Copyright 2023 Manufacturers of Cooling Towers & Systems by Delta Cooling Towers, Inc. All rights reserved. There is no one-size-fits-all solution; the best water treatment programs are specifically tailored to meet . ALF is Alfa Lavals all-purpose filter designed for installation together with Alfa Laval plate heat exchangers in closed-loop cooling applications as well as for many other filtration duties. Weve got you covered! Get a quote. These microbiological problems usually develop more quickly and are more extensivein open loop systems. This analysis should include pH, conductivity, alkalinity, hardness, and iron. A stator cooling water system contains the following components: A head tank containing the deionized water that provides suction to the pumps, Filters (cartridge filters, mesh strainers, or both), Monitoring for flow, temperature, conductivity, dissolved oxygen, and, in some cases, pH. Our focus is on offering self-contained, air-cooled recirculating chillers from 1/2 ton to 20 ton capacities from a variety of industrial chiller manufacturers. With such pure water conditions, the pits created by any localized corrosion are very small. Energy Costs = 100 kW 0.3 kW/kW 4,800 hours x $0.1 / kW-hour x 1.0 duty cycle = $14,400 per year. Reducing the contaminants and debris in the system extends the entire system'slifeby lengthening the amount of time before components need replacements. However, closed recirculating systems have an equal potential to support microbial growth, corrosion and fouling deposits. Moreover, its what gives power plants their iconic look. This process is automatic. cooling systems usually consist of a closed-loop recirculating system to cool the power supply, heat station, coils, bus, and leads. The bimetallic couple that is most difficult to cope with is that of copper and aluminum, for which chromate concentrations even higher than 5000 ppm may not be adequate. That price variability can make molybdate treatment competitive with nitriteor far more expensive. Nitrite is another widely accepted nonchromate closed cooling water inhibitor. Snow Company) is recognized as a trusted source for these important, yet often overlooked process components. 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. Closed loop systems maintain water volume and quality; typically experiencing losses of less than 10% of its total . The closed recirculating cooling water system evolved from methods used for the cooling of early engine designs. Because glycol antifreezes are not compatible with chromate-based treatments, nonchromate inhibitors should be used. The general guidelines for nitrite-based treatments are for a minimum of 700 ppm of nitrite. Pfannenberg EB 2.0 Large Packaged Chillers and PWS Series Air to Water Heat Exchangers provide contaminant-free, cost-effective component cooling without adding heat to the local environment. Sodium molybdate is generally classified as an anodic oxidizing inhibitor. Another potential division of cooling systems can be based on the heat transfer technique that these cooling systems are using. Closed loop water treatment is essential for many industrial emergency systems that rely on cooling water. However, some plants have chosen more energy- and water-efficient closed loop systems for chilling. DEEPCOOL Castle 240EX WH - With Anti-Leak. 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. On the other hand, closed-loop cooling systems that have leakageand which have significant water losscan be nearly impossible (and sometimes very expensive) to maintain at the proper treatment levels. The release rate of the copper oxides may also be affected by pH and by temperature. With 20 years of water treatment experience, including a wide range of troubleshooting and service in potable water and non-potable HVAC and industrial applications, he is an expert in water treatment chemistry for cooling towers, boilers, and closed-loop systems. Even with the same system, you can make a massive difference by running the facility and the cooling system in a different way. Personalize your experience by selecting the topics you are interested in below. Fluid coil cooling systems are usually smaller; however, they can be custom-made in order to serve as industrial cooling systems. excellent customer service, we're The primary applications that process cooling water is used for include: -Glycol cooling systems. 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. CEC coolers also eliminate the complications and expense of industrial effluent. 3D TRASAR technology for cooling water systems can help you reach your sustainability goals by reducing . 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. We wont sell you chemicals. Design, CMS, Hosting & Web Development :: ePublishing, This website requires certain cookies to work and uses other cookies to help you have the best experience. Packaged towers are the most common type of industrial cooling systems. Alkaline pH treatment can improve either the low or highdissolved oxygen regime. The free-cooler allows the chiller to be turned off for a large part of the year. (You wont know that if you are not monitoring regularly.) Closed water cooling systems also provide a reliable method of industrial process temperature control. Recommended treatment control limits are 200-300 ppm molybdate as MoO42. We are first in your inbox with the most important news in the industry―keeping you smarter and one-step ahead in this ever-changing and competitive market. 