OZONE TREATMENT

OF
COOLING TOWER WATER
Cooling Tower Stats
45MW Two Stage Oxygen Compressor
325m
3
/hr Circulation Rate
102m
3
Basin Volume
2 Heat Exchangers in Parallel
Cooling Oxygen from 125C to below 30C
Cooling Tower Trial Objectives
Reduce water consumption
Improve Heat transfer efficiency
Stop Chemical Treatment
Improve quality of Blow Down Water
Ultimately save on power and operating
costs
|
Flow diagramm of a typical cooling water
treatment system with ozone
Basin
Power Supply
Unit incl. PLC
Cooling Tower
Ozone-
Generator
Feedgas Options:
Liquid Oxygen, Dry Air
VSA Oxygen
O
3
Blow Down
: Optional dosing points
Make-up
Water
Ozone Monitoring
Circulation Pump
Heat Exchanger
O
3
O
3
O
3
Side stream
Cooling Tower Problems
Biological counts and fouling
Corrosion
Scale formation/Increased power
consumption
Chemical handling
Water consumption
Blowdown water disposal
Water Quality before ozone treatment
Make Up Basin Make Up Basin
31-Mar 31-Mar 10-J ul 10-J ul
Conductivity
(mS/m @25'c) 240 86 16 44
pH 7.8 8.1 7.8 8.2
TSS
(mg/l @105'C) <10 <10 <10 <10
TDS
(mg/l @180'c) 126 288
Total Alkalinity
(CaCO3) 107 108 56 97
Total Hardness
(CaCO3) 74 63 52 109
Ca Hardness
(mg/l) 34 27 29 67
Mg Hardness
(mg/l) 40 36 23 42
Cl (mg/l) 368 101 10 41
Na (mg/l) 71.2 45.9
Fe (mg/l) 0.17 0.38 0.09 0.55
Si (mg/l) 11 25 5.6 10
NH3 (mg/l N) 3.2 0.4 0.7 0.2
TKN (mg/l N) 4.7 <0.1 <1 <1
NO3 (mg/l N) <0.1 0.4 1.1 1.4
PO4 (mg/l) <0.1 0.4 <0.1 0.4
TP (mg/l P) <0.1 2.8 <1 2.4
SO4 (mg/l) 455 136 14 64
COD (mg/l O2) 30 22 27 37
SRB (cfu/1ml) neg neg pos pos
HPC (cfu/1ml) 108000 40000 1540 14200
Heat Exchanger Efficiency
Hot
gas
Cooled
gas
Cold
Water
Heated
Water
Monitor
Difference
Heat Exchanger Efficiency
0
2
4
6
8
10
12
14
16
7
/
1
0

1
5
7
/
1
1

1
3
7
/
1
1

1
7
7
/
1
2

1
1
7
/
1
2

1
5
7
/
1
3

1
1
7
/
1
3

1
5
7
/
1
4

1
1
7
/
1
4

1
5
7
/
1
5

1
1
7
/
1
5

1
5
7
/
1
6

1
1
7
/
1
6

1
5
Dat e
D
e
l
t
a

T
e
m
p
17/07/2006 Before Ozone
20/07/2006 After Ozone
17/07/2006
Before Ozone
20/07/2006
After Ozone
Heat Exchanger Efficiency
0
2
4
6
8
10
12
14
16
7
/
1
0

