Closed Loop Chiller Water Non-Oxidizing

Microbiocide
A chiller is a machine that removes heat from a liquid via a vapor-compression or
absorption refrigeration cycle. This liquid can then be circulated through a heat

exchanger to cool air or equipment as required.

Cooling towers are heat removal devices used to transfer process waste heat to the
atmosphere. Cooling towers may either use the evaporation of water to remove
process heat and cool the working fluid to near the wet-bulb air temperature or in the
case of closed circuit dry cooling towers rely solely on air to cool the working fluid to
near the dry-bulb air temperature.

Biocides and MicroBiocides are chemicals that prevent and eradicate unwanted
biological fouling from the system. Biocides are of various nature such as oxidizing,
non-oxidizing, cationic, anionic etc. Biological Fouling or Biofouling is the
undesirable accumulation of micro-organisms, algae and diatoms, plants, and animals
on surface, pipelines and heat-exchangers of cooling systems. Bio-fouling can be of
aerobic (that require oxygen) or anerobic (that dont require oxygen) organisms. In
general the former is found in Cooling Towers and the later in closed circuit systems.

Another very important reason for using Cooling Tower Micro Biocides in cooling
towers is to prevent the growth of Legionella, including species that cause
legionellosis or Legionnaires disease, most notably L. pneumophila, or
Mycobacterium avium. The various Legionella species are the cause of Legionnaires
disease in humans and transmission is via exposure to aerosolsthe inhalation of mist
droplets containing the bacteria. Common sources of Legionella include cooling
towers used in open recirculating evaporative cooling water systems, domestic hot
water systems, fountains, and similar disseminators that tap into a public water
supply.
Micro biocides function in eradication of sulfate reducing bacteria, aerobic and
anaerobic bacteria that are formed and found in Cooling Tower Water.Micro Biocides
are very vital for Closed and Open Circuit Cooling Water Treatment.

TCF (Totally Chlorine Free) micro biocides are compatible with heat transfer fluids
(HTF) and can be used without any fear of corrosion of chlorine addition to the
system or depletion or degradation of HTF and corrosion of PHE (plate type heat
exchangers)

Chemtex s Closed loop Micro biocide surpasses the performance of other such less
effective closed loop treatment chemicals (such as Nalco 7330, Nalco 77352NA etc.)

Application:

Engine Jacket, Chiller Water Circuit, Glycol Brine System, Hot Water Circuit,
Engine Coolant, Process chilling and heating etc.

Specification:

Chemical Type:Organic/Inorganic Chemical Compound (TCF)

Form:Liquid

Specific Gravity :Ranges from 1.0-1.2 depending upon product

Solubility:Completely Soluble in Water

Dosage:
The amount of Closed Loop Biocide required to inhibit or remove bio fouling
depends on the type of system, application, re-circulating fluid property and plant
operating conditions. The specific dosage rates will be specified by the CSL technical
representative.

Major Benefits:

1. Prevention of Bio-fouling of system

2. Avoid plugging of nozzles
3. Avoids MIC (Microbiologically Induced Corrosion)
4. Prevent Water Borne Diseases
5. Improve heat loss because living organisms cause rise in temperature of water
6. Does not add chloride to the system

Closed loop cooling systems provide a unique set of environmental and

microbiological conditions for biocides to control microbial growth and
fouling. Key factors for biocide selection include in-use stability,
solvent content, and materials compatibility. A new biocide product based
on the methylisothiazolone active ingredient was recently developed for
use in closed loop cooling systems. The new biocide is water-based,
effective versus a range of bacteria, stable in high pH and high
temperature conditions, and contains no salts, metals, or organic
solvents. Results of comparative efficacy and stability studies versus
commercial biocides will be presented.
Methylisothiazolone: A New Biocide Product for Closed Loop Systems.
About Sodium Nitrite
Sodium Nitrite has been used as a corrosion inhibitor for closed loop water systems
for many years. Sodium Nitrite functions as an anodic corrosion inhibitor in much the
same manner as chromate and molybdate. As an anodic corrosion inhibitor
nitrite works to form a protective gamma iron oxide film on the metal surface. This
layer is formed by the reaction of nitrite and dissolve oxygen and then kept in repair
by the nitrite alone. Nitrite is not consumed to any practical extent since little is
needed to from this film. It is this film that protects the metal surface from corrosive
attack.

