How To Achieve The Lowest Specific Water Consumption PDF

Juschem
Solutions Pvt. Ltd.,

Presents
How To Achieve The Lowest Specific Water Consumption (SWC) In Hinterland

Coal Based Thermal Power Stations?
Mr. Soumitra Banerjee will share his experience, the process of achieving SWC 2.0 litres per unit of power without having CW
blowdown recycling. (With CW Blowdown recycling he estimated it to be 1.74 litres per unit of power).
He will also hand hold you to implement Water Management System at your power stations. Analytics play an important role.
Visit us at www.just-chemicals.com
Water Consumption Scenario
• About 51% of 156 thermal plants across 12 states whose data
could be obtained declared themselves compliant with water
norms early 2019 (source: RTI response received by the Manthan
Adhyayan Kendra, a research centre that analyses water and
energy issues in India.)
• Up to 19% of the remaining plants declared themselves
noncompliant, as per the RTI responses.
• The others either did not supply any data or offered insufficient
information.
• As of August 30, 2019, there were 269 thermal power plants in
India, according to the Central Electricity Authority.
• Taken together, these 269 plants consume 87.8% of the total
amount of water consumed by the industrial sector, according to
a study conducted by The Energy and Resources Institute (TERI).
• To put this in perspective, such amounts of water could fulfil the
water needs of four cities for two days.
• Between 2013-17, 61 coal plants were shut down because of water shortages, resulting in a loss of 17,000 gigawatt-
hours of electricity, according to a report by the Institute for Energy Economics and Financial Analysis (IEEFA)
• “National Thermal Power Corporation’s Super Thermal Power Plant in Farakka, West Bengal and Rihand Super Thermal
Power Project in Uttar Pradesh, Parali Thermal Power Plant in Maharashtra, Raichur Thermal Power Plant in Karnataka
and Ennore Thermal Power Station in Tamil Nadu are all located in water-stressed areas and have been shut-down
because of water storages,” said Deepak Krishnan, manager with the energy programme at the WRI, India.
• Until December 2015, there were no norms to monitor water usage of thermal power plants.
• Then, on December 7, 2015, the Ministry of Environment Forest and Climate Change (MoEFCC) issued a notification
which declared that old plants could use 3.5 cubic meters of water per megawatt-hour and those installed after
January 1, 2017 could use 2.5 cubic meters of water per megawatt-hour.
• In October 2017, the government eased the water consumption norms for even plants that started operations on or
after January 1, 2017--they are now allowed to consume up to 20% more water than permitted earlier. Passed as
amendments to the Environment (Protection) Rules, 1986, the new rules allow plants to use up to 3 cubic metres per
megawatt-hour. This additional amount is enough to irrigate 700 hectares of land a year.
How to lower the specific water consumption?
• Create a water balance for your power station, as accurate as possible, populate data every day
• Have meters installed (smart meters and implementation of IoT is the best solution)
• Cleanse and Analyse the data, you will arrive at:
• Points where the consumption is high
• Points where collection and recycling is possible
• Monitor continuously
• MACRO CONTROL: AHS and recovery of ash water and the clarifiers for Ash water should work perfectly
• MACRO CONTROL: Get the storm water collection pond, it helps a lot in reduction of SWC but it should not have
contamination from RO reject or DM Plant effluent
• MACRO CONTROL: CW makeup will be always the highest consumer, get the COC up, it saves a lot, methods and real
examples are given in subsequent slides. There is a method of increasing COC with appropriate understanding of water
chemistry
• MACRO CONTROL: Try to get lower evaporation by not operating turbine at (Phase transition zone) PTZ, limiting vacuum
to 0.9 only, this will help in getting good heat rate by allowing condensate not to supercool and helps reduce CW
evaporation by switching few fans (avoid stopping CW pumps)
• MICRO CONTROL: Get EDI installed in place of MB. (RO-EDI is the best solution for making DM Water of <0.08 µs/cm
• Review the process on daily basis, apply CAPA
Audit – Efficiency, effectiveness of water management process contributes significantly to power plant
economics
Audit criteria – what should be and what is?
Audit finding – what is compared with what should be?
Determine the causes and effects of the finding – recommend in audit report
Training on aspects, How, What, why, When, Where, Who/Whom on area of concern
Defining process, SWOT and Planning improvement projects
Estimate likely DELTA of Improvements, KIZEN

