Why is circulating cooling water treated? This article explains it all!
Published Time:
2022-12-20
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The Value and Quantification of Recirculating Cooling Water Treatment
As we all know, cooling water treatment solutions address scaling, corrosion, microbial growth, and sedimentation issues commonly found in cooling water systems. A complete cooling water treatment solution should include the following three parts:
1. Automatic monitoring and chemical dosing equipment;
2. Chemical treatment programs tailored to makeup water characteristics;
3. Service
In daily operation and maintenance, in addition to focusing on the water system and the solution itself, we should pay more attention to the economic benefits brought by the water treatment solution, that is, the value brought by controlling scaling, corrosion, microbial growth, and sedimentation problems in the water system, and focus on the overall operating cost of the water system.
Typically, a targeted water treatment program can deliver the following value improvements.
Refrigeration units, air compressors, and other equipment are major electricity consumers in factories, relying on electric power to drive compressors to perform work and meet process requirements. Improving cooling water scaling, sedimentation, and microbial issues can significantly enhance heat exchanger efficiency, reducing compressor workload and thus saving electricity consumption. The most direct method is to track and compare electricity consumption before and after implementing the water treatment solution under similar operating times and loads to calculate the electricity cost savings.
Electricity cost savings RMB/yr = Annual electricity savings KWh/yr × Electricity price RMB/KWh
For refrigeration units, the coefficient of performance (COP) can also be compared and calculated to estimate electricity savings.
By increasing the concentration factor of cooling water, water consumption can be directly reduced. In addition, water consumption can also be saved by changing water usage methods, recovering and reusing wastewater, etc. The benefits of this part can be easily calculated using the saved water consumption and the unit price of water:
Water consumption savings RMB/yr = Annual water savings tons/yr × Water price RMB/ton
It should be noted that for specific makeup water conditions, the cooling water system has a suitable operating concentration factor, and the concentration factor cannot be increased blindly to pursue water saving.
Plate heat exchangers and shell-and-tube heat exchangers are commonly used key heat exchange equipment in factory production processes. This type of equipment uses cooling water and process media for heat exchange, cooling the process media to the required process temperature. When cooling water has scaling, sedimentation, and microbial problems, it is easy to cause blockage of this type of heat exchange equipment, resulting in the process media not being able to be cooled to the process temperature, thus causing production interruption.
The water treatment solution, by reducing scaling, corrosion, microbial growth, and sedimentation, maintains the cleanliness of the heat exchanger pipe surface, greatly extending the continuous operating time of the heat exchange equipment and improving production efficiency. The benefits of this part can be quantified using the following formula:
Reduced downtime economic benefits RMB/yr = (Original annual equipment downtime hrs - Current annual equipment downtime hrs) × Unit time output value RMB/hr
The water treatment solution significantly extends the service life of pipelines and equipment by slowing down corrosion in the water system pipelines and heat exchangers, protecting customer assets.
Corrosion rate can be calculated through corrosion rate coupon tests to estimate the service life of pipelines and equipment.
The economic benefits of improving the corrosion rate can be quantified using the following formula:
Corrosion improvement economic benefits/yr = C÷T0 - C÷(CR0×T0÷CR)
C—Total investment in pipelines and equipment, RMB
T0—Baseline service life, yrs
CR0—Baseline corrosion rate, mm/yr
CR—Operating corrosion rate, mm/yr
Scaling, microbial growth, and sedimentation in the cooling water system significantly reduce the heat transfer efficiency of the heat exchanger and easily cause blockage of the heat transfer pipelines. Factories have to clean the heat exchanger to restore its working condition.
The cooling water solution, by controlling the above problems, can extend the cleaning cycle of the heat exchanger and reduce the cleaning frequency. The benefits are quantified as follows:
Reduced cleaning economic benefits RMB/yr = Reduced number of cleanings times/yr × Cost per cleaning RMB/time
Through a deep understanding of the customer's water system and professional knowledge, improvement measures are proposed for the factory's water usage, reuse methods, and process flow, The benefits often far exceed those brought by the water treatment solution. This is the greatest value of professional services, and this part is quantified by the benefits of specific renovation projects.
This part of the benefit is usually brought by highly intelligent chemical dosing equipment and leading chemical technology (such as solid chemicals, safer chemical components, etc.). The benefit calculation is as follows:
Labor savings benefits RMB/yr = Saved labor hours hrs/yr × Labor cost RMB/hr
Based on the above calculations, we can obtain the ROI (return on investment) of the circulating cooling water solution to evaluate the total benefits of the solution.
ROI = ( Increased economic benefits RMB/yr - Increased expenses RMB/yr) / Increased expenses RMB/yr × 100%
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