Sodium Nitrite offers excellent corrosion protection for ferrous metals. Nitrite
functions best when used in the pH range 9.0-10.5 and formulations for closed
systems often make use of borate buffers. In addition to buffering the pH into the
desired range, borates promote passivation by facilitating the absorption of oxygen,
and also provide some microbiological control. The concentration of nitrite required
for inhibition increase with temperature.

Sodium Nitrite is not considered a good corrosion inhibitor for copper or copper
alloys.

Concerns With Nitrite

Nitrite converts to nitrate when exposed to oxygen. It is also susceptible to
microbiological attack. It not recommended for open systems or where exposure to air
is present (open tanks or sumps and cold storage systems).

Compatibility Concerns

Sodium Nitrite is an oxidizing agent and is not compatible with reducing agents such
as sodium sulfite. It also has reduced effectiveness when chlorides and sulfides are
present in the water, unless the dosage of nitrite is increased. In general, maintain no
less than 500 ppm of sodium nitrite (preferably 1000 ppm), keeping levels of at least
350 ppm above the total concentration of chloride and sublet present in the closed
loop system.

Biological Concerns

The reactions that affect nitrite are controlled by varying forms of bacteria. Some
fungi and other forms of microorganisms have the ability to react with other forms of
Nitrogen. The nitrite ion (NO2-) is included either as a primary food source or as an
intermediate food source in a number of autotrophic reactions. Within the context of
the Nitrogen Cycle there are three microbiological processes that are relevant to the
use of Sodium Nitrite as a corrosion inhibitor in closed recirculating water systems.

This article is Part 2 of 3 of a series on nitrite closed loop treatment programs.

In Part 1, we introduced nitrite programs closed loops, discussing how they perform
and some of the issues to be aware of with these programs. In Part 2, we will take a
deep dive into the nitrogen cycle and how that can impact nitrite based programs, or
quite simply, what are the technical reasons behind why your nitrite residuals keep
disappearing.

As a review, the reactions that affect nitrite are controlled by varying forms of
bacteria that use nitrite as food. Some fungi and other forms of microorganisms have
the ability to react with other forms of Nitrogen. The nitrite ion (NO2-) is included
either as a primary food source or as an intermediate food source in a number of
autotrophic reactions. Within the context of the Nitrogen Cycle there are three
microbiological processes that are relevant to the use of Sodium Nitrite as a corrosion
inhibitor in closed recirculating water systems.
Nitrification
Nitrification is a term used to describe a two-step process involving the nitrite ion.
Step 1 involves the oxidation of ammonia ions to nitrite in the following manner:
- -
NH3 + OH + 3/2 O2 NO2 + 2H2O

This step of the nitrification process usually occurs only when at least 100 ppm of
NH3 is present. Because ammonia is not generally found naturally in such high
concentrations, this step of the nitrification process is generally found only in systems
with process ammonia contamination.

Step Two of the nitrification process involves the oxidation of nitrite to nitrate. This
reaction proceeds as follows:
- -
NO2 + 1/2 O2 NO3

This reaction occurs naturally when nitrite ions are in the presence of oxygen. Certain
bacteria, the most common of which come from the genera Nitrobacter, are able to
use enzymes to catalyze this oxidation re- action. The energy produced is then used
within the cells to assimilate carbon dioxide.

Each step of the nitrification process is carried out by separate microbial populations.
Nitrifying bacteria are most commonly found in soil where they are an important part
of the earth's natural fertilizing system. The nitrification process is aerobic and will
not proceed under anaerobic conditions.

Denitrification
Denitrification refers to a process whereby nitrite ions are converted into molecular
nitrogen (N2). Denitrification proceeds through nitrite to the formation of nitric oxide,
nitrous oxide and finally molecular nitrogen.
-
NO2 NO N2O N2

Denitrification is a facultative anaerobic process. In this instance, facultative means

denitrification can occur under conditions of no oxygen or conditions of extremely
low oxygen concentration. Denitrifying bacteria are generally found in stagnant water.
Low flow or no flow areas within a closed recirculating water system, such as dead
legs and occasionally used piping, would be ideal areas for denitrifying bacteria to
flourish.

