Cooling Water Treatment

Basic Calculations
Sigit Pratama
 Material Balance Across Cooling Tower
Evaporation, E M=E+B+W
TL = B + W = E/ (C-1)
E is 1% for every 100F difference
Percent is % R

Water Distribution

Fill Windage, W
Heat
Air exchanger
Makeup.
M Circulation rate,R

Blowdown, B C is cycles of concentration

Calculation of Evaporation Loss (E)

Rule of thumb: 1% of recirculation rate

per 10 oF temp drop
across the tower.

E = R x 0.01 x T(oF)/10

E = R x 0.01 x 1.8 x T(oC)/10

For more accurate calculations (required for large

accounts), the air temperature and relative humidity
have to be taken into consideration.
 More Accurate Calculations of Evaporation
Rate (Metric unit)
 %E = [ (Tad - 1.6667) x Km + 0.1098 ] x T in oC

Tad : ambient air temperature

Table for Km

Delta T range Percent Relative Humidity

< 30% 30 - 90% > 90%
> 7.2 oC 0.0013 0.0013 0.0013
3.9 to 7.2 oC 0.0029 0.0019 0.0010
< 3.9 oC 0.0058 0.0032 0.0010
 More Accurate Calculation of Evaporation
Rate (English unit)

 %E = [ (Tad - 35) x Ke + 0.061 ] x T in oF

Tad : ambient air temperature

Table for Ke
Delta T range Percent Relative Humidity
< 30% 30 - 90% > 90%
> 13 oF 0.0004 0.0004 0.0004
7 to 13 oF 0.0009 0.0006 0.0003
< 7 oF 0.0018 0.0010 0.0003
 Estimated Windage Loss (W)

Type of Cooling Equipment % W (Modern Tower)

 Induced Draft 0.2 (< 0.05)
 Forced Draft 0.2 (< 0.05)
 Natural Draft 0.5
 Spray Pond 2.5
 Evaporative Condenser 0.1
 Determination of
Theoretical Cycles (TC)
%E + %W
TC =
%W

E: Evaporation
W: Windage
B: Blowdown
TC: Theoretical Cycle
Determination of Permissible Cycles
 CSiO2 = 150
MUSiO2

 C Gypsum = 1.5 x 106

CaH x TSO4

 Conductivity = 3,000
MU Conductivity in uS/cm
Where CaH = Ca Hardness in Makeup
TSO4= Total SO4 in Makeup including any
sulfuric acid addition
 Determination of Cycles of
Concentration in Operating Systems
Pcycle = Chloride(CW)
Chloride(MU)
or
= Conductivity(CW)
Conductivity(MU)

or = Makeup
Blowdown + Windage
 Calculation of Makeup
 % mu = % E + % W + %B

Where
mu= makeup, B = Bleed , W =
Windage loss
E = evaporation loss
 Calculation of Blowdown

 Blowdown %B = % E - %W
C-1
Where E = evaporation loss
W = windage loss
C = cycles of conc.
 Calculation of System
Retention Time
 System Retention Time

T = V/B+W
Where:

E = evaporation loss B = bleedoff

w = windage loss V = Volume
C = cycles of conc. T = retention time
 Calculations of System Half-life
and % Treatment Remaining
 System Half Life(hrs)
= 0.693 X V (m3)
(B+W) m3 / hr

 % Treatment Remaining for slug dosage

= [1/e KT/ V ]x 100

Where e = 2.718 ( a constant)

K = B+W in m3/hr
T = Elapsed time (hrs)
V = System Volume (m3)
COOLING WATER SYSTEM - RATINGS

• RT is refrigerant ton

• 1RT = 12,000 Btu/h or 3024 Kcal/h or 3.5 kW

• 1RT = 3 gpm or 0.68 m3/h recirculation rate

for compression system
= 4 gpm or 0.91 m3/h recirculation rate
for adsorption system

• 1RT = 10 gallons or 37.85 liters system volume

 Calculation for
Continuous Feeding
 Based on Make-up

(kg /day) = ppm product X mu ( m3)

cycle x 103
or
 Based on Blowdow + Windage or (B+W)*

kg / day = ppm product X (B+W) in

m3/day
* Total Loss = B +W
Calculation for Slug Feed

kg/ slug = ppm of product X V (m3 )

1000

where V is system volume in m3

• Slug feeding is normally done for non-oxidizing
biocides, dosing of chemicals into closed systems
and initial dosing of chemicals into open cooling
systems
 Slug Feeding of Non-oxidizing
Biocide Based on Half -life
Example:
Let’s say the half-life of an open cooling system is 12 hours and
to be effective the non-oxidizing biocide must between 25-50
ppm for 24 hours in the system once per week.

