Industrial water

 Acid water is corrosive in nature

 Hard water contains dissolved Ca and Mg salts, due to presence of them the boiling
point of water becomes high, lamination decreases and flow disturbs.
 Hard water is water that contains calcium or magnesium mineral ions often in the form
of carbonate. These ions do not pose any health threat, but they can engage in reactions
that leave insoluble mineral deposits. Hard water mineral deposits, or scaling, is the
precipitation of minerals which form lime scale. Scale can clog pipes and can decrease
the life of metal pipes.
 High TDS, more hardness, more scaling & more chances of corrosion at high temp.
 Hardness in water can be removed by Lime-soda, Zeolite & Ion exchange methods etc.
 Soft water doesn’t contain hardness producing Ca and Mg ions but contain Na ions and
microorganism.
 Deionsed water doesn’t contain any ions including hardness causing cations but contain
microorganism.
 Distilled water doesn’t contain any ions and microorganism since distilled water is
obtained by condensing the vapors of boiling water.
 Water has high heat capacity and thermal conductivity than air therefore water can
exchange more heat than air.
 Total dissolved solids (TDS) are inorganic salts and small amounts of organic matter
present in solution in water. Whereas, Total Suspended Solids (TSS) are solids
in water that can be trapped by a filter.
 Acidic water can react with metal produce a metal salt and hydrogen gas bubbles which
can be dangerous if gas is trapped inside pipe then it can pressurized metal pipe to blow
up.
 Base water especially reacts with organic compounds.
 Industrial water should have less scaling and corrosion
 Industrial water pH range should be 5.5-6.5.
 More acidity of water more is the corrosion. But if the pH is very low the hydrogen ion
liberates hydrogen gas instead of water.
 Corrosion due to high pH is more dangerous than acidic corrosion as it can cause cracks
in the equipment (a phenomenon known as Caustic embrittlement). The tubes of the
overhead exchangers will become like dry wood and break into large pieces which are
extremely difficult to fix.
 Corrosion slows down due to the presence of oxides/hydroxides on the surface, forming
the passive layer (film).
 Immunity zone, where the metal does not react with the environment, or react is such a
small rate that any change into oxide is negligible.
 Temperature accelerates all the processes involved in corrosion. One would expect that
the corrosion rate steadily increases with temperature. Since the corrosion rate was
raised due to the oxygen diffusion on the metal surface, therefore, at low pH protective
films do not occur. The situation changes markedly when solubility of salt was exceeded,
typically at high pH. In that case, increased temperature accelerates rapidly the kinetics
of precipitation and protective film formation, decreasing the corrosion rate. The peak
in the corrosion rate was usually seen between 50 and 80C depending on water
chemistry and dynamic condition.
 Magnetite (Fe3O4) is called saturated iron oxide, it is a chemical of iron and oxygen thus
it is an oxide. If there is not enough oxygen in water to finalize the oxidation, then
magnetite (Fe3O4) forms, instead of more common rust (Fe2O3). Magnetite is black
layer deposited on metallic surface (metal pipe). This black layer make the pipe inert
against new corrosion, the black layer is almost like a passivation. This black layer
doesn’t let MIC (microbiologically induced corrosion which harm to steel surfaces. Once
magnetite is exposed to enough oxygen, the black layer disappears after a short time and
forms normal rust again.
 Red oxide is used in paints and primers as a rust preventive. If traces of rust are present
on an iron surface, red oxide paint will adhere (stick), because it interacts with the
surface by forming chemical bonds. Other methods are Tin plating, Galvanization (Zinc
plating), Coating, Enameling and Copper plating
 Passivation is a technique of a light coat of a protective material, such as metal oxide, to
create a shell against corrosion.
 Sodium Nitrite use as a Corrosion Inhibitor for Mild Steel (MS).
 BIOCIDE act against bacteria and used to control other micro-organisms such as fungi
in water.
 Iron level in water system should be <1.50ppm in MS pipes.
 Dispersants Effectively disperses iron, clay, and zinc deposits, and is used extensively
in cooling water systems.
 Sodium hypochlorite (NaOCl) normally called as HYPO is a compound that can be
effectively used for water purification. It is used on a large scale for surface purification,
bleaching, odor removal and water disinfection.
 Due to the presence of caustic soda in sodium hypo chlorite, the pH of the water is
increased. When sodium hypo chlorite dissolves in water, two substances form, which
play a role in for oxidation and disinfection. These are hypochlorous acid (HOCl) and
the less active hypochlorite ion (OCl-). The pH of the water determines how much
hypochlorous acid is formed. While sodium hypochlorite is used, hydrochloric acid
(HCl) is used to lower the pH. Sulfuric acid (H2SO4) can be used as an alternative for
acetic acid. Less harmful gasses are produced when sulfuric acid is used. Sulfuric acid is
a strong acid that strongly reacts with bases and that is very corrosive
 Hypochlorite can be used to prevent algae and shellfish growth in cooling towers.

MAXIGUARD (SCALE & CORROSION INHIBITOR)

MAXIGARD may be used with waters that have hardness contamination, provided the
total hardness levels are less than 170 ppm or as otherwise recommended by the engine
manufacturer, whichever is less. The chloride level in the cooling system should be limited
to 100 ppm or as otherwise recommended by the engine manufacturer, whichever is less.
Benefits
 Protects against variable metal corrosion
 Reduces corrosion due to cavitation
 Maintains heat transfer effectiveness
 Helps prevent overheating caused by sludge and mineral scale deposits Reduces
cleaning and maintenance costs
 Stabilizes cooling water pH

Chemical products name used for water treatment in industries by different companies.
R-25 (biocide)
R-95 (scale & corrosion inhibitor)
Aquaprime 808 (iron removal)
Aquaprime 2005, Maxi guard (anti corrosion) (maintain nitrate level and prevent
oxidation)
R-25, R-95, R-3100, HYPO (uses to decreases scaling & TDS)
H2SO4 (uses to maintain PH)