WO1995001591A1 - Water control system - Google Patents

Water control system Download PDF

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Publication number
WO1995001591A1
WO1995001591A1 PCT/US1993/006192 US9306192W WO9501591A1 WO 1995001591 A1 WO1995001591 A1 WO 1995001591A1 US 9306192 W US9306192 W US 9306192W WO 9501591 A1 WO9501591 A1 WO 9501591A1
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WO
WIPO (PCT)
Prior art keywords
water
soap
sensing means
orp
response
Prior art date
Application number
PCT/US1993/006192
Other languages
French (fr)
Inventor
Todd R. Eden
Original Assignee
H.E.R.C. Incorporated
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by H.E.R.C. Incorporated filed Critical H.E.R.C. Incorporated
Priority to PCT/US1993/006192 priority Critical patent/WO1995001591A1/en
Priority to AU46565/93A priority patent/AU4656593A/en
Publication of WO1995001591A1 publication Critical patent/WO1995001591A1/en

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Classifications

    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05DSYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
    • G05D21/00Control of chemical or physico-chemical variables, e.g. pH value
    • G05D21/02Control of chemical or physico-chemical variables, e.g. pH value characterised by the use of electric means
    • CCHEMISTRY; METALLURGY
    • C02TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02FTREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00Treatment of water, waste water, or sewage
    • C02F1/008Control or steering systems not provided for elsewhere in subclass C02F
    • CCHEMISTRY; METALLURGY
    • C02TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02FTREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00Treatment of water, waste water, or sewage
    • C02F1/52Treatment of water, waste water, or sewage by flocculation or precipitation of suspended impurities
    • C02F1/54Treatment of water, waste water, or sewage by flocculation or precipitation of suspended impurities using organic material
    • CCHEMISTRY; METALLURGY
    • C02TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02FTREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F2103/00Nature of the water, waste water, sewage or sludge to be treated
    • C02F2103/02Non-contaminated water, e.g. for industrial water supply
    • C02F2103/023Water in cooling circuits

