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Evaporative Condenser Passivation: Cameron Klein Strand Associates, Inc
Evaporative Condenser Passivation: Cameron Klein Strand Associates, Inc
Cameron Klein
Strand Associates, Inc.
Evaporative Condenser Wetted Surface Materials of
Construction
▪ Galvanized Steel
• Protective zinc coating fused to a steel substrate
• Zinc layer offers sacrificial protection of steel substrate
• Standard construction material
• Requires passivation
▪ Stainless Steel
• Upgraded construction material
• Added equipment cost (varies based on size)
• Passivation is not required
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What is White Rust?
3
What is White Rust?
Picture courtesy of Evapco literature
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What is Galvanized Steel Passivation?
5
Water Chemistry Requirements for Passivation
6
Passivation Duration
▪ Varies by manufacturer
• BAC: 4-8 weeks
• Evapco: 4-12 weeks
• Marley: minimum of 8 weeks
▪ Varies by climate and water chemistry
▪ No load on system during passivation
• Elevated temperature and changing water chemistry make
passivation very difficult
• Evaporation can concentrate corrosive ions and increase pH
▪ Coordinate with water treatment supplier to create a plan
and to monitor the surfaces to determine when complete
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Visual Difference of Galvanized Surface
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Evaporative Condenser Expected Useful Life
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Considerations
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Passivation Water Treatment Log
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Questions
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Cooling Tower / Boiler Treatment
& Control
Joe Wenn
IMPURITIES COMMONLY FOUND IN WATER
HARDNESS
• Calcium and Magnesium salts expressed as CaC03 either Ca+Mg+
• Chief source of scale in heat exchange equipment, boilers, pipelines,
etc. Forms curds with soap, interferes with dyeing.
• Softening, Demineralization, Internal boiler water treatment, Surface-
active agents.
ALKALINITY
• Bicarbonate (HC03), Carbonate (C03), and Hydrate (OH), expressed <1:5
CaC03
• Foaming and carryover of solids with steam, Embrittlement of boiler steel.
Bicarbonate and carbonate produce CO2 in steam
• Lime and lime-soda softening, Acid treatment, Hydrogen zeolite softening,
Demineralization, Dealkalization by anion exchange.
IMPURITIES COMMONLY FOUND IN WATER
CARBON DIOXIDE
• CO2
• Corrosion in water lines and particularly steam d condensate lines.
• Aeration, Deaeration, Neutralization with alkalies.
pH
• Hydrogen ion concentration defined as pH + log 1L(H)
• pH varies according to acidic or alkaline solids in water. Most natural
waters have a pH of 6.0- 8.0.
• pH can be increased by alkalies and decreased by acids.
EXTERNAL TREATMENT
Demineralized
• Cation - Anion
• Regenerants - Sulfuric Acid and Caustic Soda
• Strong Basic Resin removes Silica
• Aerator needed for CO2 removal
• Used for High Pressure Boiler
EXTERNAL TREATMENT
Reverse Osmosis
• Membrane Technology_
• Reduces make-up minerals by 90 to 95%.
• Pretreatment (water softener and carbon filter) typically required
• Substantially reduce boiler blowdown requirements and chemical
usage
White Rust
White Rust
Control
Control
STEAM AND RETURN LINE CORROSION
Oxygen
• Iron pipe will show pitting
• 4 Fe +6(H20) +3(02) = 4 Fe(OH)3 Iron Ferric Hydroxide
• 02 can increase carbonic acid corrosion lOx
2). Carbon Dioxide
• Iron pipe has grooving or etching usually at elbows or
horizontal runs
• CO2 +H20 = H2CO3 (Carbonic Acid) 2 (HzCO3) +Fe:= Fe
(HCO3)2 + H2 (Ferrous Bicarbonate)
• Boiler Alkalinity converts to CO2
– 1 ppm Bicarbonate Alkalinity evolves to . 79 ppm CO2
– 1 ppm Carbonate Alkalinity evolves to .35 ppm CO2
– 100% of Bicarbonate Alkalinity completes reaction at Boiler P .S.I. 0 - 50
– 10 - 30% of Carbonate Alkalinity completes reaction at Boiler P.S.I. 50- 150
– 30 - 80% completes reaction at Boiler P.SJ. 150 and over
– 80 - 100% completes reaction
STEAM AND RETURN LINE CORROSION
Coil Leakage
Closed Systems- Boilers
Issues
• Water Volume relative to system Volume
• Boilers Fail
Solution
• Soft Water
Real World Examples