Follow the Process Management Model in Audits-improvement
projects (JURAN’S TRILOGY)
Design Measure Manage

Define the Establish the Measure and check the Stabilise:
Process metrics performance Eliminate Variation
Feedback to hold gain
Improve
Execute Analyse & Plan Set Improvement
Feedback to Design Process improvement Improvement Goals
Action Plans
6. Identify the Measures that will
5. What are the key steps? 2. Identify the Output of the 1. Identify the Purpose reflect if Customer Needs are
Process that will meet requirement being met
What is being Measured?

What is the
Target
What is
Key Process
output of
machine /
Efficiency (In-Process) Effectiveness (Output)
Data being Water
Steps process / Predictability
supplied Management Performance
system Measure Target & Measure Target
? improvement
Prescription
• Design • Lag • Create a water • Control on Reduction of % reduction in 33% min. 90% % adherence 100% 30% minimum on
• Commissioni Indicators balance SWC, it SWC to 2.0 SWC to Quality & Efficiency and
ng of • Have meters should come liters per unit Quantity of large on
• Real-time efficiency installed down to 2.0 of power output effectiveness
meter data and Cleanse and liters per (KWHR) (meeting
effectivene Analyze the KWHr demand) Quantifiable in
Plant ss data, improvement
Operation • Quality • Monitor trends of lead
parameters continuously and lag indicators
• Process • MACRO& 9. Identify the
parameter MICRO
Measures that
• Breakdown CONTROLS 7. Set Target for the identified
Info. CONTROL will reflect is
Measure
• Eqpt. Info efficient
• Overhaul
info
10. Set Target for the Efficiency 8. Impact on performance.
Measures Measurable?
4. Who will 3. What and how inputs 11. Asset life predictability and
provide those are required to start the prescription writing
Inputs? activities?
What are the bottlenecks in reducing Specific Water Consumption?
Technical
• Non-availability of As built Water Balance Diagram
• Non-availability of water meters (smart metering with IOT will work well as it works with Energy Management Systems).
Skills
• Not understanding water chemistry of Cooling water, thus due to fear of scaling/corrosion, do not take risk of :Reaching
high COC”. Subsequent slides will take you through the journey of excellence in this matter.
• Lack of awareness on performing analytics on data received from meters, or work fatigue to do the analytics
• Lack of Awareness of Troubleshooting the problems
• Unable to manage Ash-Water system
• Unable to operate turbine in pre PTZ, unable to avoid supercooling and thus transfers sensible heat to towers
• Switching of CWS Pump and not CT fans
System
• Lack of CAPEX for the water recycle project(s)
• Lack of funds to implement projects for reduction of evaporation from Reservoirs. (Example of methods in subsequent
slides)
Regulatory system implementation
• Government not forcing penalties and not shutting down the plants exceeding water consumption as they due in Water
and Air acts. It remains somehow unmonitored and untouched except for the CESS collection.
• Government Granting CTO to new state owned plant on old 2015 SWC norms
What is the Typical Water Consumption points in a power plant?
Expected SWC with 91% accuracy: In m3/day, For 1980 MW Super Critical Power Station
SWC SWC At 100% PLF SWC
CW Evap. 80648 1.70 CW Evap. 70262 1.48 CW Evap. 61097 1.29
BD at 8 COC 11521 0.24 BD at 8 COC 10037 0.21 BD at 8 COC 8728 0.18
CWMake-UP 92169 1.94 CWMake-UP 80299 1.69 CWMake-UP 69825 1.47
Fire+Service 2321 0.05 Fire+Service 2321 0.05 Fire+Service 2321 0.05
DM+Potable 2134 0.04 DM+Potable 2134 0.04 DM+Potable 2134 0.04