Definitions

  • Water cooling towers are in widespread use for large capacity heat exchange systems. These cooling towers are used to remove absorbed heat from a circulating water coolant by evaporating a portion of the coolant in the cooling tower. The remaining coolant is extracted from a reservoir or
  • TDS total dissolved solids
  • probes for sensing the conductivity of the cooling tower water, as well as the conductivity of the make-up water provide signals to a controller unit, which proportionally adjusts the trip point at which dumping of the cooling tower water occurs, based upon the sensed
  • the patent to Derham No. 4,931 , 187 discloses another cooling tower system in an effort to automate control of pH, temperature and TDS.
  • these parameters are monitored to control the addition of make-up water to the cooling tower, either by means of a bypass or through a water softener, or both, in accordance with the different variables measured by the system.
  • Derham states that the system eliminates virtually any bleed-off of coolant. To accomplish this, however, an additional particle filter must be included to remove suspended solids from the coolant. It is necessary, however, to backwash the filter with water from outside the system on a periodic basis. It is not clear how scaling can be prevented without any dumping of the water recirculated in the cooling tower system, since at some point the TDS in that water
  • An automatic control system for controlling scale formation in a water circulating, purification and/or distribution system comprising: first sensing means for measuring the oxygen reduction
  • ORP ORP potential of a soap having a 1 : 1 stoichiometric equivalent of an organic carboxylic acid and an amine base in the water for controlling scale formation in said system and supply means for supplying said soap in response to a predetermined ORP measured by said first sensing means for controlling said scale.
  • an automatic control system for a water system includes a first sensor (ORP sensor) for measuring the oxygen reduction potential (REDOX) of the water recirculated in the water system.
  • ORP sensor oxygen reduction potential
  • a reservoir for chemical additives is
  • ORP sensor measures the conductivity of the water, as a factor of total dissolved solids (TDS). Whenever the conductivity (measured in mHos) of the cooling tower water (representative of TDS) reaches a pre-established conductivity, water is removed or dumped from the system.
  • ORP is a measurement of the electron exchange potential which occurs in an ionic reaction, Since most heat transfer systems, including cooing tower systems, are constructed of metal, utilizing ever-changing water, there typically is an undesired equilibrium created. The ORP measurement allows control of the electrochemical equilibrium. Chemical equilibria determines whether the stable form of a material is soluble or insoluble. If soluble species of material are stable, it is possible for a metal
  • Oxidation may be difficult to pinpoint, since according to corrosion terminology, it can mean either the rusting of iron or the development of white oxides on aluminum or zinc. In order to understand their meanings from a chemical
  • This formula indicates iron in water in a state of equilibrium where no current flow exists.
  • the "Fe” is iron as a metal
  • the “Fe + +” is the ionized form of iron
  • the electrons indicate the negative charges given up when the metal changes to an ion.
  • the movement of the iron from the metal form to the ion form is called oxidation. Therefore, in a corrosion cell, the metal is oxidized when it goes into solution as an ion. This occurs
  • Gold for example, exists primarily in the reduced state, e.g., as a metal.
  • Potassium exists primarily in either the oxidized state as an oxide or in the ionic state as a salt.
  • oxidation-reduction potential It may also be called a redox potential, half-cell potential, or solution potential.
  • ORP measurement when it is calculated properly, it permits maintenance of a system such as a cooling tower system, within operable, ideal parameters, in the operation of the preferred embodiment described subsequently, it has been found that to control corrosion or scaling, the oxidation potential must be controlled.
  • the oxidation electrochemical reaction produces an electron flow which can be measured through ORP measurement probes. This measured potential then may be utilized to effect the introduction of controlled quantities of additives to control corrosion or scale, regardless of changing environmental conditions.
  • ORP measurements also are affected by other variables, including biological; so that the analysis of changing environmental factors can be controlled through ORP instrumentation. This is accomplished by the
  • magnesium and calcium carbonate which are predominate constituents of water scale/deposit.
  • concentration levels of the chemical additives are measured by measuring the ORP (oxygen reduction potential) of the water.
  • the cooling tower 10 has a sump or reservoir 1 1 at its bottom, with a pipe 12 for introducing make-up water whenever the water level in the sump 11 drops below some
  • a pump 15 withdraws the water from the reservoir 11 through a pipe or conduit 14, and supplies that water through another pipe or conduit 17 to a heat load 18, from which the water continues through the pipe 17 to spray nozzles 19 located in the top of the cooling tower 10.
  • the system described thus far is a conventional cooling tower system, and may be constructed in a variety of different standard configurations.
  • a reservoir 20 for a liquid chemical additive is indicated, with a pump 21 located to withdraw
  • the pump 21 typically would be operated in response to a manually activated control at such times and for such durations as determined by an observer of the water quality recirculating through the system.
  • control of the pump 21 is effected through a meter/monitoring unit 40.
  • the inputs to the monitoring unit 40 are provided from an ORP probe 38, a pH probe 37 and
  • a valve 28 is located between the T 27 and a strainer 29 to supply water in the shunt through a flow regulator 30 to establish a constant flow rate; so that the measurements made by the probes 36, 37 and 38 are constant, irrespective of changing flow conditions which may take place in the conduit 17.
  • a valve 39 is located at the outlet side of the unit 34 at the outlet side of the unit 34 at the outlet side of the unit 34 at the outlet side of the unit 34 at the outlet side of the unit 34.
  • the valves 28 and 39 typically are manually controlled valves, which are normally open; so that the shunt is constantly operated to bypass small amount of the water supplied from the pump 15 through the shunt for the measurement by the probes 36, 37 and 38. All of the water which passes through the section 34 is returned to the