Molecular nitrogen can be converted to ammonium ions through a process called

Nitrogen Fixation. In nitrogen fixation the ammonium ions are used to assimilate
amino acids and proteins. Nitrogen fixation is an aerobic process. However, aerobic
nitrogen-fixing bacteria can withstand extremely low levels of oxygen.
Nitrite Ammonification
Nitrite ammonification refers to the process where nitrite ions are converted to
ammonium ions via hydroxylamine (NH2OH) in a reduction reaction:
- +
NO2 NH2OH NH4

Ammonium production from this reaction occurs at a relatively high rate. The enzyme
responsible for facilitating this reaction is inhibited by the presence of oxygen making
this a strictly anaerobic process. Again, areas such as dead legs and occasionally used
piping are ideal areas for this to occur.

As a troubleshooting tool, keep these processes in mind when you start to see nitrite
residuals dropping with no apparent water losses and a possible increase in biological
activity. While this may be the in depth technical explanation as to why and how your
nitrite residuals keep disappearing, the bottom line is that bugs may be out of control
in your closed loop.

In Part 3 of this series, we will discuss the consequences of an out of control system
and how to remedy the situation.

This article is Part 3 of 3 of a series on nitrite closed loop treatment programs.

In Part 1, we introduced nitrite programs for closed loops, and in Part 2, we discussed
the nitrogen cycle and how biological problems will show themselves with nitrite
based programs by consuming any available nitrite in the system. In Part 3, we will
discuss the consequences and ways to correct program deficiencies with nitrite treated
systems.

CONSEQUENCES
The use of Sodium Nitrite in a closed system as a corrosion inhibitor at levels of 800 -
1500 ppm of nitrite offers an excellent source of nutrition for the three processes
described earlier. Most closed recirculating water systems will have areas of
anaerobic and aerobic conditions. Therefore it is possible to have more than one
process operating within the same system. At the present time there are no field tests
available to determine either qualitatively or quantitatively if these processes are
occurring.

Therefore, a system experiencing a drop in nitrite levels should be investigated with

particular attention given to the following:

1. Corresponding increase in nitrate levels

2. Corresponding increase in ammonia levels
3. Microbiological activity increase
4. Corresponding loss of alkalinity
 5. Addition of make-up water (decrease in conductivity)

If it is suspected that one or more of the microbiological processes described here is

operating within the system, it is imperative that the condition be addressed
immediately. The loss of inhibitor levels can lead to excessive corrosion within the
system. In addition, low levels of ammonia in the presence of low levels of oxygen
have been shown to cause severe corrosion cracking. Copper corrosion is accelerated
by the presence of ammonia.

CORRECTIVE ACTIONS
Clean the system If cleaning and purging the system is an option, it highly recommend that
the water circuit, including all dead legs and isolated piping, be purged and sanitized with
peroxide or chlorine dioxide. The system should then be retreated with a nitrite-free
corrosion inhibitor and occasional doses of an appropriate biocide.
Filtration - Side stream filtration is highly recommended for most closed systems and is
considered a best practice. Besides removing corrosion by products and debris that will
cause under deposit corrosion and growth sites for microbes, filtration helps to remove to
the dead microbiological matter which will eliminate a source of nutrients for these
processes.
Biocide selection Glutaraldehyde and Isothiazoline biocides are typically recommended but
have been shown to be marginally effective in control these types of microorganisms. For
this reason, the occasional addition of these biocides may not arrest the problem.

Here is a summary of various biocidal options that may typically be used

for treatment in a closed system.

Glutaraldehyde is readily biodegradable and can add nutrients for biological activity. It reacts
with ammonia and the rate of killing reaction is slowed.
Isothiazoline presents handling and skin sensitizing concerns. Copper versions will increase
bulk water copper concentration over time.
Use of biodispersants and the microbicide TTPC has been shown to be extremely effective in
mitigating the results of denitrification and ammonification.
Oxidizing biocides are not recommended for closed systems for routine biological control.
These would include sodium hypochlorite, stabilized bromine/chlorine and chlorine dioxide.
As referenced above, some oxidizers may be used to clean up a system for a one time
treatment.

