Copyright 2012 - 2018 Walter Louis Fluid Technologies /, Cooling Water Corrosion and Scale Inhibitors, Its Just Water-How Can It Cause So Many Problems, Water Treatment is Key to Maintaining Boiler Efficiency, Cooling Tower: Total Dissolved Solids Control. After chemical treatment is added to a system a water analysis should be performed. When left unchecked, microbiological growth can quickly form a biofilmon wetted surfaces. Nitrite- molybdate-azole blends inhibit corrosion in steel, copper, aluminum, and mixed-metallurgy systems. This can lead to complacency. Closed circuit cooling towers, also known as evaporative fluid coolers, keep the system clean and contaminant-free in a closed loop. Matt Welsh is the Vice President and Water Consultant at Chardon Labs. Personalize your experience by selecting the topics you are interested in below. The system should then be flushed. Other closed recirculating cooling applications include smelt spout cooling systems on Kraft recovery boilers and lubricating oil and sample coolers in power plants. Specific equipment such as cooling towers, boilers and closed loop systems can use less water than they currently do. Corrosion is an electrochemical event in which a destructive interaction occurs between a metallic surface and non-metallic environment. From resistance welding machinery to metal forming, from chemical & pharmaceutical to medical and lasers. Others can produce ammonia which will increase pH and cause corrosion. Nitrites are utilized by some bacteria as an energy source. Closed-Loop Cooling Systems 101 By HydroThrift Corp. Dry, evaporative and liquid-to-liquid cooling systems are explained. The byproducts of bacterial respiration are often acidic, and respiration also consumes oxygen, causing the base of the biofilm to be conducive to corrosion of the base metal. Closed loop systems are more efficient than open systems. Systems containing steel and copper couples require treatment levels in the 5000-7000 ppm range. Sodium Molybdate. Still, every scenario is unique in its own way and you can contact us today to learn more about our, Closed-Loop System with Plate Heat Exchanger, Closed-Loop System with Shell & Tube Exchanger. Compare our closed-loop solution to your current method for cooling your machinery: CEC coolers recirculate one tank of water, eliminating the need for a continuous and expensive on-line water supply. If you regularly monitor and treat the water in the cooling mechanism, it will reduce problems from water deposits. 4.4 4.4 out of 5 stars (314 . Visit our updated. Among the equipment that may be on closed cooling networks are steel mill furnace housings, refinery and chemical plant process heat exchangers, turbine lubricating oil coolers, pump bearings, air compressor interstages, building heating/cooling systems, and more (see Fig. You will be redirected once the validation is complete. The free-cooler allows the chiller to be turned off for a large part of the year. If bimetallic couples are present, galvanic corrosion may develop. In a vented system, this tendency is reduced by the decreased solubility of oxygen at higher temperatures. Closed loop systems maintain water volume and quality; typically experiencing losses of less than 10% of its total . 300 days x 16 hours/day = 4,800 hours. These industries need to invest in a system that will operate at its peak and require lower maintenance levels throughout the year. Any closed system has the potential to become contaminated with microbes. Closed-loop chillers are used to exchange heat from industrial or commercial applications by running coolant through a closed-loop system. In a closed system, water circulates in a closed cycle and is subjected to alternate cooling and heating without air contact. The basic components to a closed-loop dry cooling system are the fluid cooler, which contains the air to liquid heat exchanger with the fan/s, the pump and control skid, the coolant, and the field installed system piping. We stock many models of water chillers that are ready for quick delivery! Carbamates Isothiazalone based biocides have proven to be effective in closed systems and are not prone to foaming. Thats why stator cooling water should be continuously monitored for conductivity and dissolved oxygen. Read More Why a Water Chiller? If water is being utilized in a closed loop system in a northern climate, it is imperative that a minimum flow be maintained at . One of the most common industry uses for cooling systems of this type can be found in power stations or natural gas plants. Chromate treatments in the range of 500-1000 ppm as Cr4O2are satisfactory unless bimetallic influences exist. An appropriate inhibitor such as nitrite or molybdate should be added to sufficient levels to maintain corrosion protection. Closed loop systems have more uses than for emergencies. However, closed recirculating systems have an equal potential to support microbial growth, corrosion and fouling deposits. The simplest way to describe the way in which this system works would be to compare it to a massive, complex chimney. Closed-Circuit Industrial Coolers Water Systems with Closed-Circuit Industrial Coolers have many advantages and are ideal for cooling in any climate for a wide variety of reasons. This is why these industrial cooling systems are manufactured from different materials to allow for higher temperature ranges and overall efficiency. Replace water-cooled equipment with air-cooled equipment or best