  • the probe 38 is a standard ORP probe (such as TBI model 540) manufactured by TBI-Baily controls), and it supplies ORP voltage or potential measurements to the ORP monitoring/comparison section 44 in the unit 40.
  • the measured potentials typically are characterized as oxidation potentials, since the magnitude of the measured potential from the probe 38 is representative of the relative ease with which reductants in the water oxidize. It has been found that measurement of ORP provides a more
  • an ideal composition for the additive in the reservoir 20, for effecting the removal and prevention of scale in the cooling tower water has been found to be a composition containing a 1 :1 stoichiometric equivalent of an organic carboxylic acid and an amine base.
  • Various acids and amine may be used, in accordance with the disclosure of the above identified application.
  • the comparison section 44 operates an ORP output switch 50 to provide a signal to a pump 21 to operate the pump to withdraw additive through the pipe 22 from the reservoir 20. This operation continues until the ORP potential measured by the probe 38 returns to a "safety" range of potential. At that time, the ORP switch 50 is once again opened, and the pump 21 ceases operation.
  • the pH probe 37 is optional, but may be used in addition to the ORP probe 38 to control the addition of acid to the water from a reservoir 65. If low acidic conditions are sensed by the probe 37, a signal is supplied to a monitoring/comparison section 45 in the unit 50. The section 45 operates a pH switch 49 to provide a signal to a pump 66. The pump 66 withdraws acid from the reservoir 65 and supplies it through a pipe 67 to a T 69, where the acid is added to the recirculating water in the system. This operation continues until the pH sensed by the probe 37 is correct. The switch 49 then is opened, and the pump 66 is turned off.
  • the conductivity sensor 36 coupled to the unit 40 is set to measure conductivity produced by these significantly higher TDS levels. Since the TDS level of the water can be an order of magnitude or more than can be tolerated in conventional systems a much more sensitive or accurate conductivity probe 36 may be employed. Whenever the TDS level reaches a level of for example 30,000 ppm, a signal is provided by the conductivity probe 36 to the comparison section 46 to cause a conductivity switch 52 to be closed. This supplies a
  • the bleed-off is effected through a normally open manual valve 56 and a strainer 57 to dump the bleed-off or blow-down water from the reservoir 1 1 of the cooling tower.
  • the strainer 57 is
  • the operation of the conductivity switch 52 may be effected
  • Operation of the switch 52 may be used to coordinate the
  • valve 54 With a sensor or float in the reservoir and another valve (not shown) between the water supply and the pipe 12 illustrated in the drawing. In this condition, all of the water in the sump could be dumped, if desired, (blow-down). After this has been accomplished, as measured by the float in the reservoir 1 1 , the valve 54 is once again closed, and make-up water is permitted to be supplied to the sump 1 1 through the pipe 12.
  • an additional solenoid-controlled valve 59 and a biocidal feeder 60 also preferably are provided to biologically shock the system simultaneously with the operation of the blow-down or bleed valve 54.
  • the valve 59 is operated by the switch 52 with the valve 54.
  • the additives, described above, as supplied from the reservoir 20, are not affected when the chemicals in the biocidal feeder are quaternary ammonia compounds.
  • these compounds are mixed with water, which is diverted through the valve 59 from a T 61 to a T 63 to be added to the water circulating through the conduit 17.
  • Quaternary ammonia is a non- oxidizing biocide for use in microbial suppression and destruction.
  • Oxidizing compounds however, also can be supplied by the
  • biocidal feeder 60 to obtain the desired microbial treatment.
  • a typical preferred oxidizing compound contains bromine. Bromine compounds cause the ORP readings to increase significantly. This condition, however, is temporary, and normal operation of the ORP sensing and control resumes within a relatively short time after each "shock" treatment from the feeder
  • the drawing also illustrates devices which may be coupled to the meter/monitor 40 for providing a record of the observed conditions established by the probes 36 and 38.
  • the signals which are continuously produced by the probes 36 and 38 may be supplied to a computer system 70 for processing, to a modem 71 for transmission to a remote location, or to a printer or plotter 73 to provide a continuous record
  • an alarm 74 may be provided to produce a visible or audible indication whenever either of the probes 36 and 38 provide an output indicative of an out-of-balance condition of the water recirculating through the cooling tower 10.
  • valve 76 has been illustrated connected between the valve 28 and 29 in the shunt line to permit a sample of the water to be withdrawn from the system for test purposes. Normally, the valve 76 is closed; and water is only withdrawn infrequently for conducting analysis of
  • ORP parameters if set up correctly in the comparator or meter 44, analyze the solubility of the water with a millivolt reading output from the probe 38. Any element in the water, irrespective of its characteristics, affects the ORP. If the ORP reading raises, the solubility of the water increases. If the ORP reading lowers, the solubility decreases.
  • ORP is an electron activity measurement. This measurement
  • ORP reading which correspond to pH of 6.8 and 8.5, respectively, initially must be independently calibrated for each system. It has been found that even when the same make-up water 12 is supplied to tow identical systems side-by-side, ORP readings may vary considerably. Consequently, as the sump water concentrates with solids, ORP readings need to be determined which correspond with the pH readings of
  • the system which has been described above typically reduces the water dumped from the system, whether the water is dumped by means of bleed-off or blow-down, by as much as 95% over conventional cooling tower systems. This is equivalent to a 30% reduction in the total water consumption for the process. As a result, significant savings in operating costs are realized. In addition, utilization of the chemical additives described above significantly reduces the fouling of the cooling tower system; so that more efficient operation takes place, and longer life of all of the system components results. This equates to additional significant savings.

