Process cooling water system

Condenser and Process Cooling Water System Piping ... 

Cooling tower blowdown can be reduced by improving the energy efficiency of processes, thus reducing the thermal load on cooling towers. Alternatively, cooling water systems can be switched to air coolers, which eliminates the problem altogether. 

Continuous chlorination of a cooling water system often seems most pmdent for microbial slime control. However, it is economically difficult to maintain a continuous free residual in some systems, especially those with process leaks. In some high demand systems it is often impossible to achieve a free residual, and a combined residual must be accepted. In addition, high chlorine feed rates, with or without high residuals, can increase system metal corrosion and tower wood decay. Supplementing with nonoxidizing antimicrobials is preferable to high chlorination rates. 

Computer Control. The use of computer systems to control the operation of submerged arc furnaces, including calcium carbide, has been successfully demonstrated in the United States (see Expert systems Process control). Operations direcdy under control are mix batching, electrode position and sHp control, carbide gas yield, power control, and cooling water systems. Improvements in energy usage, operating time, and product quaHty are obtained. 

Almost all cooling water system deposits are waterborne. It would be impossible to list each deposit specifically, but general categorization is possible. Deposits are precipitates, transported particulate, biological materials, and a variety of contaminants such as grease, oil, process chemicals, and silt. Associated corrosion is fundamentally related to whether deposits are innately aggressive or simply serve as an occluding medium beneath which concentration cells develop. An American... 

Galvanic corrosion in typical industrial cooling water systems is the net result of the interplay of these factors. Some factors may accelerate the corrosion process others may retard it. In their approximate order of importance, the more influential factors are discussed below. 

All areas of the cooling water system where a specific form of damage is likely to be found are described. The corrosion or failure causes and mechanisms are also described. Especially important factors influencing the corrosion process are listed. Detailed descriptions of each failure mode are given, along with many common, and some not-so-common, case histories. Descriptions of closely related and similarly appearing damage mechanisms allow discrimination between failure modes and avoidance of common mistakes and misconceptions. 

Many sources contain scattered information concerning cooling water system corrosion and defects, and many literature studies describe corrosion processes and mechanisms from a predominantly theoretical viewpoint. Until now, however, no source discusses cooling water system corrosion with emphasis on identification and elimination of specific problems. Much of the information in this book is unique every significant form of attack is thoroughly detailed. Color photos illustrate each failure mechanism, and case histories further describe industrial problems. 

Siiica S1O2 Scale in boilers and cooling water systems Insoluble turbine blade deposits due to silica vaporization Hot process removal with magnesium salts adsorption by highly basic anion exchange resins, in conjunction with demineralization distillation... 

Cooling water systems used for process heat rejection can be classified under one of the following headings ... 

The character of surface waters can change significantly and rapidly throughout the year, and any process or cooling-water system should be designed accordingly. 

NOTE The view that deposition is an indicator of more widespread problems is also common to cooling water systems. As a result of the complex nature of deposits, their removal by acid or mechanical cleaning of boiler or cooling systems is not always as simple a process as may be portrayed. 

Ensure the adequacy (in terms of quality, quantity and reliability) of services/utilities, e.g. steam, process/cooling water, electricity, compressed air, inert gas, fire suppression systems, ventilation. 

It makes sense therefore to periodically (once per year or so) resurvey all cooling water systems from a point prior to the source of makeup water to a point beyond the discharge of bleed water in order to be aware of cooling system changing needs and to highlight any potential bottlenecks that will ultimately interfere with the users seamless cooling process. 

These filters are useful for retrofitting to existing cooling water systems that may be required to operate with a deteriorating water quality, and they usually present minimal installation problems. For most applications, however, they are installed in-line, and this can present installation problems in larger industrial process cooling systems that cannot be shut down. 

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