available energy/water-efficient technology. Nitrite is another widely accepted nonchromate closed cooling water inhibitor. Fluid Discharge Temperature: 65 F. In theory, a closed loop system should never leak. Molybdate treatment levels can be anywhere between 200 ppm and 800 ppm as molybdate. A Brief History of U.S. Coal Ash Since the Kingston Spill, Germanys Energiewende at a New Turning Point, Beyond the Firewall: Best Practices for Cybersecurity Risk Management, Xcel Energy: Committed to Renewables, but Going Its Own Way, New Metering Solution Controls Condensate in HRSG Systems, Entergy Grows Revenue, Increases Customer Satisfaction with Value-Added Services, Flexible & Reliable: Optimal performance amid variable power generation, AI in Renewables: The Secrets to Successfully Scaling a Diversified Fleet. Minimize your system energy, maintenance, and installation costs with the FXV Closed Circuit Cooling Tower, the industry standard for closed-loop systems. The bearing cooling water system generally provides cooling for critical pump bearings and seals, hydrogen coolers for the generator, lube oil, and air compressor coolers. To prevent corrosion in carbon steel components, the water must maintain a high or alkaline pH. The simplest way to describe the way in which this system works would be to compare it to a massive, complex chimney. For example, hollow strands for cooling water flow may be in the top right-hand corner of a stator bar on one end and come out somewhere in the middle of the stator bar on the other end. In the end, its important to point out that without these cooling systems there is no heavy industry (or industry of any kind). When the system is returned to high-temperature operation, oxygen solubility drops and the released oxygen attacks metal surfaces(Figure 32-1). For this reason, they are sometimes referred to as a closed loop circulating pump. The recommendation is to replace the demineralizer resins if the conductivity exceeds 0.5S/cm or if the pressure differential across the deionizer exceeds 15 psid. This forces the copper to the CuO form of the oxide and maintains the passivation layer with very little release of oxide into the cooling water. Compact Pfannenberg EB 2.0 Large Packaged Chillers allow maximum cooling capacity in the smallest possible footprint. Chilled water systems (air chillers) exchange heat with the compressor, which in turn uses a cooling tower to throw heat back into the environment. Nonmetallic components, such as natural or synthetic rubber, asbestos, and carbon, are also used. These microbes can be introduced to the system in many ways. Get a quote. The closed loop system will need an expert to change the filters, conduct pH balance checks and perform maintenance checks. A significant change in the dissolved oxygen changes the electrochemical potential of the water. This creates two separate fluid circuits; an external circuit, in which spray water circulates over the coil and mixes with the outside air, and an internal circuit, in which the . Cooling water treatment services. If bacteria are allowed to propagate inside the closed-loop system, they can create a living deposit. During this conversion, the oxide layers become unstable and will be released into the water, where they move downstream and reattach to another area. To achieve similar inhibition with chromate, higher treatment concentrations are required. But it is more common for differential pressure across the resin bed (caused by the collection of corrosion products in the resins) to require the resins to be replaced. In a typical dual-loop system, VIPPower Supply Unit cooling is achieved through a heat exchanger coupled to a furnace cooling tower loop. -Furnace cooling water systems. The benefit of packaged towers is that theyre much simpler and quicker to install, can be modular for future expansion and dont carry the risk of field erection time and costs. , these mechanical draft cooling systems can be found in various shapes and sizes. Some success has also been recorded with nitrite-based treatment of closed brine systems at treatment levels of about 2000 ppm as. Like backup generators in hospitals, closed loop systems for nuclear power plants must always be ready to engage fully in an emergency. Monitoring the makeup water usage in a stator cooling system is also important. They're made for water-cooled, heat-producing processes and equipment that require coolant supply temperatures . Similar polymers are also now sold for use in closed-loop systems. This is the only way in which the system works, seeing as how there has to be a difference in density between hot air at the top and the air outside of the. Alfa Laval ALF filters remove unwanted material including sand and various biological matter from the cooling water before it enters the plate heat exchangers. Top 5 Best Closed Loop CPU Coolers. Over time, magnetic iron oxide particles bind together and collect on narrowed parts of the system. Depending on the current condition of the water, as they reattach, the deposits may contain either of the two copper oxides mentioned above or copper metal. Small changes in the chemistry or the flow rates and differential pressures throughout the system may not be noticed. Closed-loop cooling systems provide clean, nonfouling, nonscaling, noncorrosive coolant for many types of industrial equipment and processes. System pH is normally controlled between 7.0 and 9.0. The shape of the system is such that