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  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Hydrology & Water Resources (AREA)
  • Environmental & Geological Engineering (AREA)
  • Water Supply & Treatment (AREA)
  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Automation & Control Theory (AREA)
  • Treatment Of Water By Oxidation Or Reduction (AREA)
  • Preventing Corrosion Or Incrustation Of Metals (AREA)

Abstract

An automatic control system for maintaining the quality of water in a cooling tower utilizes a probe (38) which senses the oxygen reduction potential (ORP) of a soap having a 1:1 stoichiometric equivalent of an organic carboxylic acid and an amine base in the water. The soap is pumped from a chemical supply means (20) containing the soap in response to the ORP of the soap in the water falling below a predetermined threshold. A second sensing probe measures the conductivity (in MHos) of the water as a factor of the total dissolved solids (TDS) to control the bleed-off or blow-down of the water. The chemicals, which are supplied for maintaining the ORP, permit significantly higher total dissolved solids in the water than with standard cooling tower systems, without the buildup of scale. As a consequence, water consumption is significantly reduced; and the system functions automatically, without requiring periodic visual inspection, water analysis or manual operation.

Description

WATER CONTROL SYSTEM
RELATED APPLICATION
Co-pending application, Serial No. 07,700,780, filed on May
16, 1991 and assigned to the same assignee as the present application discloses chemical additives of the type used in the system of the present application; and the disclosure of such co-pending application is incorporated herein by reference. BACKGROUND
Water cooling towers are in widespread use for large capacity heat exchange systems. These cooling towers are used to remove absorbed heat from a circulating water coolant by evaporating a portion of the coolant in the cooling tower. The remaining coolant is extracted from a reservoir or
sump at the base of the tower by a pump, and supplied through the heat load on a continuous basis. Because a large quantity of water evaporates in such a system, a significant and fairly rapid build-up of scale, sludge and the like takes place in the water. Various chemicals are employed preventing the precipitation out of the minerals in the water, since such precipitation causes what is known as "scaling" on the surfaces of the cooling tower and heat exchange equipment. If such scaling is not prevented or is not periodically removed, it can result in significantly reduced
heat transfer, and, therefore, significantly increased operating costs. In
addition, it enhances corrosion of the heat exchange surfaces beneath the scale.
In addition to the scaling problem mentioned above, if the pH factor in the water is too low (typically, below 6.8), increased corrosion of
the system components can result. If the pH is too high, the significant scale build-up mentioned above, takes place. Consequently, it has been the practice to add chemicals to the cooling tower water to maintain a balanced or "safe" range of pH factor in the coolant.
Even with the addition of chemical additives to maintain a chemical balance in the coolant water, the constant significant evaporation of a portion of the water rapidly builds up the amount of total dissolved solids (TDS) in the water to the point where scaling can occur, even though scale-retardant chemicals are present in the water. To prevent scaling from occurring, it is customary periodically to remove water with a high TDS
content from the system to reduce the TDS, or to increase the oxidizing potential or pH. When water is removed, it is replaced with "make-up" water, which typically is obtained from the local available or modified water supply. The removal or dumping of water from the system is accomplished in one or the other of two ways, namely a "bleed-off" in which a portion of the sump or reservoir water is drained while the system is operating, or by "blow-down", which typically is a complete draining of the sump. In both cases, the water which is drained off is replaced with the "make-up" water. Typically, the dumping of water by either "bleed-off" or "blow- down" in cooling tower systems, is effected when the TDS is somewhere around 5,000 ppm. In most systems, a TDS in excess of 5,000 ppm results in scaling, even with the use of chemical additives and oxidants. in the past, the decision to initiate dumping of water from the reservoir of the cooling tower generally has been manually determined. In
some cases, such dumping simply is done on a periodic basis. In other
cases, a visual inspection of the water in the cooling tower is made to
determine whether or not to effect dumping of some of that water. This is a very imprecise technique, and typically results in the dumping of excessive quantities of water from the system.
A system, which has been developed for providing a somewhat
more precise control of the dumping or bleed-off of water from a cooling tower system, is disclosed in the patent to O'Leary No. 4,464,315. This
patent includes probes for sensing the conductivity of the cooling tower water, as well as the conductivity of the make-up water. The probes provide signals to a controller unit, which proportionally adjusts the trip point at which dumping of the cooling tower water occurs, based upon the sensed
water conductivities. A problem with a system of the type disclosed in the O'Leary patent, however, is that at TDS concentrations of 5,000 ppm or less, the differences in conductivity at different TDS concentrations are relatively small; so that accurate determination of the concentration required for dumping of water is difficult. In addition, for such low TDS concentrations, frequent dumping, either by way of blow-down or bleed-off, is required, resulting in the waste of substantial quantity of water.
The water which is dumped from a cooling tower system
represents a significant loss. In a typical, relatively small and relatively efficient evaporative cooling tower system, a total amount of approximately 637,000 gallons per year of water is consumed by the cooling tower. Of this amount, 437,000 gallons are evaporated in the cooling process. The
other 200,000 gallons is flushed down the sewer in the bleed-off operation.
This ration, of approximately one-third of the total amount of water used being totally wasted, is typical of such systems. Some cooling tower systems waste an even greater quantity of water. Not only does this wasted water result in an appreciable loss, both in the resource of the water itself, and in its cost; but most cooling tower systems use chemicals or additives, such as acids, anti-fouling agents and corrosion inhibitors, to prevent corrosion and scaling from occurring. These chemicals constitute a substantial environmental risk, since in many cases the chemicals are toxic and/or hazardous.