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. Using a cooling water treatment can reduce the heat wear on these components, and a closed loop system cools while requiring less maintenance. This reattachment may take a number of forms. In a system without any leaks, as long as water monitoring and treatment occur regularly, this scheduling should sufficeto minimize pollutants. This cycle can cause a stator cooling problem to come out of nowhere. Curve A plots data from a completely closed system with no provision for the venting of oxygen to atmosphere. Not a subscriber or a registered user yet? 6 Ways to Prevent Legionella in Cooling Towers Successfully, Tips for Increasing Industrial Cooling Tower Efficiency. At up to 170F (77C), the curves are essentially parallel. Your water will no longer pass through once and be a disposal . A significant change in the dissolved oxygen changes the electrochemical potential of the water. Most commonly, the piping in a closed-loop system is carbon steel. The conductivity is critical and generally is kept below 0.5S/cm. However, these dry cooling systems result in warmer cold water so they are not as efficient as mechanical open industrial cooling systems. Factors like new water piping, cooling cycles, and water recycling processes can offset the efficiency of cooling systems drastically. Dont neglect your closed loop water system. block. However, if there is insufficient nitrite in the chilled water loop, an anode can form in the piping, and again we have the big cathode/little anode corrosion cell. There are three main types of closed-loop cooling systems: closed-loop dry systems, closed-loop evaporative systems, and liquid-to-liquid cooling systems. By visiting Equipment and cooling system maintenance costs are reduced, and equipment reliability and productivity are increased. If you do not agree to the use of cookies, you should not navigate 300 days x 16 hours/day = 4,800 hours. Why are Cooling Towers Used in HVAC Systems? Closed Loop Chillers come complete with an Installation Kit and Glycol for Start up. Efficiency also increases in the winter when closed loop systems can operate dry, preventing freezing during the colder months. The oxygen-deficient area underneath the deposit becomes the anode, and the area around the deposit that is exposed to the bulk water becomes the cathode. Visit us at www.atlascopco.com/industrial-cooling! replacing nitrite with molybdate to alleviate nitrifying bacteria problems. 10 Indel Ave., P.O. The only make-up water normally needed is replace waterloss from leakage at pump seals, expansion tank overflow, or surface evaporation from system vents. It also uses the most energy in a chilled water system. A well-designed cooling tower and water treatment system can also remove depositing minerals, corrosive elements and control microbe growth, resulting in a more efficient system while saving thousands of dollars in operational costs each year. They can be found in many industrial applications as well as refrigeration systems you may see atop supermarkets. During shutdown, oxygen can enter the water until its saturation limit is reached. 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 . In nuclear facilities, redundant cooling mechanisms are critical to the safety of the plant. After chemical treatment is added to a system a water analysis should be performed. Industrial water chillers are used for controlled cooling of products, mechanisms and machinery in a variety of industries. When the system is returned to high-temperature operation, oxygen solubility drops and the released oxygen attacks metal surfaces(Figure 32-1). The metallurgy used in constructing modern engines, compressors, and cooling systems includes cast iron, steel, copper, copper alloys, and aluminum as well as solders. Low dissolved oxygen can be maintained by keeping the system leak free to limit the amount of makeup water. 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. Water systems help cool bearings, while other coolers chill lube, air compressors and oil. Protects the water source from contamination, Only 20% of the space compared to shell-and-tube. As shown, the molybdate-based treatment provides the best overall steel and Admiralty protection. Since 1965, Chardon Laboratories has provided professional water treatment techniques for Greater Cincinnati, including Avondale, Queensgate, College Hill and more. Effective pretreatment defends against the majority of closed loop system concerns. 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. 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. 