Advance Scale Control Technology For Cooling Water Systems

Advance Scale ControlTechnology ForCooling WaterSystems1 /GE /

Agenda• Cooling Systems Problems• Scale• Scale Inhibition & Control• GE New Stress Tolerant Polymer• Case History2 /GE /

Cooling Systems ProblemsScaleMicrobio3 /GE /

Scale4 /GE /

Scale formationDissolved AtomsNucleation formationCrystal GrowthScale Formation5 /GE /

Common Scale Minerals• Calcium Phosphate• Calcium Carbonate• Iron Phosphate• Iron Oxides• Silicate.6 /GE /

Factors Affecting Scale formation• Water composition• pH• Temperature• Water velocity• System metallurgy7 /GE /

Water Composition8 /GE /

pH9 /GE /

Temperature10 /GE /

Water Velocity11 /GE /

System Metallurgy12 /GE /

Scale Inhibition & Control• Change in Operationparameters such as waterchemistry.• Mechanical Methods.• Change in systemmetallurgy.• Use chemical Inhibitors.13 /GE /

Chemical Inhibitor Mechanism• Threshold inhibition• Crystal Modification• Sequestration.• Dispersion.14 /GE /

Polymeric Scale Dispersant• PAA (Polyacrylic Acid)• PMA (Polymaleic anhydride)• AEC ( Alkyl Epoxy Carboxylate)• TMPS (Terpolymer)• HPS ( Hydroxy Propyle EtherSulfonate Copolymer)• ACM (Acrylamid Copolymer)15 /GE /

GE New StressTolerantPolymer - STP16 /GE /

Stress Tolerant Polymer (STP) -Overview• Superior Performance– Under Neutral pH Conditions– Under Alkaline pH Conditions• Chlorine Stable• High Performance at thepresence of Fe and Al• Testable– Off-line– On-line17 /GE /

0 0.5 1 1.5 2 2.5 3 3.5New Stress Tolerant Polymer (STP)STP Performance vs. SAAFarSuperiorHigh pH Excursion 1Presence 1of Iron1Presence of AluminumSuperior Calcium o-PO14 Inhibition Calcium pyro-PO 1 4 Inhibition Zinc PO 4 Inhibition1Improved Suspended 1 Solids18 /GE /

% PO4 InhibitionCalcium Phosphate InhibitionStatic Bottle TestWater Conditions: 400 ppm Ca, 100 ppm Mg, pH 8.2, 10 ppm PO 4 ,160°F (70°C), 18 hrs10090807060504030201005 ppm 10 ppmPolymer Dosage (ppm)Terpolymer C Terpolymer B Terpolymer A AA/AMPS SAA STPLab Data19 /GE /

% Zn Inhibition% PO4 InhibitionZinc Phosphate InhibitionStatic Bottle TestWater Conditions: 300 ppm Ca, 10 ppm PO 4 , 5 ppm Zn,pH 8.0, 120°F (50°C ), 18 hrsZn Inhibition (pH 8.0)PO4 Inhibition (pH 8.0)10010090908080707060605050404030302020101005 ppm 7.5 ppm05 ppm 7.5 ppmPolymer Dosage (ppm)Polymer Dosage (ppm)Tagged Polymer AA/AMPS SAA STPTagged Polymer AA/AMPS SAA STP20 /GE /

% Zn Inhibition% PO4 InhibitionZinc Phosphate InhibitionStatic Bottle TestWater Conditions: 300 ppm Ca, 10 ppm PO 4 , 5 ppm Zn,pH 8.5, 120°F (50°C ), 18 hrsZn Inhibition (pH 8.5)PO4 Inhibition (pH 8.5)10010090908070807060605050404030302020101005 ppm 7.5 ppm05 ppm 7.5 ppmPolymer Dosage (ppm)Polymer Dosage (ppm)Tagged Polymer AA/AMPS SAA STPTagged Polymer AA/AMPS SAA STP21 /GE /

Dynamic Dispersion TesterTurbidityMeterDataAcquisitionpHMeterDispersionColumnSumpFlow MeterPump22 /GE /

NTUDynamic Iron Oxide Dispersion TestWater Conditions: 500 ppm Ca, 200 ppm Mg, pH 7.5750 ppm Fe 2 O 3Fe 2 O 3 dispersion test (Timing from polymer addition)NTU > 2000was overscale35003000250020005 ppm STP2 ppm STP5 ppm SAAControlLab Data1500100050000 200 400 600 800 1000 1200 1400Time elapsed (min)23 /GE /

Bench Top Recirculating Unit - BTU24 /GE /

Bench Top Recirculating Unit - BTU25 /GE /

Iron TestingNeutral pH Program: Stabilized PhosphateWater Conditions: 3 ppm iron, 600 ppm Ca, 300 ppm Mg, pH 7.215 ppm o-PO 4 , 3 ppm pyro-PO 4 , 1.2 HRA135°F (57°C) Surface Temp, 120°F (49°C) Bulk TempSTPLCS 0.2 mpyADM 0.0 mpySame Polymer Dosage (7ppm)STPSAALab DataSAALCS 2.4 mpyADM 0.5 mpy26 /GE /