The patent to Derham No. 4,931 , 187 discloses another cooling tower system in an effort to automate control of pH, temperature and TDS. In the Derham system, these parameters are monitored to control the addition of make-up water to the cooling tower, either by means of a bypass or through a water softener, or both, in accordance with the different variables measured by the system. Derham states that the system eliminates virtually any bleed-off of coolant. To accomplish this, however, an additional particle filter must be included to remove suspended solids from the coolant. It is necessary, however, to backwash the filter with water from outside the system on a periodic basis. It is not clear how scaling can be prevented without any dumping of the water recirculated in the cooling tower system, since at some point the TDS in that water
reaches a saturation point. While some precipitated solids will be removed by the filter 20, it appears that scaling also can occur as a result of saturation, irrespective of the operation of the water softener and the filter.
These additional components also require extra periodic maintenance for
their operation.
Other cooling tower systems have been designed, which include an automatic pre-established timer control of backwash and chemical addition (Derham No. 3,628,663) or some type of float responsive to the water level in the cooling tower for controlling either make-up water addition (Kinkead No. 4,836,239), or make-up water addition and chemical addition
(O'Leary No. 3,788,340 and Glad No. 3,627,032).
In addition to corrosion and scaling conditions, materials are introduced through air, water and environmental changes, which provide sources for biological support of aerobic or anaerobic algae and the like. While, to some extent, suspended solids in the water may provide a visual indication of the existence of undesirable biological conditions, typically, the
conditions are not discernable to the viewer until a critical condition exists.
It is desirable to provide automatic control of the electron equilibrium of the water in a system, to significantly reduce the amount of water which must be dumped from the system, to accurately sense the conditions required for the addition of chemical additives, with a minimum of maintenance or supervision in its operation.
SUMMARY OF THE INVENTION
An automatic control system for controlling scale formation in a water circulating, purification and/or distribution system, comprising: first sensing means for measuring the oxygen reduction
potential (ORP) of a soap having a 1 : 1 stoichiometric equivalent of an organic carboxylic acid and an amine base in the water for controlling scale formation in said system and supply means for supplying said soap in response to a predetermined ORP measured by said first sensing means for controlling said scale.
It is an object of this invention to provide an improved water system.
It is an additional object of this invention to provide an improved automatic control of the operation of a water system.
It is another object of this invention to provide an improved control system for a water system for automatically monitoring the conditions required for adding chemical additives to the water, and effecting
the addition of such additives to control various parameters affecting the water quality.
It is a further object of this invention to provide an improved water system for effectively controlling the dumping of water from the system in response to the conductivity of the water, and for automatically adding chemical additives to the water in response to a sensed condition of the water.
In accordance with a preferred embodiment of the invention, an automatic control system for a water system includes a first sensor (ORP sensor) for measuring the oxygen reduction potential (REDOX) of the water recirculated in the water system. A reservoir for chemical additives is
coupled with the ORP sensor to supply chemicals to the water whenever a
pre-established ORP is measured by the ORP sensor. Another sensor measures the conductivity of the water, as a factor of total dissolved solids (TDS). Whenever the conductivity (measured in mHos) of the cooling tower water (representative of TDS) reaches a pre-established conductivity, water is removed or dumped from the system. BRIEF DESCRIPTION OF THE DRAWING
The sole figure of the drawing is a diagrammatic representation of a preferred embodiment of the invention.
DETAILED DESCRIPTION
Before entering into a description of the operation of the system shown in the drawing, a brief discussion of ORP measurement is in order. ORP is a measurement of the electron exchange potential which occurs in an ionic reaction, Since most heat transfer systems, including cooing tower systems, are constructed of metal, utilizing ever-changing water, there typically is an undesired equilibrium created. The ORP measurement allows control of the electrochemical equilibrium. Chemical equilibria determines whether the stable form of a material is soluble or insoluble. If soluble species of material are stable, it is possible for a metal
rapidly to corrode into aqueous forms. If insoluble species of material are stable, there is a tendency to form a scale, inhibiting corrosion, but inducing "under scale" corrosion. Both corrosion and scale are undesirable conditions in a cooling tower system, since degradation of the system operation occurs
when either of these conditions are present to any substantial extent.
Two terms commonly used in chemistry and important to note from the standpoint of corrosion are oxidation and reduction. Oxidation may be difficult to pinpoint, since according to corrosion terminology, it can mean either the rusting of iron or the development of white oxides on aluminum or zinc. In order to understand their meanings from a chemical
standpoint, it is necessary to examine a chemical formula such as that for iron:
H20 Fe <- → Fe+ + + 2e"
This formula indicates iron in water in a state of equilibrium where no current flow exists. The "Fe" is iron as a metal, the "Fe+ + " is the ionized form of iron, and the electrons indicate the negative charges given up when the metal changes to an ion. The movement of the iron from the metal form to the ion form is called oxidation. Therefore, in a corrosion cell, the metal is oxidized when it goes into solution as an ion. This occurs
at the anode where the term oxidation also commonly applies to rust forms.
When proceeding in the opposite direction and adding electrons to the ionized iron, the reaction occurs in the direction of the iron as metal, and is referred to as reduction. A metal, therefore, which has been changed from its oxidized state to the metal, has been reduced. This is what takes place when iron ore is changed to metal in a blast furnace.
Different metals have different capacities for being reduced and for being oxidized. Gold, for example, exists primarily in the reduced state, e.g., as a metal. Potassium, on the other hand, exists primarily in either the oxidized state as an oxide or in the ionic state as a salt. The symbolic
reaction for iron given above and its relative potential for the electrochemical
reactions known is called an oxidation-reduction potential. It may also be called a redox potential, half-cell potential, or solution potential.