It is worth mentioning in this part of the article that when a water treater is presented
with ongoing biological problems with a nitrite program that are not easily resolved,
one of the common ways to combat this issue is after a proper cleanup, to convert to
an alternative chemistry such as molybdate. Molybdate based programs, for example,
do not pose the risks of biological problems as a nitrite program does but may be a
more costly program in many cases.

While the use of sodium nitrite in closed water systems has merit as an inexpensive
and very effective corrosion inhibitor, very careful consideration should be given to
the proper application of this program to avoid the potential downsides discussed in
this series.

Air Washer
An effectively-operating Air Washer is an important aspect in certain manufacturing
facilities in maintaining the required air quality. Bellacide products assist in the
operational efficiency of these units.

Products
Biocide Control: Non-oxidizing biocides that work over a wide pH range without the
need for high free halogen residuals.

Bellacide 301
Broad spectrum non-oxidizing biocide for routine application. Halogen compatible.

Data Sheet

Bellacide 355
Superior long lasting performance biocide.

Data Sheet

Case Study

Closed Loop
Being mindful of water conservation, closed loop cooling systems are important in
water reuse. BWA products have a lower cost of operation even than industry
standards.

Products
Corrosion Control: Technologies that provide exceptional corrosion inhibition at
metal surfaces for maintaining plant integrity and efficient heat transfer.

Belclene 500
Mild steel corrosion control in low hardness zinc formulations.

Data Sheet
Belcor 575
All organic corrosion inhibitor, allowing for metal free formulations.

Data Sheet

Belcor 585
Corrosion protection low cycles, low phosphorus nonmetal, all organic.

Data Sheet

Belcor 593
All organic corrosion inhibitor, environmentally compatible alternative to nitrite.

Data Sheet

Biocide Control: Non-oxidizing biocides that work over a wide pH range without the
need for high free halogen residuals.

Bellacide 355
Superior long lasting performance biocide.

Data Sheet

Case Study

Cooling and Process

BWA chemistry is created with consideration for use, performance and the
environment. Our effective multifunctional products provide customers with the
flexibility to formulate higher performance, lower dosage, more compliant products
for scale, corrosion and bacterial control.

Products
Biocide Control: Oxidizing and non-oxidizing biocides that work over a wide pH
range without the need for high free halogen residuals.

Bellacide 301
Broad spectrum non-oxidizing biocide for routine application. Halogen compatible.

Data Sheet

Case Studies
Bellacide 355
Excellent clean up biocide for dirty systems or where organic
contamination/biological loading is high. Excellent for closed loop systems.

Data Sheet

BromiCide Granules
Fast kill broad spectrum oxidizing biocide.

Data Sheet

BromiCide Tablets
Fast kill broad spectrum oxidizing biocide.

Data Sheet

LiquiBrom 4000
Bromide salt supplement for oxidizing biocide programs.

Data Sheet

LiquiBrom 4300
Bromide salt supplement for oxidizing biocide programs.

Data Sheet

LiquiBrom 4600
Bromide salt supplement for oxidizing biocide programs.

Data Sheet

Corrosion Control: Technologies that provide exceptional corrosion inhibition at

metal surfaces for maintaining plant integrity and efficient heat transfer.

Belclene 640
Phosphonate for use in all organic scale and corrosion programs.

Data Sheet

Belclene 650
Phosphonate for use in all organic scale and corrosion programs.
 Data Sheet

Belclene 660
Phosphonate for use in all organic scale and corrosion programs.

Data Sheet

Belcor 575
All organic corrosion inhibitor, allowing for metal free formulations.

Data Sheet

Belcor 585
Multifunctional scale and corrosion inhibitor.

Data Sheet

Scale Control: These technologies provide exceptional scale inhibition for

maintaining clean heat transfer surfaces for operational reliability and reduced energy
costs.

Belclene 108
Highly effective in sugar juice applications for various mineral compositions such as
carbonates, sulfates, phosphates, oxalates, hydroxides & oxides of divalent & trivalent
metals. FDA approved 21CFR 173.73, for sugar juice evaporators.

Data Sheet

Belclene 109
Effective deposit control for sugar refining, mining water treatment, and paper water
treatment where various scaling potentials are possible. FDA approved 21CFR
173.73, for sugar juice processing.