Required Dosing Regime:

Once per week, slug dose 50 ppm of the biocide into system.
Based on system volume. 12 hours later, when the residual
of biocide in system will have dropped to 25 ppm, slug dose
25 ppm of the biocide into system.
 Calculation of Acid
Dosing for pH Control
 H2SO4 Acid Feed
H2SO4 + CaCO3 = CaSO4 + CO2 + H2O
(98) (100)
1 ppm 66o Be H2SO4 (96-98% H2SO4) neutralizes 0.98 parts
of alkalinity as CaCO3.

0
Specific Gravity of 66 Be H2SO4 = 1.83 or 1.8 approx.

litre / day = ppm TA reduction reqd. in mU X mu (m3/ hr ) X 24

of H2SO4 0.98 X 1.8 X 1000
Relationship Between pH, M-alkalinity
and Free CO2
• pH = 6.35 + log10( M-alkalinity/Free CO2)

where:
m-alkalinity is in ppm CaCO3
free CO2 in ppm CO2

• Free CO2 in open cooling water system

usually is between 2 to 5 ppm as CO2
Relationship Between pH, M-alkalinity
and Free CO2
pH = 6.35 + log10( M-alkalinity/Free CO2)
Free CO2 1 2 3 4 5
M-alkalinity pH pH pH pH pH
ppm CaCO3
10 7.35 7.05 6.87 6.75 6.65
25 7.75 7.45 7.27 7.15 7.05
50 8.05 7.75 7.57 7.45 7.35
75 8.23 7.92 7.75 7.62 7.53
100 8.35 8.05 7.87 7.75 7.65
125 8.45 8.15 7.97 7.84 7.75
150 8.53 8.23 .05 7.92 7.82
175 8.59 8.29 8.12 7.99 7.89
200 8.65 8.35 8.17 8.05 7.95
225 8.70 8.40 8.23 8.10 8.00
250 8.75 8.45 8.27 8.15 8.05
300 8.83 8.53 8.35 8.23 8.13
350 8.89 8.59 8.42 8.29 8.20
 Velocity through coupon rack*
calculation

V = 62.5 x/y
where,
V = velocity in ft/sec
x = measured flow in gpm
y = volume of 1 ft. section of pipe in ml

For example:
y = 84 ml, for 3/4” I.D.
y = 154 ml, for 1” I.D.
*This calculation is valid only for racks which flow to
atmosphere.
 CALCULATIONS OF
LANGELIER’S SATURATION INDEX
AND RYZNAR SATURATION INDEX
 SCALING INDICES
 Langelier’s Saturation Index
 Ryznar Stability Index
Both were developed based on untreated waters
and they use the following parameters:
 Calcium Hardness
 Total Alkalinity
 pH
 Total Dissolved Solids
 System Operating Temperature
LANGELIER’S SATURATION INDEX (LSI)
LSI = pH - pHs

Where pH = Actual System pH

pHs = Calculated pH of Saturation for CaCO 3

pHs = (pK2 - pKs) + pCa + pAlk

pK2 = Negative Log of the Second Dissociation
Constant of CaCO3
pKs = Negative Log of the Solubility Product Constant of
CaCO3
pCa = Negative Log of Molal Concentation of Ca
pAlk = Negative Log of Equivalnt Concentration of
Alkalinity

The LSI Calculation is Simplified by Using Nomographs

 Calculation of pHs
• More accurate calculation:
pHs = 11.2 - log10(Ca) - log10 (m-alkalinity)
+ 0.1 log10 (TDS) - 0.00915 log10 (temp. in 0F)

•Approximate calculation
pHs = 11.2 - log10(Ca) - log10 (m-alkalinity)

