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Evaluating Scale, Corrosion & Biological Control in One Cooling Tower Treatment Program
In open recirculation cooling towers, scale, metal loss and biofilm formation trigger each other. A holistic conditioning approach from analysis to monitoring.
In open recirculation cooling tower circuits, scaling, metal corrosion and microbiological growth often do not proceed independently of each other. The calcium carbonate or silicate layer formed on heat transfer surfaces not only increases energy consumption; It can also accelerate local corrosion (under-deposit corrosion) by creating oxygen-free areas underneath.
Similarly, corrosion products carry iron oxide particles into the water, increasing the sediment load; The biofilm layer covers the heat exchanger pipes and tower fillings, reducing heat transfer and making it difficult for inhibitors to reach the metal surface. Therefore, choosing a product based only on a single symptom may overlook the actual operating conditions of the system.
In the first engineering evaluation, pH, conductivity, total hardness, calcium hardness, M-alkalinity, chloride and silica values of the make-up water and tower pool water; Additionally, tower metallurgy (carbon steel, copper, stainless, galvanized), number of concentration cycles (CoC), blowdown arrangement and exchanger skin temperatures should be examined together.
In Elif Çevre Kimya's cooling tower product line, corrosion inhibitors, PBTC and polycarboxylate/terpolymer-based scale inhibitors, oxidizing or non-oxidizing biocides, biodispersants and pH conditioners are configured for separate functions. However, this diversity does not mean that the same recipe will be used in every facility. Program; Analysis results should be verified with equipment history and field measurements. There is no guarantee of fixed dosage or capacity without seeing the water analysis.
Even if the right chemical is selected, uncontrolled conductivity increase or irregular blowdown may exceed the protection limits of the program. Thanks to the conductivity-controlled automatic blowdown valve, proportional dosing pumps and regular field recordings, deviations in water chemistry are detected before the exchanger becomes clogged.
Why Should the Three Risks Be Considered Together?
In open recirculation cooling tower circuits, scaling, metal corrosion and microbiological growth often do not proceed independently of each other. The calcium carbonate or silicate layer formed on heat transfer surfaces not only increases energy consumption; It can also accelerate local corrosion (under-deposit corrosion) by creating oxygen-free areas underneath. Similarly, corrosion products carry iron oxide particles into the water, increasing the sediment load; The biofilm layer covers the heat exchanger pipes and tower fillings, reducing heat transfer and making it difficult for inhibitors to reach the metal surface. Therefore, choosing a product based only on a single symptom may overlook the actual operating conditions of the system.
Controlled Conditioning Program from Analysis to Monitoring
In the first engineering evaluation, pH, conductivity, total hardness, calcium hardness, M-alkalinity, chloride and silica values of feed (make-up) water and tower pool water; Additionally, tower metallurgy (carbon steel, copper, stainless, galvanized), number of concentration cycles (CoC), blowdown arrangement and exchanger skin temperatures should be examined together. In Elif Çevre Kimya's cooling tower product line, corrosion inhibitors, PBTC and polycarboxylate/terpolymer-based scale inhibitors, oxidizing or non-oxidizing biocides, biodispersants and pH conditioners are configured for separate functions. However, this diversity does not mean that the same recipe will be used in every facility. Program; Analysis results should be verified with equipment history and field measurements. There is no guarantee of fixed dosage or capacity without seeing the water analysis.
The Importance of Blowdown Automation and Trend Monitoring
Even if the right chemical is selected, uncontrolled conductivity increase or irregular blowdown may exceed the protection limits of the program. Thanks to the conductivity-controlled automatic blowdown valve, proportional dosing pumps and regular field recordings, deviations in water chemistry are detected before the exchanger becomes clogged.
Field Control and Monitoring List
Chemical dosage and system capacity decisions should be determined by analysis and facility conditions; There is no guarantee of fixed dosage or performance.
- Comparison of pH, conductivity (µS/cm), hardness and M-alkalinity in feedwater and tower blowdown water
- Monitoring cycle number of concentration (CoC) and Langelier/Ryznar saturation trend
- Verifying metal types in the system (carbon steel, copper alloy, galvanized)
- Alternating application and contact time recording of oxidizing and non-oxidizing biocides
- Periodic check of corrosion coupon or iron/copper transport trends
- Check out the Cooling Tower Chemicals Page
- Tower Water Analysis & Request a Quote
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- 3. Causes of Corrosion in the Condensate Return Line and Monitoring of Recovery Water
- 4. Deposit Type, Metal Compatibility and Controlled Plan for Heat Exchanger and Line Cleaning
- 5. Corrosion Management for Different Metals in Closed Circuit Chiller and Mold Cooling Water