Chemical dosage systems in Cooling Tower

Chemical dosage systems:

Cooling water treatment is very necessary in order to control corrosion, microbial activity
and scaling. For this purpose, two chemical dosage systems have been introduced.

 Chromate dosage system

 Phosphate dosage system

Chromate dosage system:

The use of chromate dosage system was quite common at industrial level. Industries
used to add zinc chromate in cooling water to control corrosion. Nowadays, its use has
become very less because of severe environmental issues. It is carcinogenic, causes skin
irritation and other health problems. Zinc chromate and sodium chromate were the main
corrosion inhibitors used to minimize the corrosion rate. Chromate is an extremely
important corrosion inhibitor in spite of its toxicity and unfavorable environmental
problems.

Working:

Chromate addition in the form of sodium or zinc chromate acts in two ways:

1- The anodic inhibitor chromate functions by oxidizing ferrous hydroxide to Fe 2O3.

Basically, chromate forms the passive layer of Fe2O3 over the metal surface. The Fe2O3 layer
is 75% of the protective film which reduces the corrosion rate. The high oxidation state of
chromium causes the metal like iron to pass into the passivation region where passive layer
forms.

2- Chromate works by interacting with the surface of the metal when it gets wet. The
zinc chromate begins to dissolve when moisture penetrates it and creates a shield of
chromium oxide (Cr2O3) which is inert and insoluble surface film. This is 25% of the
protective layer forms for the protection of metal surface. Over time, the zinc chromate
dissolves completely and the metal begins to corrode.
Phosphate dosage system:
Chromate dosage system is now being replaced by phosphate dosage system. Its use
is environmental friendly and causes no harm. In phosphate dosage system, zinc phosphate
is mainly used as corrosion inhibitor in most of the industries. Zinc phosphate is as effective
as Zinc/sodium chromate.

What are phosphates?

Phosphates are water treatment chemicals used to solve specific water quality problems
resulting from inorganic contaminants (iron, manganese, calcium, etc.) in ground water
supplies and also to maintain water quality (inhibit corrosion, scale, bio-film, reduce lead
and copper levels) in the distribution system. Orthophosphate and polyphosphate are two
general types used in water treatment along with many different phosphate compounds
that exist for use in the water treatment process. Ortho and polyphosphates work together,
stabilizing water quality and minimizing color, scale, deposits, corrosion, and chlorine
demand in drinking water systems.

Working:

Orthophosphate based additives are classified as corrosion inhibitors and as such react with
dissolved metals (e.g. Ca, Mg. Zn, etc.) in the water to form a very thin metal-phosphate
coating or it reacts with metals on a pipe surface to form a microscopic film on the inner
surface of the pipe that is exposed to the treated water.

Polyphosphate type chemicals react with soluble metals (iron, manganese, calcium,
magnesium, etc.) and keep attach themselves with metals to maintain their solubility in
water. The phosphate bind-up process minimizes the risk of scaling, taste/odor and other
water quality problems.

Phosphate easily adapt to any pre-existing water quality without changing water chemistry.
Water treatment with phosphate gives several benefits like corrosion control, Calcium
carbonate scale control and water softening etc.

The reason why it is being used at large scale because it is not carcinogenic like chromate
and has multiple functions.
Summary:
Chromate dosage system
Chromate dosing system consists of
chemicals like sodium chromate and zinc
chromate
Chromates are included in Anodic inhibitors
category
The dosing of chromates in the form of
sodium and zinc chromate acts in two ways:
 Formation of thin layer of Fe2O3
 Formation of Cr2O3 layer covers Fe2O3
layer and increases the thickness of
protective layer.
Chromates are widely used in corrosion
control as passivating inhibitor because they
form passive layer (Layer of oxides).
The combination of Fe2O3 and Cr2O3 is
synergistic which reduce the inhibitor
consumption.
The pH of the system can range from 6.5 to
7.5, with a pH of 7 being more acceptable for
its good working.
It can work on wide range of operating
temperatures.
Chromate use is not environmental friendly
as it is carcinogenic and causes many other
severe health problems.
Phosphate dosage system
Phosphate dosing consists of mainly of Zinc,
Polyphosphate and Orthophosphate
Phosphates are included in Mixed inhibitors
category.
Phosphate reacts with metals present in
water (Ca, Mg, Zn etc) and forms metal-
phosphate thin layer.
It also reacts with metals on a pipe surface
to form a microscopic film on the inner
surface of the pipe that is exposed to the
treated water
Phosphates are used as corrosion inhibitors
which form surface layer.
Phosphate requirement is more as compare
to chromate because the layer formation
depends upon the amount of metal present
in water.
It works perfectly when pH is 7.5 – 8.2
Like chromate, it also has the ability to
perform in a wide range of operating
temperatures.
Phosphate use has no effects on
environment. Most of the industries have
started using this system for water
treatment.