Data Sheet

Belclene 110
Low cost, good general mixed calcium scale inhibitor.

Data Sheet

Belclene 200
Excellent calcium carbonate scale inhibitor for severe service conditions.
 Data Sheet

Belclene 220
Controls calcium carbonate scale for high hardness, high alkalinity, and
high-temperature systems.

Data Sheet

Belclene 245
Halogen tolerant maleic polymer with excellent crystal growth blocking and calcium
ion stabilization capabilities.

Data Sheet

Belclene 283
Excellent phosphonate and zinc stabilizer for scale and corrosion formulations.

Data Sheet

Belclene 400
Controls calcium phosphate and zinc deposition, iron oxide and silt dispersant.

Data Sheet

Belclene 440
Excellent calcium carbonate and phosphate scale inhibitor that is halogen stable with
low phosphorous content.

Data Sheet

Belclene 460
Halogen stable, strong dispersant with good thermal stability. Effective over a wide
pH range, with excellent threshold inhibition and crystal modification. Excellent
choice for cooling and boiler water treatment programs.

Data Sheet

Belclene 640
Phosphonate for use in all organic scale and corrosion programs.

Data Sheet
Belclene 650
Phosphonate for use in all organic scale and corrosion programs.

Data Sheet

Belclene 660
Phosphonate for use in all organic scale and corrosion programs.

Data Sheet

Belclene 810
Severe condition, halogen stable, biodegradable calcium carbonate scale inhibitor.

Data Sheet

Belcor 585
Multifunctional scale and corrosion inhibitor.

Data Sheet

Water Clarifier
Algaecides are common organisms found in all natural waters. Even under favorable
conditions and sunlight, algae can grow rapidly to cause operational issues. Bellacide

products provide assurance that your systems will remain free from algae issues.

Products
Algaecide Control: Non-oxidizing biocides that work over a wide pH range without
the need for high free halogen residuals.

Bellacide 325
Low cost, routine use algaecide.

Data Sheet

Case Study
Closed circuit or closed loop water systems are a

convenient way of heating or

cooling building services applications and industrial and commercial processes. As
the name closed loop suggests the intention is generally to retain the same water in
the system for an indefinite period which means that without effective water treatment
corrosion products and foulants can build up impairing flow and heat transfer and
control valves can become blocked and inoperative.

Heating systems can become scaled up; chilled water systems can become corroded,
choked with pseudomonas slime-forming bacteria. A poorly treated closed circuit
water system will be wasting your money long before it starts to leak.

To overcome these many potential problems we offer a comprehensive range of cost

effective inhibitors and biocides which are designed specifically for closed systems. If
your system is already suffering because of inadequate water treatment dont despair
because we can provide products and services which will restore flow and heat
transfer to even heavily fouled systems.

Understanding Problems in Closed Loop Systems

Posted by Doug Frassa on Jul 8, 2015 9:00:00 AM

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When treating a closed loop cooling system, you may encounter some of the same
issues or problems that you have experienced when treating cooling towers. Closed
loops can experience problems that rob efficiency and destroy equipment through
corrosion, scale, biological growth and fouling. The initiation of these shared issues
may be different between a closed loop and a cooling tower system, but the water
related problems to be addressed are fundamentally the same.

Closed loop systems are closed to the atmosphere and the heat exchange is
facilitated by heat exchangers where the closed loop water does not mix with the
media or water that is being heated or cooled. By design they are less vulnerable to
outside contaminants caused by environmental exposure. There is no evaporation
which conserves water. The water chemistry tends to be less variable than a cooling
tower over time.

However, you must not overlook or become complacent with the inherent stability of
a closed system because problems can arise. Closed loop systems can become out of
balance if ignored.

The Problems With Closed Loop Systems

The harm caused by corrosion is well known. Metal wastage will cause leaks, and
generate high levels of metal oxides that lead to deposition and fouling leading to
system repairs and replacement expenses.

In closed loops, corrosion is a greater concern since the corrosion products

continually build up since there is no blowdown. Particulates generated by corrosion
can lead to deposition. The deposition can further exacerbate corrosion by providing
locations for the under deposit corrosion mechanism.

Dissolved oxygen corrosion is also a contributor to corrosion in a closed

system. Make up water, open tanks and system vents can transport oxygen into the
closed loop.