Polymer Dosage as Function of pHTreatment Program: Stabilized PhosphateStandard Water Conditions: 600 ppm Ca, 300 ppm Mg, 15 ppm o-PO 4 ,3 ppm pyro-PO 4 , 1.2 ppm HRA, 120°F (49°C) BulkTempTest pH SurfaceTemp., O FPolymerPolymerDosage,ppmTurbidity,NTUDeltappm PO 41 7.2 130 SAA 4 0.32 0.1Heat Exchanger TubeAppearanceSurface free of deposits2 7.2 130 STP2 0.35 0.13 7.4 130 SAA 8 0.3 0.34 7.4 130 STP40.3 0.45 7.6 130 SAA 13 0.5 0.56 7.6 130 STP80.5 0.57 7.8 130 SAA 18 0.7 0.6Surface free of depositsSurface free of depositsSurface free of depositsSurface free of depositsSurface free of depositsSurface free of deposits8 7.8 130 STP12 0.9 0.2 Surface free of deposits27 /GE /

High pH ExcursionNeutral pH ProgramStandard Water Conditions: 600 ppm Ca, pH 7.9, 15 ppm o-PO4, 3 ppmpyro-PO 4135°F (57°C) Surface Temp4 ppm STPLab Data8 ppm SAA28 /GE /

ppmppm1816141210Effect of pH Excursion on Calcium PhosphateControl86420Neutral pH ProgramStandard Water Conditions: 600 ppm Ca, 300 ppm Mg, pH 7.2 - 7.9,15 ppm o-PO4, 3 ppm pyro-PO 4 ,135°F (57°C) Surface Temp, 120°F(49°C) Bulk TemppH 7.24 ppm STP – StandardConditionspH 7.4Available PolymerpH 7.6pH 7.9 pH 7.4 Soluble PO 46/ 15 6/ 19 6/ 23 6/ 27 7/ 1 7/ 5 7/ 9 7/ 13 7/ 17Time (Date)pH 7.21816141210864208 ppm SAA – StandardConditionspH 7.2 pH 7.9 pH 7.2pH 7.4 pH 7.4 (8 ppm SAA Added)Soluble PO 4Available Polymer5/ 30 6/ 3 6/ 7 6/ 11 6/ 15 6/ 19 6/ 23 6/ 27 7Time (Date)29 /GE /

Aluminum TestingNeutral pH Program: Stabilized PhosphateWater Conditions: 2 ppm Aluminum, 600 ppm Ca, pH 7.2, 15 ppm o-PO 4 , 3 ppm pyro-PO 4 , 135°F (57°C) Surface TemperatureSame Polymer Dosage (5 ppm)STP - Surface free of DepositsSAA - Moderate AlPO 4 DepositLab Data30 /GE /

200 ppm Clay TestAlkaline pH ProgramWater Conditions: 400 ppm Ca, pH 8.6, 4 ppm o-PO 4 , 3 ppm Penta13 ppm STP 15 ppm SAALab Data31 /GE /

Polymer Dosage as Function of TemperatureTreatment Program: Stabilized PhosphateStandard Water Conditions: 600 ppm Ca, 300 ppm Mg, pH 7.215 ppm o-PO 4 , 3 ppm pyro-PO 4 , 1.2ppm HRA120°F (49°C) Bulk TempTest pH SurfaceTemp., o FPolymerPolymerDosage, ppmTurbidity,NTUDelta ppmPO4Heat Exchanger TubeAppearance1 7.2 130 SAA 4 0.32 0.12 7.2 130 STP 2 0.35 0.1Surface free of depositsSurface free of deposits3 7.2 140 SAA 6 0.5 0.24 7.2 140 STP 3 0.1 0.1Surface free of depositsSurface free of deposits5 7.2 160 SAA 8 0.2 0.16 7.2 160 STP 4 0.4 0.4Uniform Ca-PO 4 depositSurface free of deposits32 /GE /

High TemperatureTreatment Program: Stabilized PhosphateStandard Water Conditions: 600 ppm Ca, pH 7.2, 15 ppm o-PO 4 , 3 ppmpyro-PO 4 ,160°F (70°C) Surface Temperature4 ppm STP - Surface free of Deposits8 ppm SAA - Uniform CaPO 4 Deposit33 /GE /

STP PolymerSTP Testing & Monitoring• OFF-LINE Testing– Bench testing with spectrophotometerusing new reagent chemistry– Measures polymer concentration directly– Easier than the Mo test!!• TrueSense ON-LINE Monitoring– Continuous monitoring of polymerconcentration in the cooling system34 /GE /

TrueSense Online Dynamic Laboratory StudyWithout Polymer ControlNeutral pH ProgramStandard Water ConditionspH: 7.2Calcium: 600 ppm as CaCO 3Orthophosphate: 15 ppmPyrophosphate: 3 ppmSkin Temperature: 135°F (57°C)Retention Time: 3 days35 /GE /

TrueSense Online Dynamic Laboratory StudyWith Polymer Control (continued)Neutral pH ProgramStandard Water ConditionspH: 7.2Calcium: 600 ppm as CaCO 3Orthophosphate: 15 ppmPyrophosphate: 3 ppmSkin Temperature: 135°F (57°C)Retention Time: 3 days36 /GE /

Case HistoryEuropean plastics producer saves US$135,000 year with STPTechnologyGoal• Reduce phosphate discharge – new regulations made itdesirable to reduce the phosphate discharge from thecooling water program• Reduce acid consumption – with acid pricesskyrocketing, any acid feed reduction meant significantsavings• Reduce water consumptionSolution• Upgrade toSTP and revise the chemistry targetsOriginalTargetsGenGardTargetsOrthophosphate 17-18 ppm 12-14 ppmpH 7.3-7.4 7.7-7.8Active polymer 30 ppm 22.5 ppmCycles ~4.0 ~5.0Results• Discharge compliant• 25% acid reduction• Water reduction• Excellent corrosionprotection of

Thank you38 /GE /