1
5
7
/
1
1

1
7
7
/
1
2

1
5
7
/
1
3

1
5
7
/
1
4

1
5
7
/
1
5

1
5
7
/
1
6

1
5
7
/
1
7

1
1
7
/
1
8

1
1
7
/
1
9

1
1
7
/
2
0

1
1
7
/
2
1

1
3
7
/
2
2

1
1
7
/
2
3

1
1
7
/
2
4

1
1
7
/
2
5

1
1
7
/
2
6

1
1
7
/
2
7

1
1
7
/
2
8

1
0
Dat e
D
e
l
t
a

T
e
m
p
Water Quality after ozone treatment
Make Up Basin Make Up Basin
14-Aug 14-Aug 15-Aug 15-Aug
Conductivity
(mS/m @25'c) 244 651 242 615
pH 7.4 8.2 9.7 8.7
TSS
(mg/l @105'C) 18 46 26 10
TDS
(mg/l @180'c) 144 4106 1420 4018
Total Alkalinity
(CaCO3) 132 211 255 278
Total Hardness
(CaCO3) 202 636 84 507
Ca Hardness
(mg/l) 141 444 34 150
Mg Hardness
(mg/l) 61 192 50 157
Cl (mg/l) 278 950 199 780
Na (mg/l) 351 1084 435 1233
Fe (mg/l) 0.39 <0.05 0.12 0.05
Si (mg/l) 5.77 16.96 4.54 16.78
NH3 (mg/l N) 2.9 0.3
TKN (mg/l N) 4.5 2
NO3 (mg/l N) <0.1 15.3
PO4 (mg/l) <0.1 2.7
TP (mg/l P) <0.1 2.9
SO4 (mg/l) 630 1860 500 1590
COD (mg/l O2) 40 18
SRB (cfu/1ml)
HPC (cfu/1ml) 410000 42
Water Quality after ozone treatment
0
2
4
6
8
10
12
Hour s
p
H
0
2000
4000
6000
8000
10000
12000
14000
C
o
n
d
u
c
t
i
v
i
t
y

(
u
S
/
c
m
)
Make-up Water pH Basin pH
Make-up Water Conductivity Basin Conductivity
Water Quality after ozone treatment
Di fference Between Wet Bul b and Basi n water Temperatures
0
2
4
6
8
10
12
14
13579
1
1
1
3
1
5
1
7
1
9
2
1
2
3
2
5
2
7
2
9
3
1
3
3
3
5
3
7
3
9
4
1
4
3
4
5
4
7
4
9
5
1
5
3
5
5
5
7
5
9
6
1
6
3
6
5
6
7
6
9
7
1
7
3
7
5
7
7
7
9
8
1
8
3
8
5
Hour s
wet diff Linear (wet diff)
Saturation Index
1) P1 = log 10 (calcium * 2.5 * total alkalinity)
2) P2 = (max. system water temp,F * 0.00912) + P1
3) P3 = ((log 10 (conductivity * 0.8) * 0.1) + 12.27
4) pH saturation = P3 P2
5) SI = pH of cycled water - pH saturation
Inserting values from latest analysis gives a value of 2.18
POSI Number
Maximumum conductivity :
= 10
(1/(log(CaxMg)/(Na+Cl)]xlog(Alk/10)
x cond(mu)
(Practical Ozone Scaling Index)
Using this formula = 3.74 cycles of concentration
Current cycles of concentration = 4.82
Cycles of concentration
0.00
1.00
2.00
3.00
4.00
5.00
6.00
31-Mar 10-J ul 19-J ul 25-J ul 8-Aug 14-Aug 15-Aug 22-Aug
Cl Na Ca Cond
Ozone Consumption
in
Cooling Towers
0.3 to 0.6 g O
3
/ m
3
in the total recirculation flow
For average cooling tower of 1500m
3
recirculation flow
= 216kg Oxygen consumption per day per tower
Expected Results per Ave. Tower
Current Expected Savings
Tower Volume (m3) 650.00 650.00 0.00
Recirculation Rate (m3/hr) 1,500.00 1,500.00 0.00
Evaporation Loss (m3/hr) 9.90 9.90 0.00
Drift Loss (m3/hr) 1.50 1.50 0.00
Blow Down Rate (m3/hr) 4.38 0.60 3.78
Make Up Water (m3/hr) 15.78 12.00 3.78
Concentration Ratio 4.38 20.00
Cost of Make up water (R/month) 23,859.53 18,114.00 5,745.53
Cost of Treatment (R/month) 7,385.00 9,536.00 -2,151.00
Total Costs (R/Month) 31,244.53 27,650.00 3,594.53
TOTAL Savings (R/month) 3,594.53
Advantages of ozone
treatment
Excellent cooling water quality, e.g. very good
visibility depths
Long term protection against bio-fouling
Reduction of colony forming units
Effective control of Bacteria Legionella
Improved heat transfer
Reduced waste water costs because COD and AOX are
clearly under the discharge limits
Corrosion rates < 0.1 mm/y (carbon steel)
Improved industrial safety due to no storage, and
handling of hazardous chemicals
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