it naturally draws a draft into the tower, eliminating the need for a mechanical fan system with a propeller and motor. It is important to understand that it is not necessarily the corrosion of the stator bar per se that creates the problems. Closed recirculating systems have many advantages. Closed circuit cooling towers, also known as evaporative fluid coolers, keep the system clean and contaminant-free in a closed loop. Without routine care, your water could cause corrosion or excessive mineral deposits on the parts of the closed loop system. We have water treatment professionals who know the right way to balance the water chemistry in your system. If there is copper in the closed-loop system, an azole may be added to the treatment to maintain a protective chemical layer on top of the exposed copper metal surfaces. With the small amount of makeup water required, adequate treatment can virtually eliminate corrosion and the accumulation of corrosion products. EnwaMatic is a unique, chemical free solution for treatment of water in closed loop heating and cooling systems. The only points of possible oxygen entry are at the surface of the surge tank or the hot well, the circulating pump packings, and the makeup water. This can lead to low inhibitor levels and biological fouling. Therefore, high-quality water can usually be used for makeup, and as a result, scale deposits are not a problem. What is an industrial water chiller system? Consult with experts in the field. Your personalized homepage experience is available here. Thanks to the closed design, the system can go weeks between chemical treatments with well-treated and monitored water. Stator cooling water is contained in a closed-loop system that cools the copper stator bars in water-cooled generators. Defense Daily subscriber and registered users, please log in here to access the content. We wont sell you chemicals. Application / Industry: Industrial, Hydraulic, Other. The first step in the process, however, is becoming acquainted with how each system works! Water systems help cool bearings, while other coolers chill lube, air compressors and oil. 1). One of the advantages of this treatment is that it is thought to be very environmentally benign, although as long as the closed-loop system remains closed, there should be no impact on the environment. In some systems, nonoxidizing biocides such as glutaraldehyde or isothiazoline are added to the treatment to prevent bacterial growth. Flushing and chemical pretreatment are necessary to keep bacteria, algae and fungi from proliferating on pipe surfaces. Copyright 2023 Manufacturers of Cooling Towers & Systems by Delta Cooling Towers, Inc. All rights reserved. | Molybdate works with the dissolved oxygen in the water to form a protective ferricmolybdate complex on the steel. When a closed-loop cooling system is tightexperiencing no water lossthe chemical treatment that is applied can last for weeks or months before it needs to be refreshed. The chemistry of copper in oxidizing and reducing conditions has been the subject of a great deal of research, and we have a better understanding now of the conditions that cause corrosion, which is a common problem. These microbiological problems usually develop more quickly and are more extensivein open loop systems. However, in diesel and gas engines, the high temperature of the jacket water significantly increases its tendency to deposit scale. A closed-loop cooling system is a cooling system that uses a liquid coolant (which can be water/water-based coolants or oil/oil-based coolants) to exchange heat from the industrial process in a closed-loop setup. We mold the entire casing of the cooling tower as one piece so there are no joints or seams to require maintenance or develop leaks. -Water source heat units. *Trademark of Veolia; may be registered in one or more countries. Regardless of which of the three chemical treatments you choose, they are likely to also contain pH buffers (caustic and sodium borate are common) to maintain an alkaline pH, which is conducive to minimizing corrosion in carbon steel. As the name suggests, closed-loop HVAC systems are sealed units containing a fixed volume of water. Below we list of few options that you can successfully use for treating closed-loop cooling systems such as the bearing cooling water system or closed-loop air chiller system. Your personalized homepage experience is available here. Dont neglect your closed loop water system. BW007 Pure Loop 280mm All-in-One Water Cooling System. This is the basis of mechanical deaeration. Any level below 1 ppm should generate immediate action to correct the problem. Somethimes it might be necessary to change treatment programs to help reduce microbial problems, i.e. You can get expert service for the water in your closed loop cooling system. However, once corrosion processes get a foothold in these systems, it can be very difficult to correct them. However, when leaks occur, it can be costly and difficult to maintain the treatment levels necessary for corrosion and deposit control. Adding more nitrite only further accelerates the reproduction of the bacteria, making the problem worse. Symptoms of oxygen pitting may be rusty water or recurring maintenance on bearings due to the abrasion caused by the corrosion products against the seal surfaces. This blog is written once per month by one of our technical sales managers. Many processes today rely on chiller systems that are closed-loop. While open