Closed Recirculating Cooling Systems

Closed Recirculating Cooling Systems
The closed recirculating cooling water system evolved from methods used for the
cooling of early engine designs. In a closed system, water circulates in a closed cycle
and is subjected to alternate cooling and heating without air contact. 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
Closed recirculating cooling water systems are well suited to the cooling of gas
engines and compressors. Diesel engines in stationary and locomotive service
normally use radiator systems similar to the familiar automobile cooling system.
Other closed recirculating cooling applications include smelt spout cooling systems
on Kraft recovery boilers and lubricating oil and sample coolers in power plants.
Closed systems are also widely used in air conditioning chilled water systems to
transfer the refrigerant cooling to air washers, in which the air is chilled. In cold
seasons, the same system can supply heat to air washers. Closed water cooling
systems also provide a reliable method of industrial process temperature control.
ADVANTAGES OF CLOSED SYSTEMS
Closed recirculating systems have many advantages. They provide better control of
temperatures in heat-producing equipment, and their small makeup water
requirements greatly simplify control of potential waterside problems. Makeup
water is needed only when leakage has occurred at pump packings or when water
has been drained to allow system repair. Little, if any, evaporation occurs. Therefore,
high-quality water can usually be used for makeup, and as a result, scale deposits are
not a problem. The use of high-quality water also minimizes the dangers of cracked
cylinders, broken heads, fouled exchangers, and other mechanical failures. Closed
systems are also less susceptible to biological fouling from slime and algae deposits
than open systems.
Closed systems also reduce corrosion problems drastically, because the recirculating
water is not continuously saturated with oxygen, as in an open system. The only
points of possible oxygen entry are at the surface of the surge tank or the hot well,
the circulating pump packings, and the makeup water. With the small amount of
makeup water required, adequate treatment can virtually eliminate corrosion and the
accumulation of corrosion products.
SCALE CONTROL
Some closed systems, such as chilled water systems, operate at relatively low
temperatures and require very little makeup water. Because no concentration of
dissolved solids occurs, fairly hard makeup water may be used with little danger of
scale formation. However, in diesel and gas engines, the high temperature of the
jacket water significantly increases its tendency to deposit scale. Over a long period,
the addition of even small amounts of hard makeup water causes a gradual buildup
of scale in cylinders and cylinder heads. Where condensate is available, it is
preferred for closed system cooling water makeup. Where condensate is not
available, zeolite softening should be applied to the makeup water.
CORROSION CONTROL
An increase in water temperature causes an increase in corrosion. In a vented system,
this tendency is reduced by the decreased solubility of oxygen at higher
temperatures. This is the basis of mechanical deaeration.
Corrosion rates at increasing water temperatures for two different sets of conditions.
Curve A plots data from a completely closed system with no provision for the
venting of oxygen to atmosphere. Curve B shows data for a vented system. At up to
170°F (77°C), the curves are essentially parallel. Beyond 170°F (77°C), curve B
drops off. 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. However, in many closed systems, the dissolved
oxygen entering the system in the makeup water cannot be freely vented, resulting
in the release of oxygen at points of high heat transfer, which may cause severe
corrosion.
Untreated systems can suffer serious corrosion damage from oxygen pitting,
galvanic action, and crevice attack. Closed cooling systems that are shut down
periodically are subjected to water temperatures that may vary from ambient to
180°F (82°C) or higher. During shutdown, oxygen can enter the water until its
saturation limit is reached. When the system is returned to high-temperature
operation, oxygen solubility drops and the released oxygen attacks metal surfaces.
The metallurgy used in constructing modern engines, compressors, and cooling