The benefit of ORP measurement is that when it is calculated properly, it permits maintenance of a system such as a cooling tower system, within operable, ideal parameters, in the operation of the preferred embodiment described subsequently, it has been found that to control corrosion or scaling, the oxidation potential must be controlled. The oxidation electrochemical reaction produces an electron flow which can be measured through ORP measurement probes. This measured potential then may be utilized to effect the introduction of controlled quantities of additives to control corrosion or scale, regardless of changing environmental conditions. ORP measurements also are affected by other variables, including biological; so that the analysis of changing environmental factors can be controlled through ORP instrumentation. This is accomplished by the
system disclosed in the drawing.
Reference now should be made to the drawing, which illustrates a preferred embodiment of the invention. The embodiment shown in Figure 1 functions to permit up to 30,000 ppm TDS concentration
(measured as 0 to 100,000 mHos) in the water recirculated in a cooling
tower system without scale or corrosion. This is accomplished by the use of chemical additives of the type disclosed in the above identified co- pending application to control the quality of the water. These additives
preferably comprise aqueous solutions of 1 : 1 stoichiometric soaps of organic carboxylic acids and amine. These soaps are effective in solubilizing
magnesium and calcium carbonate, which are predominate constituents of water scale/deposit. The concentration levels of the chemical additives are measured by measuring the ORP (oxygen reduction potential) of the water.
A conventional cooling tower 10 is shown. The cooling tower 10 has a sump or reservoir 1 1 at its bottom, with a pipe 12 for introducing make-up water whenever the water level in the sump 11 drops below some
minimum level. A pump 15 withdraws the water from the reservoir 11 through a pipe or conduit 14, and supplies that water through another pipe or conduit 17 to a heat load 18, from which the water continues through the pipe 17 to spray nozzles 19 located in the top of the cooling tower 10. The system described thus far is a conventional cooling tower system, and may be constructed in a variety of different standard configurations.
In the system shown in the drawing, a reservoir 20 for a liquid chemical additive is indicated, with a pump 21 located to withdraw
chemicals from the reservoir 20 through a pipe 22, and supply those chemicals through a pipe 24 and an injection T 25 and a T 26 to the water recirculating through the conduit or pipe 17. in systems of the prior art, the pump 21 typically would be operated in response to a manually activated control at such times and for such durations as determined by an observer of the water quality recirculating through the system.
In the system disclosed in the drawing, however, control of the pump 21 is effected through a meter/monitoring unit 40. The inputs to the monitoring unit 40 are provided from an ORP probe 38, a pH probe 37 and
a conductivity probe 36 located in a measuring section 34 of a shunt line
connected between a T 27 and the T 26. A valve 28 is located between the T 27 and a strainer 29 to supply water in the shunt through a flow regulator 30 to establish a constant flow rate; so that the measurements made by the probes 36, 37 and 38 are constant, irrespective of changing flow conditions which may take place in the conduit 17. At the outlet side of the unit 34 is another valve 39. The valves 28 and 39 typically are manually controlled valves, which are normally open; so that the shunt is constantly operated to bypass small amount of the water supplied from the pump 15 through the shunt for the measurement by the probes 36, 37 and 38. All of the water which passes through the section 34 is returned to the
recirculating water in the system by means of the T 26.
The probe 38 is a standard ORP probe (such as TBI model 540) manufactured by TBI-Baily controls), and it supplies ORP voltage or potential measurements to the ORP monitoring/comparison section 44 in the unit 40. The measured potentials typically are characterized as oxidation potentials, since the magnitude of the measured potential from the probe 38 is representative of the relative ease with which reductants in the water oxidize. It has been found that measurement of ORP provides a more
accurate indication of the condition of the water than a measurement of pH, since pH is difficult to adjust in a system of the type shown in the drawing in which the water has very high TDS. As mentioned above, an ideal composition for the additive in the reservoir 20, for effecting the removal and prevention of scale in the cooling tower water, has been found to be a composition containing a 1 :1 stoichiometric equivalent of an organic carboxylic acid and an amine base. Various acids and amine may be used, in accordance with the disclosure of the above identified application.
Whenever a condition is sensed by the ORP probe 38, indicative that additional chemical additives need to be supplied to the recirculating water in the system, the comparison section 44 operates an ORP output switch 50 to provide a signal to a pump 21 to operate the pump to withdraw additive through the pipe 22 from the reservoir 20. This operation continues until the ORP potential measured by the probe 38 returns to a "safety" range of potential. At that time, the ORP switch 50 is once again opened, and the pump 21 ceases operation.
The pH probe 37 is optional, but may be used in addition to the ORP probe 38 to control the addition of acid to the water from a reservoir 65. If low acidic conditions are sensed by the probe 37, a signal is supplied to a monitoring/comparison section 45 in the unit 50. The section 45 operates a pH switch 49 to provide a signal to a pump 66. The pump 66 withdraws acid from the reservoir 65 and supplies it through a pipe 67 to a T 69, where the acid is added to the recirculating water in the system. This operation continues until the pH sensed by the probe 37 is correct. The switch 49 then is opened, and the pump 66 is turned off.
When the chemical additive contains a 1 : 1 stoichiometric soap equivalent, as described above, applicant has found that the TDS (total dissolved solids) in the water, which can be reached without scaling or corrosion, are significantly higher than the 5,000 ppm typical of
conventional cooling tower systems. TDS concentrations of 30,000 ppm,
or higher, (measured as 0 to 100,00mHos) can be attained by the system without requiring dumping by way of either bleed-off or blow-down of the water from the cooling tower reservoir. Consequently, the conductivity sensor 36 coupled to the unit 40 is set to measure conductivity produced by these significantly higher TDS levels. Since the TDS level of the water can be an order of magnitude or more than can be tolerated in conventional systems a much more sensitive or accurate conductivity probe 36 may be employed. Whenever the TDS level reaches a level of for example 30,000 ppm, a signal is provided by the conductivity probe 36 to the comparison section 46 to cause a conductivity switch 52 to be closed. This supplies a
signal to operate a solenoid-controlled valve 54 located in a bleed-off shunt from the conduit 17. The bleed-off is effected through a normally open manual valve 56 and a strainer 57 to dump the bleed-off or blow-down water from the reservoir 1 1 of the cooling tower. The strainer 57 is