Ca is calcium hardness as ppm CaCO3

M-alkalinity as ppm CaCO3
LANGELIER’S SATURATION INDEX
LSI TENDENCY OF WATER

POSITIVE SCALE FORMING

NEGATIVE CORROSIVE

ZERO NEUTRAL

LSI Only predicts the directional tendency of water and not the
quantity of CaCO3 scale formed
 CALCULATION OF LSI-EXAMPLE
Temperature = 120oF
pH = 8.0
Calcium Hardness = 120 ppm as CaCO3
Total Alkalinity = 100 ppm as CaCO3Referring to
Chart,
pCa = 2.92
p Alkalinity = 2.70
C at 120oF = 1.70
Therfore pHs = 7.32

LSI = pH - pHs
= 8.0 - 7.32
= +0.68

Hence, Water Has Scale Forming Tendency

RYZNAR STABILITY INDEX (RSI)

Developed from a study of actual operating

results with waters of various Saturation Indices

RSI = 2 pHs - pH

RSI is often used in combination with LSI to

improve acuracy in predicting the scaling or
corrosion tendencies of a water.
 INTERPRETATION OF RSI
RSI Tendency Of Water
4.0 - 5.0 Heavy Scale
5.0 - 6.0 Light Scale
6.0 - 7.0 Little Scale or Corrosion

7.0 - 7.5 Corrosion Significant

7.5 - 9.0 Heavy Corrosion
Above 9.0 Corrosion Intolerable
TYPICAL QUALITY OF SINGAPORE
TOWN WATER QUALITY
pH 7.5
Total Alkalinity 13 ppm CaCO3
Total Hardness 27 ppm CaCO3
Calcium Hardness 25 ppm CaCO3
Magnesium Hardness 2 ppm CaCO3
Chloride 13 ppm Cl
Sulfate 7 ppm SO4
Silica 4 ppm SiO2
Iron 0.1 ppm Fe
Conductivity 86 microSiemens/cm
LSI at 280C -1.9
CHARACTERISTICS OF SINGAPORE TOWN
WATER AT VARIOUS CYCLES OF
CONCENTRATION
CYCLES 2 3 4 5 6 7

pH 7.7 7.8 7.9 7.9 8.0 8.0

LSI -0.8 -0.4 -0.05 +0.2 +0.4 +0.5

RSI 9.3 8.5 7.9 7.5 7.2 6.9

PUCKORIUS 9.9 9.0 8.3 7.8 7.4 7.1

LARSON-SKOLD 1.96 1.96 1.96 1.96 1.96 1.96

* All indices are calculated for 400C

JURONG TOWN INDUSTRIAL WATER
pH 7.4
Total Alkalinity 140 ppm CaCO3
Total Hardness 230 ppm CaCO3
Calcium Hardness 155 ppm CaCO3
Magnesium Hardness 75 ppm CaCO3
Chloride 400 ppm Cl
Sulfate 145 ppm SO4
Silica 30 ppm SiO2
Conductivity 2000 microSiemens/cm
LSI +0.005
RSI 7.4
Puckorius 6.7
Larson-Skold 5.2

* All indices calculated for 400C

 CHARACTERISTICS OF JURONG TOWN
INDUSTRIAL WATER AT VARIOUS CYCLES
OF CONCENTRATION
CYCLES 2 2.5 3.0 3.5 4.0

pH 8.0 8.1 8.2 8.3 8.4

LSI +1.1 +1.4 +1.6 +1.9 +2.0

RSI 5.8 5.3 5.0 4.6 4.4

PUCKORIUS 5.2 4.8 4.4 4.1 3.8

LARSON-SKOLD 5.2 5.2 5.2 5.2 5.2

*All indices calculated for 400C

 LARSON-SKOLD INDEX
An indication of pitting corrosion potential

Larson-Skold Index = (Cl/35.5) + (SO4/48)

(T ALK/50)

Where : Cl = Chlorides as ppm Cl

SO4 = Sulfates as ppm SO4
TALK = Total Alkalinity as ppm CaCO3
LARSON-SKOLD INDEX -
INTERPRETATION
Larson-Skold Pitting Potential
Index
1 to 2 Slight

2 to 4 Moderate

>4 Heavy
PHOSPHATE SATURATION
INDEX (PSI)
PSI = pH - 1.54[11.76 - log(Ca) -
log(PO4) - 2log(Tc)]

Where: pH = System pH (actual or calculated)