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. Industries often need backup plans in the event of power losses. This occurs because the lower solubility of oxygen with increasing temperatures in a freely vented system decreases the corrosion rate faster than the rise in temperature increases it. Moreover, keep in mind that this type of division requires classification from several different standpoints. The problem is the release of the copper oxides from one area that collect in another. Lowering the pump speed can conserve energy when cooling needs decrease. The closed loop evaporative system is an open tower with a closed-loop heat exchanger built into the tower. Cold Plates Connect these plates to cold liquid lines in process chillers and liquid-to-air cooling systems to cool equipment through direct contact. We also have the expertise to design optimized combinations of the two, and the project management experience to deliver according to specification. Visit our privacy In some parts of the world, an integrated cooling system is required, combining closed-loop PHEs and If these vital parts of the building services jigsaw puzzle are poorly constructed and . Compact Pfannenberg EB 2.0 Large Packaged Chillers allow maximum cooling capacity in the smallest possible footprint. These microbes can be introduced to the system in many ways. This can cause the copper oxide to be converted from one form (cupric) to the other (cuprous). It is a collaborative effort and one which we hope you find informative and helpful. 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. Current legislation has significantly reduced the allowable discharge limits and the reportable quantity for the spill of chromate-based products. Therefore, high-quality water can usually be used for makeup, and as a result, scale deposits are not a problem. Industrial process cooling with innovative solutions that determine an increase in productivity with minimum environmental impact. Quaternary Ammonium/Tin biocides have been shown to control most types of microorganisms found in closed loop systems. These cooling or processing water systems may need some minor changes to how they operate before you see major returns in water conservation. 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. document.getElementById( "ak_js_1" ).setAttribute( "value", ( new Date() ).getTime() ); Learn more about Inductotherm Group and our 40 companies around the world. You may personalize your experience at any time during your visit. You can get expert service for the water in your closed loop cooling system. 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. However, when leaks occur, it can be costly and difficult to maintain the treatment levels necessary for corrosion and deposit control. In the end, its important to point out that without these cooling systems there is no heavy industry (or industry of any kind). When a chiller is substituted out for city water, the payback can be as short as a year. An increase in the stator cooling water temperature increases the release rate of copper oxides into the water. When such bimetallic couples as steel and copper are present, chromate treatment levels should be increased to exceed 2000 ppm. The frequency with which the filter needs to be changed, due to particulate plugging, is an indication of corrosive conditions in the system. Privacy Policy 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. Nonmetallic components, such as natural or synthetic rubber, asbestos, and carbon, are also used. In very high heat transfer rate applications, such as continuous caster mold cooling systems, chromate levels should be maintained at 100-150 ppm maximum. this website, certain cookies have already been set, which you may delete and The narrow passages, bends, and twists in the hollow copper strands, including those caused by the Roebel transpositions, create many places for small amounts of mobile corrosion products to partially or completely block the cooling waters path (Figure 4), causing the stator bar to overheat. First, it protects one of the most critical pieces of equipmentthe generator. This recirculates under pressure within the system to provide heating and cooling; for temperature control or to absorb excess heat from industrial processes. This produces a general, but overall low level of corrosion. This can be a problem. Australia's leading Evaporative Cooling manufacturer! The critical difference between these is the amount of exposure the water has to the air. This loop also requires a condenser water pump to circulate the CW through the piping between the chiller and the cooling tower or heat rejection device (radiator or closed circuit cooler). However, fewer utilities have opted to go for the extra steps required to create and maintain an alkaline pH. Some closed systems, such as chilled water systems, operate at relatively low temperatures and require very little makeup water. With decades of experience selling water chillers, Industrial Water Chiller (a division of T. J. The system should then be flushed. The stator cooling water system is a very special closed loop for a couple of reasons. data. 