systems includes cast iron, steel, copper, copper alloys, and aluminum as well as
solders. Nonmetallic components, such as natural or synthetic rubber, asbestos, and
carbon, are also used. If bimetallic couples are present, galvanic corrosion may
develop.
The three most reliable corrosion inhibitors for closed cooling water systems are
chromate, molybdate, and nitrite materials. Generally, the chromate or molybdate
types have proven to be superior treatments. For mixed metallurgy systems, the
molybdate inhibitors provide the best corrosion protection.
Chromate treatments in the range of 500-1000 ppm as Cr4O2¯ are satisfactory unless
bimetallic influences exist. When such bimetallic couples as steel and copper are
present, chromate treatment levels should be increased to exceed 2000 ppm.
Maximum inhibitor effectiveness can be achieved if the pH of these systems is kept
between 7.5 and 9.5.
In a closed system, it can be quite difficult to prevent corrosion of aluminum and its
alloys; the pH of the water must be maintained below 9.0. Aluminum is amphoteric-
it dissolves in both acid and base, and its corrosion rate accelerates at pH levels
higher than 9.0. 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.
Where circulating pumps are equipped with certain mechanical seals, such as
graphite, chromate concentrations may not exceed 250 ppm. This is due to the fact
that water leaking past the seals evaporates and leaves a high concentration of
abrasive salts that can damage the seal.
Another problem is encountered when chromate inhibitors are used in cooling
systems serving compressors that handle sour gas. 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 very high heat transfer rate applications, such as continuous caster mold cooling
systems, chromate levels should be maintained at 100-150 ppm maximum. Under
these extreme conditions, chromate can accumulate at the grain boundaries on the
mold, causing enough insulation to create equipment reliability problems.
The toxicity of high-chromate concentrations may restrict their use, particularly
when a system must be drained frequently. Current legislation has significantly
reduced the allowable discharge limits and the reportable quantity for the spill of
chromate-based products. Depending on the type of closed system and the various
factors of State/Federal laws limiting the use of chromate, a nonchromate alternative
may be needed.
Molybdate treatments provide effective corrosion protection and an environmentally
acceptable alternative to chromate inhibitors. Nitrite- molybdate-azole blends inhibit
corrosion in steel, copper, aluminum, and mixed-metallurgy systems. Molybdate are
thermally stable and can provide excellent corrosion protection in both soft and hard
water. System pH is normally controlled between 7.0 and 9.0. Recommended
treatment control limits are 200-300 ppm molybdate as MoO42¯. Molybdate inhibitors
should not be used with calcium levels greater than 500 ppm.
Nitrite is another widely accepted nonchromate closed cooling water inhibitor.
Nitrite concentrations in the range of 600-1200 ppm as NO2- will suitably inhibit iron
and steel corrosion when the pH is maintained above 7.0. Systems containing steel
and copper couples require treatment levels in the 5000-7000 ppm range. If
aluminum is also present, the corrosion problem is intensified, and a treatment level
of 10,000 ppm may be required. In all cases, the pH of the circulating water should
be maintained in the alkaline range, but below 9.0 when aluminum is present. When
high nitrite levels are applied, acid feed may be required for pH control.
One drawback to nitrite treatments is the fact that nitrites are oxidized by
microorganisms. This can lead to low inhibitor levels and biological fouling. The
feed of nonoxidizing antimicrobial may be necessary to control nitrite reversion
and biological fouling.
Product performance data developed in laboratory studies simulating a mixed-

metallurgy closed cooling system identified steel and Admiralty corrosion rates for
three closed system inhibitors at increasing treatment levels. As shown, the
molybdate-based treatment provides the best overall steel and Admiralty protection.
To achieve similar inhibition with chromate, higher treatment concentrations are
required. Nitrite-based treatment also provides effective steel protection, with results
comparable to those obtained with molybdate; however, acceptable Admiralty
corrosion inhibition is not achieved.
Closed systems often require the addition of a suitable antifreeze. Nonchromate
inhibitors are compatible with typical antifreeze compounds. Chromates may be
used with alcohol antifreeze, but the pH of the circulating water should be
maintained above 7.0 to prevent chromate reduction. Because glycol antifreezes are
not compatible with chromate-based treatments, nonchromate inhibitors should be
used. Molybdate treatments should not be used with brine-type antifreezes.
In closed systems that continuously run at temperatures below 32°F (0°C), a closed
brine system is often employed. The American Society of Refrigeration Engineers
has established chromate limits in brine treatments. Calcium brines are limited to
1250 ppm chromate, and sodium brines are limited to 2500 ppm chromate. The pH
should be 7.0-8.5 with caustic adjustment only. Some success has also been recorded
with nitrite-based treatment of closed brine systems at treatment levels of about 2000
ppm as NO2¯

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Closed Recirculating Cooling Systems

The metallurgy used in constructing modern engines, compressors, and cooling

Product performance data developed in laboratory studies simulating a mixed-

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