower
Description Data (provided as example, actual data
to be filled in by end-user)
Make -
Type -
Framework Wood
Filling PVC
Basin Concrete
Temp. In / Out, °C 42 / 32
Normal CW Circulation Rate, m3/hr
Drift Loss, m3/hr (0.1% of circulation rate)
Evaporation Loss, m3/hr
Approximate Blowdown Rate, m3/hr
Approximate System Volume (Basin +
Piping + Heat Exchange equipment), m3
- Filtration
Description Data (provided as example, actual data
to be filled in by end-user)
Type of Filter Dual Media Sand Filter – Downflow Type
No. of Filters Two
- Blowdown
Maximum Blowdown Rate to be considered as ___________ m3/hr
2. Makeup Water Characteristics
Parameters Units Range
Total Hardness as CaCO3 mg/L
Calcium Hardness as CaCO3 mg/L
Magnesium Hardness as CaCO3 mg/L
Silica as SiO2 mg/L
Chloride as CaCO3 mg/L
m-alkalinity as CaCO3 mg/L
Sulphate as CaCO3 mg/L
Iron mg/L
Zinc mg/L
pH -
Turbidity NTU
3. Chemical Treatment Package
3.1 Corrosion Control
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Chemical corrosion inhibitors shall be used to reduce corrosion to an acceptable level
which form protective films on heat transfer surfaces. Choice of corrosion inhibitors shall
be one of the following:
a. Stabilized Phosphate (Ortho / Polyphosphate)
b. Zinc-Polyphosphate
3.2 Scale inhibitors / Dispersants
Scale and sludge deposits in cooling water systems cause loss of heat transfer and provide the
conditions for pitting corrosion. Scale consists of inorganic salts which have precipitated from
the cooling water forming a coating on heat transfer surfaces. Sludge consists of organic and
inorganic suspended matter that settles in quiescent areas and in heat exchangers. The key to
prevention of both scale and sludge formation in a cooling water system is keeping water
velocities greater than 0.9 m/s and the use of chemical additives in combination a blow down
rate that keeps the impurity concentration below the level which causes deposits. Following
scale inhibitors / dispersants are recommended for use:
a. Inhibitors such as Hydroethylidene Diphosphonate (HEDP) / Phosphate Esters /
Aminomethylene Phosphonate (AMP)
b. Dispersants, based on either anionic or nonionic polymers, such as polyacrylamide,
polyacrylate, or polymaleic acid
3.3 Biocides for Biological Control
Operating conditions in recirculated cooling water are ideal for the growth of biological matter.
Water temperatures from 20°C to 50°C, favorable water pH, continuous supply of nutrients
including carbon, nitrogen, and phosphorous, inorganic salts and sunlight all lend themselves to
environmental conditions encouraging microbiological growth and plant life. If biological
growth gets out of control some of the following operating problems will occur:
- Fouling of heat transfer surfaces by bacterial slimes resulting in flow restriction and high
process temperatures.
- Reduced cooling tower efficiency resulting from algae, fungi, and bacterial slime growths
in the water distribution basin and fill area of the cooling tower.
- Excessive plugging of screens and filters.
- Corrosion.
- Clogging of water distribution nozzles
- Excessive sludge accumulation in the cooling tower basin
An important part of cooling tower water treatment program is to control biological activity by
dosing a biocide chemical. Following chemicals are recommended for use:
a. Chlorine as Sodium hypochlorite (liquid feed) or 100% chlorine (gas feed) to be
added to cooling tower basin
b. Chlorine Dioxide (gas) as a solution with water. Chlorine dioxide is highly soluble in
water and remains as a dissolved gas in water without reacting with water.
Prepared by: Ankur Srivastava
Chemical Engineer
ankurcheme@gmail.com
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