systems need monitoring of water levels and watching for particulate matter from the environment, closed circuit systems need control of the waters chemistry. When it comes to the application, packaged types are usually used in small to medium size facilities (like basic manufacturing processes, hospitals or HVAC buildings). Not changing the cartridge filters or replacing the demineralizer resins when the differential pressure calls for it will accelerate the plugging of the stator bars. In all cases, the pH of the circulating water should be maintained in the alkaline range, but below 9.0 when aluminum is present. Another advantage of getting a closed-loop cooler is that it can be significantly more efficient at maintaining low . A slightly alkaline pH increases the stability of either oxide layer. These industrial cooling systems are critical to have 100% uptime to not stop the production line within the facility. The ion exchange resin can become exhausted over time (as indicated by increasing conductivity). The water in your cooling or heating system dramatically affects performance. The target pH for the water is generally considered between 8.5 and 9.0 and may be obtained by adding small amounts of caustic to the water or by substituting sodium exchange resin for the hydrogen form cation resin in one of the deionizer vessels and metering the water through this exchanger until the pH reaches the desired level. Oxygen may also leak in through flanges, pumps, and seals. Adjust the pH level to assist with problems resulting from. Compact Efficiency Easy Maintenance and Repair Rugged Protection while allowing for easy maintenance and wash down High Flow - Long Life - Dependable Rugged Dependability - Long Life Additional Specs: Chill Water Circuit - Stationary Flow 2-100 Ton (Single) Chill Water Circuit - Stationary Flow 2-100 Ton (Dual) Cold Plates Connect these plates to cold liquid lines in process chillers and liquid-to-air cooling systems to cool equipment through direct contact. Cooling Capacity: 26.38 kW. Moreover, keep in mind that this type of division requires classification from several different standpoints. Heavy-duty finned-tube condensers deliver high efficiency and long service life in hot, corrosive, or dirty ambient environments. When high nitrite levels are applied, acid feed may be required for pH control. By visiting this website, certain cookies have already been set, which you may delete and block. Any particles that are trapped by the filters or by the deionization resins are particles that cannot reattach to the surface of the stator cooling channel. Polymer Treatments. Due to increased iron level (up to 50 ppm), we plan to flush the systems and replace it with new glycol water. Moreover, its what gives power plants their iconic look. Alkaline pH treatment can improve either the low or highdissolved oxygen regime. A major consideration when considering mechanical. ok. Work produces heat, which means that too much work produces too much heat. Visit AtlasCopco.com - Legal Notice & Cookies, Saving Money with Water-Cooled Chillers What to Know. The amount of work produced is proportional to the amount of heat generated. Packaged towers are the most common type of industrial cooling systems. These changes in position of the strands in a single bar are referred to as Roebel transposition and are done to reduce circulating electrical currents in the stator bars. At up to 170F (77C), the curves are essentially parallel. For instance, most food and beverage processing plants use open cooling towers for process chilling. Treating the water to prevent corrosion and freezing is part of maintaining these systems. The resulting heat transfer performance is much closer to that of a wet cooling . The reason why this method is so popular is due to the fact that its a natural cooling system, which uses direct contact with fresh air to cool the hot water from the system. HydroThrift's industrial closed-loop chilled-water (CW) cooling systems are the solution for your most demanding equipment cooling requirements and severe environmental conditions. Now, cooling systems are generally used to control the temperature but the temperatures that these systems are supposed to handle are far higher in some industries. Because glycol antifreezes are not compatible with chromate-based treatments, nonchromate inhibitors should be used. The benefits of closed-loop chillers are multifold: There are three main types of closed-loop cooling systems: closed-loop dry systems, closed-loop evaporative systems, and liquid-to-liquid cooling systems. Biocides make it possible to control such factors, with two classes of biocides available: It is crucial to control bacterial levels in closed water systems from the point of the first fill. The copper coils contain hollow strands in the stator bar through which the cooling water travels (Figure 3). Heat exchange surfaces, such as air chiller assemblies, may be copper or even aluminum. Compared to other technologies such as stand-alone cooling towers, closed-loop cooling with plate heat exchangers requires less make-up water and minimal water treatment. For mixed metallurgy systems, the molybdate inhibitors provide the best corrosion protection. stand-alone cooling towers, closed-loop cooling with PHEs requires less make-up water and a minimum of water treatment. Monitoring the water quality of your cooling or heating system may not be a task you have the experience or equipment to do