provided to prevent silt and other particles from interfering with the proper operation of the valve 54. The operation of the conductivity switch 52 may be effected
until the conductivity sensed by the probe 36 drops to some second lower predetermined value, whereupon the switch 52 is opened to turn off the valve 54. This is a typical operation for a "bleed-off" dumping of water from the system while it is continuously running. Obviously, make-up water through the pipe 12 will be provided to the sump 1 1 , as soon as the water
level drops to some minimum value, as described above, as a result of the dumping of water through the valve 54.
Operation of the switch 52 may be used to coordinate the
operation of the valve 54 with a sensor or float in the reservoir and another valve (not shown) between the water supply and the pipe 12 illustrated in the drawing. In this condition, all of the water in the sump could be dumped, if desired, (blow-down). After this has been accomplished, as measured by the float in the reservoir 1 1 , the valve 54 is once again closed, and make-up water is permitted to be supplied to the sump 1 1 through the pipe 12.
Whenever there is a bleed-off or a blow-down of water from the reservoir 1 1 , an initial significant imbalance of the chemical condition of
the water occurs as a result of replacement of a substantial quantity (or replacement of all) of the water in the cooling tower system. Consequently, an additional solenoid-controlled valve 59 and a biocidal feeder 60 also preferably are provided to biologically shock the system simultaneously with the operation of the blow-down or bleed valve 54. The valve 59 is operated by the switch 52 with the valve 54. The additives, described above, as supplied from the reservoir 20, are not affected when the chemicals in the biocidal feeder are quaternary ammonia compounds. Thus, if such compounds are provided in the biocidal feeder 60, these compounds are mixed with water, which is diverted through the valve 59 from a T 61 to a T 63 to be added to the water circulating through the conduit 17. Quaternary ammonia is a non- oxidizing biocide for use in microbial suppression and destruction.
Oxidizing compounds, however, also can be supplied by the
biocidal feeder 60 to obtain the desired microbial treatment. A typical preferred oxidizing compound contains bromine. Bromine compounds cause the ORP readings to increase significantly. This condition, however, is temporary, and normal operation of the ORP sensing and control resumes within a relatively short time after each "shock" treatment from the feeder
60.
The drawing also illustrates devices which may be coupled to the meter/monitor 40 for providing a record of the observed conditions established by the probes 36 and 38. For example, the signals which are continuously produced by the probes 36 and 38 may be supplied to a computer system 70 for processing, to a modem 71 for transmission to a remote location, or to a printer or plotter 73 to provide a continuous record
of the conductivity and ORP being monitored. In addition, an alarm 74 may be provided to produce a visible or audible indication whenever either of the probes 36 and 38 provide an output indicative of an out-of-balance condition of the water recirculating through the cooling tower 10. These devices 70, 71 , 73 and 74 are not necessary for the automatic operation of the system which has been described, but may be utilized in conjunction with that
system to enhance its utility by monitoring its operation.
An additional valve 76 has been illustrated connected between the valve 28 and 29 in the shunt line to permit a sample of the water to be withdrawn from the system for test purposes. Normally, the valve 76 is closed; and water is only withdrawn infrequently for conducting analysis of
the water quality which is not covered by the automatic system described
above.
What has been discovered, is that ORP parameters, if set up correctly in the comparator or meter 44, analyze the solubility of the water with a millivolt reading output from the probe 38. Any element in the water, irrespective of its characteristics, affects the ORP. If the ORP reading raises, the solubility of the water increases. If the ORP reading lowers, the solubility decreases.
ORP is an electron activity measurement. This measurement
is related to the pH of the water, and by maintaining the ORP within a safety range, currently arbitrarily independently calibrated at the set-up of each system operation, the pH remains between 6.8 and 8.5. Consequently, as long as the ORP is set, the only considerations which remain to be dealt
with in the system are microbial corresponding to silt accumulation, biological activity and specific gravity. The table below illustrates the relationship between ORP readings (in millivolts) and pH, along with a designation of the cooling tower water conditions which produce corrosion and scaling.
TABLE 1
βH ORP (millivolts)
14 - 1000
SCALING
8.5 - 100
SAFETY ZONE
7 0
6.8 + " 100
CORRODING
0 + 1000
The ORP reading which correspond to pH of 6.8 and 8.5, respectively, initially must be independently calibrated for each system. It has been found that even when the same make-up water 12 is supplied to tow identical systems side-by-side, ORP readings may vary considerably. Consequently, as the sump water concentrates with solids, ORP readings need to be determined which correspond with the pH readings of
significance (typically, 6.8 and 8.5). Once these have been established, the comparator in the ORP meter 44 is adjusted accordingly to respond to these
readings. The readings then remain consistent throughout the operation of the system; and fully automatic cooling tower system operation is possible. An ideal starting water condition is given below: CONDITION MIN MAX
TEMPERATURE 40°F 80°F
PH 6.8 7.4
OXIDANT FREE & TOTAL 0.0 1.5 mg/L
TOTAL ALKALINITY 60 180 mg/L
TOTAL DISSOLVED SOLIDS 500 1750 ppm
CONDUCTIVITY 750 2625 mHos
TOTAL HARDNESS 100 300 mg/L
CALCIUM HARDNESS 150 1000 mg/L
DISSOLVED OXYGEN 6 10 mg/L
The system which has been described above typically reduces the water dumped from the system, whether the water is dumped by means of bleed-off or blow-down, by as much as 95% over conventional cooling tower systems. This is equivalent to a 30% reduction in the total water consumption for the process. As a result, significant savings in operating costs are realized. In addition, utilization of the chemical additives described above significantly reduces the fouling of the cooling tower system; so that more efficient operation takes place, and longer life of all of the system components results. This equates to additional significant savings.
The foregoing description of the preferred embodiment of the invention should be considered as illustrative, and not as limiting. For example, although the embodiment described is used with a cooling tower, the system also may be used for water purification systems (distillation),
reverse osmosis, etc., closed heat exchange systems (automotive radiators), swimming pools, water distribution systems, and industrial systems. Various other uses, changes and modifications will occur to those skilled in the art, without departing from the true scope of the invention as defined in the appended claims.