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. Process water loops often experience much higher temperatures and velocities as much as 10 feet per second. Corrosion is an electrochemical event in which a destructive interaction occurs between a metallic surface and non-metallic environment. If bimetallic couples are present, galvanic corrosion may develop. EVAPCO's wide range of closed circuit coolers, or simply "fluid coolers" provide a heat rejection alternative for engineers or end users who want (or need) to reduce water consumption and equipment maintenance, or a number of other considerations that exist with open-loop cooling applications. This can lead to low inhibitor levels and biological fouling. With the small amount of makeup water required, adequate treatment can virtually eliminate corrosion and the accumulation of corrosion products. Closed systems often require the addition of a suitable antifreeze. It appears that the polymer acts as a dispersant for any corrosion products or scale that might form, so it prevents corrosion by keeping the surface clean and ensuring that any dissolved oxygen in the water attacks all surfaces evenly. 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. Nitrites are utilized by some bacteria as an energy source. Various microbes will produce acidic by-products that will suppress pH and increase corrosion. In a closed-loop system, oxygen pitting is the most common type of corrosion (Figure 1). The most common of these are recirculating systems that use either evaporative . Systems using nitrite should be regularly tested for the presence of bacteria. Treating the water to prevent corrosion and freezing is part of maintaining these systems. A closed-loop industrial water chiller recirculates a clean coolant or clean water with condition additives at a constant temperature and pressure to increase the consistent and repeatable variables. Often just leaving the head tank vented is sufficient to keep the stator cooling water oxygenated, but if hydrogen leaks into the cooling water, it can displace the oxygen and cause corrosion. A closed-loop industrial water chiller recirculates a clean coolant or clean water with condition additives at a constant temperature and pressure to increase the consistent and repeatable variables. Still, every scenario is unique in its own way and you can contact us today to learn more about our packaged cooling systems. System pH is normally controlled between 7.0 and 9.0. Heat Rejection Systems. Industrial Water Chiller is a division of T. J. This means that your line of work may mandate the need for a specific tower type. Alfa Laval is a world-class supplier ofclosed-loop cooling solutions for justabout any industry where such solutionsplay a key role. We provide you with a clean system via our expert maintenance. The closed circuit has four ways to adapt to cooling needs and outside temperature changes: Adaptability makes closed systems a better option for variable climates, but ultimately the upkeep of the system will determine its cost over time. By its very nature, when a closed-loop system remains closed and operates properly for an extended period of time, it is often forgottenor at least neglected. The increased efficiency of a closed circuit system from proper water treatment ensures the generator has adequate cooling water and is always ready. The most common places for this sludge include: Other problems can arise as the pH level of the water drops. Manufacturers, hospitals, industrial facilities and many other businesses and industries embrace the long-term efficiency and savings from closed loop technology. Available on demand until February 16, 2024. If the plant experiences a loss of its primary cooling, the closed loop system allows for continued heat removal. We have closed loop glycol cooling water inside the air compressor packages by Atlas Copco. A major consideration when considering mechanical industrial cooling systems alternatives is their materials of construction, durability, and ease of maintenance. Reasons include no condensation problems, no coolant contamination, and minimum corrosion, scaling, and electrolysis. Before doing the chemical treatment of any water piping system the flushing is must. Models range up to 30 Tons, so proper capacity is available for most applications, while all units . Mechanical Draft Cooling Systems Mechanical draft cooling is an industrial cooling water system, which involves the use of an evaporation process for cooling. As the name suggests, closed-loop HVAC systems are sealed units containing a fixed volume of water. Closed loop systems are more efficient than open systems. In the presence of high-purity water, under lowdissolved oxygen conditions (<20 ppb), copper forms a passive layer of cuprous oxide (Cu2O). Equipment life is extended. Sodium Molybdate. Air Strippers, Degassifiers & Odor Control Scrubbers, Work produces heat, which means that too much work produces too much heat. Nitrite-based treatment also