The continual fouling of heat exchange surfaces and system piping with corrosion
byproducts will reduce system efficiency and performance and will result in higher
operating and equipment costs. High iron and copper levels can also impede the
efficacy of some treatment chemicals.

Mineral scaling can develop in a closed systems due to the initial fill water and
subsequent make up water used to replace any water losses from equipment
maintenance or leaks. Temperature, pH and retention time and play a role in the
precipitation of dissolved solids.

Fouling can occur due to contaminants left during initial construction or when making
system additions. Fouling particulates also provide surfaces for microbial growth
and the formation of biofilm, further reducing system efficiency. Growth of biofilm,
in turn, can lead to microbiologically influenced corrosion (MIC), creating a
contamination cycle that can be challenging to escape. Microbes can consume many
treatment chemicals. This not only reduces the active inhibitor level but can convert
the inhibitors into corrosive by-products (for one example see our blog on nitrite).

Organic contamination in closed loop systems can come from process leaks, oils or
the breakdown of glycols, biocides or treatment chemicals. The organics can be a
source of nutrients for microbes in the closed system.

Finding The Right Treatment for Your Closed Loop

System
The best water treatment program mitigates all of the above. Clearly, treating for one
single issue is not sufficient to control them all.

Good closed loop system maintenance begins with a thorough system survey,
including water analysis and an understanding of previous and existing water
treatment history and problems. Then, a proper program can be designed and
established that may include cleaning the system and adding a side stream filtration
system before initiating the chemical treatment program.

After the proper chemical treatment program has been implemented, a regularly
scheduled monitoring program needs to be established and followed.

Most of all, the right treatment program will be specific to your system. At
QualiChem, we have the expertise to identify the issues and develop a program to
resolve and control them.

4 Common Problems In A Cooling System & Their

Effects
Good cooling system maintenance is good business, and good maintenance begins
with a good water treatment program. Cooling system water quality and the treatment
program directly affects the reliability, efficiency, and operating cost of any industrial
or institutional cooling system.

Facilities must monitor and maintain control of four major water treatment issues
corrosion, scale, fouling, and microbial contamination for optimal operational
efficiency and system reliability. In return, they experience reduced equipment and
operating costs for their cooling systems. This results in reduced unscheduled
downtime caused by water related problems.

Begin maximizing operating performance and minimizing system stresses by

selecting the appropriate chemical treatment program. Of the four primary water
quality issues, no single problem stands out in importance since any one can lead to
the other. Complicating matters, because water quality and chemistry vary by location,
there is no single, universal treatment program. Instead, view choosing a chemical
treatment program as a path towards a reliable and efficient cooling system that
balances management of all four water quality issues.

The Path to Reliability

Regardless of the fact that there is not one universal treatment, the path to cooling
system reliability is the same: the use of appropriate, effective water treatment
methods. With an effective program in place, facilities can control those problems that
lead to higher operating costs and unexpected expense.

Corrosion

Cooling systems present an ideal environment for the corrosion process to occur. For
example, closed loop systems lose little water and are frequently ignored during
maintenance, making them susceptible to corrosion. However, such neglect frequently
leads to costly repairs and leaks from cooling systems potentially causing expensive
damage to other locations and systems.

Scale
Heat exchange surfaces perform a cooling systems primary function, yet are
responsible for driving scale production. Scale results when high temperatures reduce
the solubility of certain species in the water, such as calcium, to form deposits on the
heat exchange surfaces. When scale forms on a heat exchange surface, it acts as an
insulator, reducing heat dispersal and tower efficiency. Energy consumption and costs
will rise.

Fouling

This common problem is commonly caused by the three-Ds: dirt, dust, and debris,
but can also be caused by other contaminants in the system such as
migratory corrosion products or microbiological growth. Fouling can dramatically
reduce system efficiency, driving up energy and operational costs.

Biological Contamination

A cooling systems warm water and rich supply of nutrients make an ideal
environment for the growth of bacteria and other biological forms of
growth. The true major issue is microbial growth leading to biological
films, or biofilm, a nuisance capable of significant harm to system
operations. With four to five times the insulating property of calcium
carbonate scale, they can cause energy costs to skyrocket while promoting
scale and corrosion.

