All-organic treatment program selected by computer modeling to cut heat exchanger fouling
Witco Chemical Co., a major manufacturer of detergents for use in motor oils, was experiencing production loss and maintenance headaches in its sulfonation unit because of iron fouling and scale build-up in heat exchangers used in the unit's recirculating cooling system. In August 1983, a water treatment program was introduced after extensive testing and analysis by computerized modeling. The objectives of the program were to improve control over iron oxide deposition, eliminate ancillary calcium phosphate scale and calcium organic phosphorous deposit problems and maintain or cut steel corrosion rates to 4 mils per year or less. An all-organic, cost-effective, non-heavy metal approach was determined to be the best way to reach these goals. The program would permit system operation at the desired cycles of concentration without the use of sulfuric acid for pH control. Based on computerized analysis, a target product concentration of 80 mg/l was determined to handle corrosion, scale and deposit control. A non-oxidizing biocide, effective at high pH on both algae and bacteria, was selected for injection into the system twice a week. Each biocide application was preceded by a surfactant to optimize penetration of the corrosion inhibitor metal surfaces. Since the installation of the new water treatment in 1983, the heat exchangers have not since needed to be cleaned with acid solution. The atmospheric pan condensers were found last September to be in better condition than they had been at any inspection in the past nine years. No iron, calcium phosphate, or calcium organic phosphorous deposits were identified during a recent examination. Steel corrosion rates were found to range between one and four mils per year.
- Research Organization:
- Witco Chemical Co., Petrolia, PA
- OSTI ID:
- 5285078
- Journal Information:
- Chem. Process. (Chicago); (United States), Vol. 48:8
- Country of Publication:
- United States
- Language:
- English
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Related Subjects
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION
ADDITIVES
PERFORMANCE
CORROSION INHIBITORS
DIRECT CONTACT HEAT EXCHANGERS
CORROSION PROTECTION
FOULING
SCALING
SCALE CONTROL
COMPUTER-AIDED DESIGN
CALCIUM PHOSPHATES
COOLANTS
COOLING TOWERS
CORROSION
ENERGY EFFICIENCY
IRON OXIDES
ORGANIC PHOSPHORUS COMPOUNDS
SURFACTANTS
WATER
WATER CHEMISTRY
ALKALINE EARTH METAL COMPOUNDS
CALCIUM COMPOUNDS
CHALCOGENIDES
CHEMICAL REACTIONS
CHEMISTRY
CONTROL
EFFICIENCY
HEAT EXCHANGERS
HYDROGEN COMPOUNDS
IRON COMPOUNDS
MECHANICAL STRUCTURES
ORGANIC COMPOUNDS
OXIDES
OXYGEN COMPOUNDS
PHOSPHATES
PHOSPHORUS COMPOUNDS
TOWERS
TRANSITION ELEMENT COMPOUNDS
360105* - Metals & Alloys- Corrosion & Erosion
320303 - Energy Conservation
Consumption
& Utilization- Industrial & Agricultural Processes- Equipment & Processes