provides effective steel protection, with results comparable to those obtained with molybdate; however, acceptable Admiralty corrosion inhibition is not achieved. HydroThrift's industrial closed-loop chilled-water (CW) cooling systems are the solution for your most demanding equipment cooling requirements and severe environmental conditions. -Closed-loop water. This separates the working fluid, which means that there is no water loss in this system, as a result. In a vented system, this tendency is reduced by the decreased solubility of oxygen at higher temperatures. Find Nanbei and Penghui for sale on Machinio. Copyright 2023. Overheating of stator bars can result in reduced generating capacity or even catastrophic failure of the generator. Hot water from the condenser or other piece of equipment is sprayed on horizontal slats or corrugated PVC fill-packs. If bacteria are allowed to propagate inside the closed-loop system, they can create a living deposit. Some smaller variants come in the form of rooftop units. Closed loop systems distribute heated or chilled water throughout a building, with water temperatures ranging from 42F to 350F and water velocities between 2 and 5 feet per second. Where condensate is not available, zeolite softening should be applied to the makeup water. For more information about our water treatment and system maintenance, contact us today. Heat, absorbed by the water in the closed system, is normally transferred by a water-to-water exchanger to the recirculating water of an open recirculating system, from which the heat is lost to atmosphere (Figure 32-1). In some systems, nonoxidizing biocides such as glutaraldehyde or isothiazoline are added to the treatment to prevent bacterial growth. Each system is impacted by the raw water source, air quality, flow rates, metallurgy, temperature, humidity, operating procedures, and a host of other factors. In the closed-loop chiller, the coolant is first chilled in a coolant tank, then circulated throughout the process/equipment; during this circulation, the coolant absorbs heat from the application and equipment. Alfa Laval ALF filters are self-cleaning and require virtually no maintenance. Cooling systems, whether open-recirculating cooling towers, closed-loops or once-through systems are an essential component in many commercial, industrial and process environments where their primary purpose is to remove heat via a heat exchanger to water in a cooling system.. The first major subgroup is water cooling systems. This means that the decrease in temperature is rapid, reliable, and as effective as it gets. The first system type well be exploring is the closed-loop cooling system. 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. Compressor (HP) 5 - 15; Cooling Capacity (refrigeration tons) 4.6 to 14.6; Single circuited systems; Large Size Water Cooled Chiller. Systems containing steel and copper couples require treatment levels in the 5000-7000 ppm range. Through these complex, industrial constructs, this high temperature is regulated quite efficiently and both the, 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. Without proper cooling systems, the temperature would be unbearable both for humans and machines. Remove oxygen from the water to slow the spread of metal corrosion. Monitoring the makeup water usage in a stator cooling system is also important. Replace water-cooled equipment with air-cooled equipment or best available energy/water-efficient technology. In the meantime, critical data equipment may be damaged to the point where it affects the ability of the plant to operate. A closed circuit system keeps the water completely enclosed inside pipes, preserving water volume and quality. Where circulating pumps are equipped with certain mechanical seals, such as graphite, chromate concentrations may not exceed 250 ppm. Common applications where a circulating water pump is used include cooling systems . The flexibility to adjust to cooling and energy needs makes closed loop systems more energy efficient. If sour gas leaks from the power cylinder into the water circuit, significant chromate reduction will occur, causing poor corrosion control and deposition of reduced chromate. In a closed system, water circulates in a closed cycle and is subjected to alternate cooling and heating without air contact. If aluminum is also present, the corrosion problem is intensified, and a treatment level of 10,000 ppm may be required. The open head tank also allows in carbon dioxide, which can lower the pH of the stator water, increasing corrosion. Closed loop systems have more uses than for emergencies. 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). We offer a diverse inventory of water chillers to properly cool your industrial process! Heat Sinks for Water A fan cools water as it moves through the tubes. Compressor (HP) 20 - 40; Cooling Capacity (refrigeration tons) 18.1 to 38.4 These systemscan be configured into a variety of different systems depending on the cooling requirements of the system. 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.