yourself, though. this website. Closed loop water treatment is essential for many industrial emergency systems that rely on cooling water. Ironically, in closed-loop systems that are very tight, dissolved oxygen levels can drop, and thus minimize the effectiveness of a molybdate treatment (which requires dissolved oxygen to form a passive layer). Pfannenberg, Inc., a leading global manufacturer of thermal management and signaling technologies, highlights its high-efficiency liquid cooling solutions for industrial electronics. Unfortunately, for those who operate industrial facilities, hot-water heating, process loops or closed-loop cooling-water recirculation systems are not among them. However, the use of these products may result in foaming problems unless an anti-foam is used along with them. The problem is the release of the copper oxides from one area that collect in another. Proper monitoring and maintenance of these water systems can help you avoid more-costly repairs to the mechanical systems they cool. The two that are most likely to exist are the so-called bearing cooling water system (which takes care of more than just bearings) and the stator cooling system, for those plants that have a water-cooled stator. The compressor is what drives the entire process. Little, if any, evaporation occurs. The low-oxygen condition needs to be maintained during major outages, and that may take some planning. Search for used industrial process cooling water pump stations & systems. The slower the water travels through the stator bar, the warmer it becomes. These conditions can quickly deteriorate your system without you knowing until efficiency drops to detectable levels. Lowered pH could indicate bacterial growth or a system leak, affecting both the water levels and chemistry. High dissolved oxygen requires maintaining greater than 2 ppm of dissolved oxygen in the stator cooling water at all times. There are three main types of closed-loop cooling systems: closed-loop dry systems, closed-loop evaporative systems, and liquid-to-liquid cooling systems. This seems counterintuitive, but when everything becomes the cathode and there is no anode, corrosion stops. Cooling or heating systems that use water can dissipate heat acquired by the liquid with one of two methods closed loop or open loop. help you have the best experience while on the site. Compressor (HP) 20 - 40; Cooling Capacity (refrigeration tons) 18.1 to 38.4 Box 157 Rancocas, NJ 08073-0157. Small temperature increases in stator cooling bars can restrict load on or even shut down the generator. Due to the lower maintenance requirements of a closed system, this type may have a lower price over time than a higher maintenance open circuit system. Water chillers are used for providing cooling water in a wide range of industrial applications. Borates protect closed-loop systems in three ways: Corrosion inhibition, buffering, and cleaning. Closed loop systems do not have an opening to the air, but this does not mean the system has complete protection from foreign matter in the water. In most cooling systems, this is in the range of 10-200 degrees F. The heat flux is generally low and in the range of 5,000 to 15,000 Btu/ft 2 /hr. Deposits and partially plugged strands can reduce the water flow rate. Depending on the pressure of the closed-loop versus open-loop system at this point, the bearing cooling water may leak out, or the open cooling water may leak in. Inductotherm Closed-Circuit Industrial Coolers, 2023 Inductotherm Corp. | ALL RIGHTS RESERVED, Horizontal Induction Tunnel Furnace Systems, Induction Systems for Vacuum and Controlled Atmospheres, High Resistance Load (HRL) Melting Systems, No Condensation Problems When Used with a Diversion Valve, Minimum Corrosion, Scaling and Electrolysis, Internal Water-to-Water Heat Exchanger for Ease of Installation, Completely Closed-Loop Pressurized Circuit, Fan Cycling Controls for Reduced Power Usage. The control of biological agents, like bacteria and algae, is vital to any effective cooling water treatment. Neglecting the maintenance of a closed system promotes the growth of sludge and deposits. 2023 Access Intelligence, LLC - All Rights Reserved. This creates two separate fluid circuits: (1) an external circuit, in which spray water circulates over the coil and mixes with the outside air, and (2) an internal circuit, in which the process fluid to be cooled circulates inside the coil. alternatives is their materials of construction, durability, and ease of maintenance. At Chardon Labs, we can help with these tasks and many others for your system. Unimpeded flow through all stator bar openings is critical to operation of the generator and minimizing the transport of particles into places where they can cause blockage. Closed cooling water system To cool key processes in petrochemical plants, refineries, power plants and other heavy-duty industrial environments, many plant owners and operators rely on closed-loop cooling as the preferred cooling method. The feed of nonoxidizing antimicrobial may be necessary to control nitrite reversion andbiological fouling. In most cases, the reason to convert a closed loop system from water to glycol is to prevent freezing and the associated coil damage that results when a closed circuit cooler is exposed to lower ambient temperatures. On the other hand, larger industrial cooling systems, those that are used in heavy industry and in massive plants, are almost always constructed on-site.