Pay Now or Pay Later

In the most basic terms, prevention makes for a better investment than repair or
replacement. By addressing common cooling systems issues as part of regular
preventative maintenance, operators can avoid their potentially crippling effects
including the shutdown of the processes those systems support. Good maintenance of
cooling system water quality is good business.

Utilizing Cooling Tower Blowdown Properly

Posted by Doug Frassa on Jul 22, 2015 7:30:00 AM

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Cooling towers concentrate water by evaporation and therefore concentrate dissolved

solids in the water. They also act as air scrubbers; collecting dirt, debris and
microbiological material that gets sucked into the tower. This material circulates
throughout the water circuit and concentrates along with the dissolved solids as the
water evaporates. As the concentration increases, the dissolved solids (mineral salts)
reach the saturation point and precipitate to form a gritty sludge that accumulates and
deposits on condenser tubes, heat exchanger surfaces and can harden into scale.

Blowdown is a fundamental method used to control total dissolved solids in cooling

towers by removing a portion of the recirculated water to keep impurities at
acceptable levels. Over-reliance on blowdown to control cooling tower total dissolved
solids (TDS) levels results in excessive makeup water consumption and can promote
corrosive water conditions. Too little blowdown can lead to scale formation and other
problems.

Proper cooling tower treatment begins with reviewing the makeup water and
operating parameters of the system to find the ideal chemical treatment program to
control scaling, deposition, fouling and corrosion. Once the chemical program is
designed, blowdown is employed to maintain the proper water balance and chemistry
balance in the cooling tower.

How Blowdown Is Controlled

Conductivity is an easily measured parameter that is proportional to TDS. In order
to control TDS, conductivity controllers are used to monitor and adjust conductivity
levels in the cooling tower. The set points on the conductivity controller will activate
a blowdown valve that will regulate the amount of blowdown. Properly employed
conductivity control, based on your equipment, water temperature, and chemistry, will
minimize water consumption and optimize scale and corrosion control.

Over Use of Blowdown

Blowdown is used to help avoid the over cycling of dissolved solids that would lead
to deposition in your cooling system. If you find yourself over utilizing blowdown
in a worst-case scenario, your makeup water conductivity will be very close to your
cooling tower water as you dump large amounts of water to the drain.

More realistically though, your water treatment chemical program is designed to

function within a certain control range of conductivity to allow you to cycle up, or
concentrate, the tower water. This control range will provide an upper and lower
limit for conductivity.
As you operate below the designed lower conductivity control range, the potential for
scaling will certainly decrease, but the potential exists for:

1. Wasted Water - Too much blowdown forces the tower makeup water valve to open and add
water to maintain the sump level. This unnecessary use of water is caused by high
blowdown
2. Increased Sewage Costs - All that wasted water increases hydraulic loading and sewage costs
due to the increased water volume to the sewer
3. Wasted Chemicals - All the chemistry fed to help prevent deposition is unnecessarily bled out
of the system with the blowdown
4. Potential for Increased Corrosion - Lower conductivity without the proper chemical
treatment will accelerate corrosion.

All of these reduce efficiency and increase operational costs.

Under Use of Blowdown

Trying too hard to conserve water beyond the boundaries of your chemical treatment
program will present its own set of problems:

1. Increased Potential for Scaling and Deposition All the chemistry fed to help prevent
deposition is overwhelmed and can't maintain the solubility limits and the water becomes
over saturated. Scaling of tower fill and condenser will increase energy costs. Fouled
blowdown lines from scale and debris can exacerbate the situation.
2. Potential for Increased Corrosion - The higher conductivity will drive up the corrosion
potential and exceed the limits that can be controlled with the existing chemical treatment
program.
3. Increased Potential for Microbiological Growth - The high cycles and retention time means
that biological activity can increase and put a greater demand on the biocides to control the
bio-growth.

Again, all of these reduce efficiency and increase energy and operational costs.

An efficient and effective water treatment program balances the right use of treatment
chemicals and incorporates the prudent use of blowdown to maintain your systems
water quality for optimal results. QualiChem designs cooling tower water treatment
chemical programs that eliminate excessive blowdown while solving scale, corrosion,
and microbiological issues.