Claims

Claims :
(1 ) An automatic control system for controlling scale formation in a water circulating, purification and/or distribution system, comprising: first sensing means for measuring the oxygen reduction
potential (ORP) of a soap having a 1 : 1 stoichiometric equivalent of an organic carboxylic acid and an amine base in the water for controlling scale formation in said system and supply means for supplying said soap in response to a
predetermined ORP measured by said first sensing means for controlling said
scale.
(2) The system according to Claim 1 further including:
second sensing means for measuring the conductivity of the
water as a factor of total dissolved solids (TDS) in the water and means coupled with said second sensing means for removing water in response to the measurement of a predetermined conductivity of the water by said second sensing means.
(3) The system according to Claim 1 wherein the water is recirculated by a pump through a recirculating conduit, and said first'sensing means senses the soap in water supplied through the conduit by the pump.
(4) The system according to Claim 3 further including: a shunt conduit coupled across at least a portion of the recirculating conduit so that said first sensing means senses the soap in water flowing through said shunt conduit.
(5) The system according to Claim 1 wherein said soap in said supply means is in liquid form, and further including a pump for removing said soap from said supply means to supply said soap to said water, said pump being coupled with said first sensing means and operated in response
to the sensing of the predetermined ORP measured by said first sensing means.
(6) The system according to Claim 2 wherein said means for removing water removes a predetermined quantity of water from the system in response to the measurement of a predetermined conductivity of such water by said second sensing means.
(7) The system according to Claim 2 wherein said means for
removing water includes a normally-closed drain valve means; and means for opening said normally-closed drain valve means for
a predetermined time interval in response to the measurement of said predetermined conductivity of the water by said second sensing means.
(8) The system according to Claim 7 further including biocidal feeder means being coupled with said second sensing means for supplying biocidal chemicals to said water in response to the measurement of said predetermined conductivity of said water by said second sensing means.
(9) The system according to Claim 1 wherein said soap in said supply means is in liquid form, and further including a pump for removing soap from said supply means and for supplying said soap to said water, said pump coupled with said first sensing means and operated in response to the sensing of a predetermined ORP measured by said first sensing means. (10) The system according to Claim 2 further including biocidal feeder means being coupled with said second sensing means for supplying
biocidal chemicals to said water in response to the measurement of said predetermined conductivity of said water by said second sensing means.
PCT/US1993/006192 1993-06-29 1993-06-29 Water control system WO1995001591A1 (en)

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0193735A1 (en) * 1985-02-13 1986-09-10 Siemens Aktiengesellschaft Method and device for protecting steam generators, especially in nuclear power plants
EP0196259A1 (en) * 1985-03-26 1986-10-01 Compagnie Francaise De Produits Industriels Regulation method for a chemical medium
EP0207804A2 (en) * 1985-07-04 1987-01-07 S.D.I. Water Technology Limited The management of water in recirculatory water systems
EP0504520A2 (en) * 1991-03-20 1992-09-23 Nalco Chemical Company On-stream monitoring of a treating agent in a cooling water system

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0193735A1 (en) * 1985-02-13 1986-09-10 Siemens Aktiengesellschaft Method and device for protecting steam generators, especially in nuclear power plants
EP0196259A1 (en) * 1985-03-26 1986-10-01 Compagnie Francaise De Produits Industriels Regulation method for a chemical medium
EP0207804A2 (en) * 1985-07-04 1987-01-07 S.D.I. Water Technology Limited The management of water in recirculatory water systems
EP0504520A2 (en) * 1991-03-20 1992-09-23 Nalco Chemical Company On-stream monitoring of a treating agent in a cooling water system

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