Author: anderthalbAdmin

Cooling Tower Operating and Water Treatment Fundamentals – Part 1

Brad Buecker and Rich Aull

Process cooling is an important operational factor in many industrial plants and commercial office buildings around the world. Most of these plants use cooling towers for primary cooling. A large facility may have dozens of towers scattered throughout the premises. Often, plant personnel are focused on process engineering and chemistry, potentially neglecting cooling systems until a serious disruption occurs that threatens plant production or, worse, jeopardizes employee safety.

This article forms the basis of a short series of articles dealing with the chemistry of cooling systems. In this first part of the series, we examine the fundamentals of heat transfer in the cooling tower and the methods that have been developed to improve heat exchange in the tower. Subsequent parts discuss modern water treatment methods to ensure reliable performance.

PPCHEM® 2023, 25(4), 190–198

Cooling Tower Disinfection Switch to Chlorine Dioxide Reduces Boiler Chloride Cycling: Why and How? – Part 2

Emmanuel K. Quagraine, Trever McNabb, Taneal Weiss, Gillian Bailey, Nikki Wirtz, Khrystyna Vasylkiv, and Daniel Schorr

This is the second half of a two-part article discussing the abatement of selective boiler chloride cycling (SBCC) upon switching the recirculating cooling water (RCW) biocide from NaOCl to ClO2. The use of ClO2 treatment significantly reduces SBCC, with only sporadic spikes observed to a much lower extent. These spikes are found to be related to the plant’s operation, coinciding with sudden load drops and increased air injector flows. It is suggested that these spikes may be caused by small ClO2(g) residuals condensing at the air injector condenser and entering the feedwater, eventually reducing to chloride ions (Cl–) in the water/steam cycle. Unlike chlorination, ClO2 treatment prevents the formation and persistence of volatile chlorine compounds (VCCs), including ClO2(g). The residual ClO2 in the RCW that is responsible for the highest observed daily boiler chloride rise during ClO2 treatment is estimated to be 4.05–9.74 ⋅ 10–5 mg ⋅ L–1. However, this concentration range represents only 0.02–0.23 % of the highest to the least measured residual concentrations, confirming the previous assertions that maintenance of substantial residual ClO2 in RCW, especially when using treated municipal wastewater as make-up, is unlikely. Overall, the operational data supports the switch from NaOCl to ClO2 as an effective method for reducing SBCC in the water/steam cycle, with ClO2 treatment showing superior performance and minimal VCC formation compared to NaOCl.

PPCHEM® 2023, 25(4), 202–210

Chemistry Requirements of the Steam Turbine

Frank Udo Leidich

Safe and trouble-free operation of a steam turbine requires monitoring and control of the operating medium “steam.” In particular, it is necessary to prevent impurities in steam from causing corrosion attacks on turbine components, which, depending on the form of corrosion, can lead to sudden, unpredictable component failure. This PPCHEM 101 describes typical damage and failures that will eventually occur if the quality of the water and steam does not meet the requirements as stated in the operation manual of the steam turbine manufacturer and/or global standards and technical guidance documents as released by, for example, the International Association for the Properties of Water and Steam (IAPWS).

PPCHEM® 2023, 25(4), 220–226

ERRATA

Nobody is perfect and everybody makes mistakes sometimes. We apologize to the authors and to our readers for the mistakes in the article:

Effect of Zinc Water Chemistry on the Corrosion and Stress Corrosion Cracking Behavior of Structural Materials in Light Water Reactors – A Review

Xianglong Guo, Kai Chen, Hans-Peter Seifert, and Stefan Ritter

PPCHEM® 2023, 25(3), 124–147

Effect of Zinc Water Chemistry on the Corrosion and Stress Corrosion Cracking Behavior of Structural Materials in Light Water Reactors – A Review

Xianglong Guo, Kai Chen, Hans-Peter Seifert, and Stefan Ritter

Zinc (Zn) injection into light water reactor coolants has attracted increasing attention since the reporting of its positive effects on reducing the susceptibility to stress corrosion cracking (SCC) of steam generator tubes made of Alloy 600. Revealing the corrosion and SCC mechanisms of structural materials exposed to Zn water chemistry (ZWC) has gained importance in quantifying potential benefits for the safe long-term operation of nuclear reactors. This paper reviews the open literature on the current understanding of ZWC effects on the (uniform) corrosion and SCC behavior of structural materials used in western light water reactor plants. Some research with promising results has been conducted, but more detailed and systematic work is still needed to draw meaningful conclusions on the SCC mitigation capabilities of the ZWC.

PPCHEM® 2023, 25(3), 124–147

Impurities in Water Supplies (Natural and Reclaim) and Modern Control Methods for Industrial Plant Makeup – Part 1

Brad Buecker

Makeup water for power and industrial plants typically contains numerous impurities. Many come from natural processes, while others, often in slight but at times potentially troublesome amounts, come from human activities. The contaminants can cause fouling, scaling, and other problems in cooling, service, and high-purity makeup systems unless treatment methods are employed to reduce impurity concentrations. This series examines how impurities enter water supplies, and it provides an overview of modern treatment methods.

PPCHEM® 2023, 25(3), 148–154

Cooling Tower Disinfection Switch to Chlorine Dioxide Reduces Boiler Chloride Cycling: Why and How? – Part 1

Emmanuel K. Quagraine, Trever McNabb, Taneal Weiss, Gillian Bailey, Nikki Wirtz, Khrystyna Vasylkiv, and Daniel Schorr

This is the first half of a two-part article which discusses the abatement of selective boiler chloride cycling (SBCC), which has plagued the subject power plant, upon switching the recirculating cooling water (RCW) biocide from NaOCl to ClO2. Evidence has been given to attribute this mainly to gaseous ingress of volatile chlorinated compounds (VCCs) through weak tube-to-tubesheet joints. Based on Henry’s constants in aqueous solutions, ClO2 partitions more into the gaseous phase compared to chlorine species associated with NaOCl, i.e., chloramines, Cl2, HOCl, and OCl–. The SBCC abatement hence seems paradoxical. Based on literature and operational data, this is explained. Properties of ClO2 make keeping residual ClO2 in RCW difficult, if not impractical. At the cooling tower, major losses occur physically and chemically and even when residual remains, its high solubility in water at such low concentrations causes deviation from Henry’s law, i.e., a lower tendency to form ClO2(g). In addition, inside the condenser, where ClO2(g) may occur, it reacts quickly with oxidizable gases and (bio)organic compounds selectively yet versatilely, where it is not only consumed but avoids formation of VCCs, thereby preventing their ingress into the condensate side.

PPCHEM® 2023, 25(3), 158–174

ERRATA

Nobody is perfect and everybody makes mistakes sometimes. We apologize to the authors and to our readers for the mistakes in these articles:

On the Usefulness of Bypass Clean-up Systems

Volker Ender and Jens Weber

PPCHEM® 2023, 25(2), 100–105

Some Basics of Power Plant Chemistry – Corrosion and Deposition

Frank Udo Leidich

PPCHEM® 2023, 25(1), 38–50