Ca = System calcium level as ppm CaCO3
PO4 = Orthophosphate as ppm PO4
Tc = Skin temperature in 0C
TDS = ppm Total Dissolved Solids
COOLING TOWER
TERMS
 Cooling Tower Terms
 Approach:
The diff. between the cold water temp. (sum
water) & the wet bulb water temp.
 Wet bulb temperature
The dew point of the air. Also the coldest temp.
to which water can be cooled by passing
through air.
 Dry Bulb Temperature
Ambient air temperature
 Cooling Tower Terms
 Heat Load
Heat removed from the circulating water within the tower
may be calculated from the following equation:

Q = MSH ( T)

Where:
Q = heat load (Btu/hr)
M = Circulating water flow (lb/hr)
SH= Specific heat (Btu/lb/oF)
T = Temperature difference ( oF)
 Cooling Tower Terms
 Cycles of Concentration
The ratio of makeup rate to blowdown rate. Normally measured by
comparing dissolved solids in the makeup with dissolved solids in
the circulating water or blowdown. As pure water is evaporated in
the tower, minerals in the circulating water remain behind,
concentrating or cycling in the tower
 Evaporation
Principal cooling mechanism of the cooling water - as liquid
changes to vapour, heat is rejected, thus, lowering the temp. of the
remaining circulating water
 Makeup
Water added to the circulating water to replace water lost from the
system by evaporation, drift, windage,controlled blowdown and
leakage.
 Cooling Tower Terms
 Blowdown
In general, any water loss other than evaporation. Usually refers to
the controlled discharge of water to limit cycles of conc.
 Drift
Tower water entrained with exit air,but excluding evaporation.
 Range
The different in temp. between the warm water returned to the
tower and cold water leaving the tower, or the temp. drop across
the tower. T.
 Cell
The smallest tower subdivision that can be function indenpently
 Types of Cooling Towers
 Natural Draft Towers
water heats the air inside and causes it to rise in the tower. As the
warm, less dense air rises, it reduces the pressure at the bottom of
the tower, drawing cool drier air through the air inlets at the bottom
of the tower. This air is then warmed and rises, as in a chimney,
drawing air through the water and enhancing evaporation.
 Induced Draft Towers
Induced draft towers use fans to pull the relative cooler,drier ambient
air through the tower. The air/water contact can either be cross-flow
or counter-flow.
 Forced Draft Towers
Forced draft towers use fans to push the relative cooler,drier ambient
air through the tower. The air/water contact can be either cross-flow
or counter-flow.Forced draft towers are typically smaller than
induced draft towers due to horsepower requirements.
 Cooling Tower Terms
 Counterflow tower
Design in which air flows upwards through the fill
section & interfaces countercurrently w/ the falling
hot water

 Crossflow tower
Design in which air flows horizontally across the fill
section & interfaces perpendicularly w/ the falling
hot water
 RECAP OF
COOLING SYSTEM
CALCULATIONS
 Material Balance Across Cooling Tower
Evaporation, E M=E+B+W
TL = B + W = E/ (C-1)
E is 1% for every 100F difference
Percent is % R

Water Distribution

Fill Windage, W
Heat
Air exchanger
Makeup.
M Circulation rate,R

Blowdown, B C is cycles of concentration

More Important Calculation Equations
• Theoretical cycles = ( E + W ) / W

• Retention Time = V / ( B + W )

• System half life = 0.693 ( B + W ) / V

• % Remaining = 100 / ( e KT/V )

where, V = system volume

K=B+W
e = 2.718 ( constant)
T = time elapsed
More Important Calculation Equations

• Continuous Chemical Feeding

kg / h = ppm x m3 makeup
cycles 1000
or ppm x m3 (blowdown+ windage)
1000
• Slug Feeding

kg / slug = ppm x m3 system volume

1000
 COOLING WATER SYSTEM - RATING
• RT is refrigerant ton

• 1RT = 12,000 Btu/h or 3024 Kcal/h or 3.5 kW

• 1RT = 3 gpm or 0.68 m3/h recirculation rate

for compression system
= 4 gpm or 0.91 m3/h recirculation rate
for adsorption system

• 1RT = 10 gallons or 37.85 liters system volume

 APPROACH TEMPERATURE

 We can check performance of cooling

tower by measuring approach
temperature
 Approach Temperature = Outlet
Cooling Tower Water Temperature –
Wet Bulb Temperature
 New Cooling Tower can reach
Approach Temperature 2.8 oC
THANK YOU