TOTAL 96624 2.03 TOTAL 84754 1.78 TOTAL 74280 1.56
Summer Yearly Winters
What is the Typical Water Consumption points in a power plant?
Expected SWC with 91% accuracy: In m3/day, For 1980 MW Super Critical Power Station
With BD Re-cycle 8814 7679 6677
SWC SWC At 100% PLF SWC
CW Evap. 80648 1.70 CW Evap. 70262 1.48 CW Evap. 61097 1.29
BD at 8 COC 11521 0.24 BD at 8 COC 10037 0.21 BD at 8 COC 8728 0.18
CWMake-UP 83356 1.75 CWMake-UP 72621 1.53 CWMake-UP 63148 1.33
Fire+Service 2321 0.05 Fire+Service 2321 0.05 Fire+Service 2321 0.05
DM+Potable 2134 0.04 DM+Potable 2134 0.04 DM+Potable 2134 0.04
TOTAL 87811 1.85 TOTAL 77076 1.62 TOTAL 67603 1.42
Summer Yearly Winters
Go with the Flow
• One of the best ways that a plant can manage its water resources more effectively is to develop a plantwide water
management plan.
• A water management plan is a comprehensive site-wide strategy for maximizing water use efficiency, minimizing
wastewater discharge, and encouraging a policy of sustainability and reuse/recycle to the maximum extent practical
to control a plant’s water footprint.
• The first step in developing a plan is to construct an overall plant water balance depicting the current plant water
picture.
• The water balance should identify all water consumers and wastewater producers throughout the facility and
indicate all the flow routes and distribution pathways.
Go with the Flow
• Get the full picture. Portable flow monitors and sample collection devices can be used to monitor inlet and outlet
flows and collect water samples from locations that are not typically instrumented to capture this data.
• Tracking plant water and wastewater flows, and developing a mass balance, can be as simple as developing an Excel
spreadsheet to log and analyze the data (next slides), We have developed specialized tools based on IoT to aid in
this process.
• The flow rates and the water quality constituents for individual plant water and wastewater streams—such as
cooling tower makeup, boiler and cooling tower blowdown, equipment drains and washdown, pretreatment system
wastewaters, captured storm waters, strainer and filter backwash waters, dewatering equipment filtrate, and many
other plant sources and users are assessed and tabulated to enable tracking throughout the plant.
• Once the plant water balance is developed and the mass balance of contaminants is tracked throughout the plant,
staff can use this tool in conjunction with the water balance to assess how operational changes or stream redirection
might allow the plant to reuse some internal wastewater streams and reduce its water footprint, or reduce the level
of contaminants that are discharged or that need to be removed.
Water Balance Table 100% PLF
Design 2016-17 2017-18 with ETP-UF-RO Avgerage
Intake Mn CWST 134268 94592 91930 83017 2017-18 Proposed
2.51% HRSCC 2849 2134 2134 2134 Achieved Further Scope
Total Intake 137117 96726 94064 85151
SWC 2.885 2.035 1.979 1.792 1.994 1.774
Use CW MU 120660 91476 89609 80696 95.26% 94.77%
Service 13608 2321 2321 2321 2.47% 2.73%
Fire 0 795 0 0 0.00% 0.00%
WTP in 2729 2119 2119 2119 2.25% 2.49%
WTP use Breakup RO-MB 1857 1011 1011 1011 1.07% 1.19%
Potable 520 410 410 410 0.44% 0.48%
CW Use Breakup CW Evap 95328 78408 78408 78408 83.36% 92.08%
CW BD 23832 13068 11201 11201 11.91% 13.15%
BD Re-cycled 8913 0.00% 10.47%
Intermediate Effluent Mn Clf. 3360 20 20 20 0.02% 0.02%
HRSCC 120 15 15 15 0.02% 0.02%
DMF-RO-MB 417 633 633 633 0.67% 0.74%
CW BD 23832 13068 11201 11201 11.91% 13.15%
Water Balance Table 100% PLF
Design 2016-17 2017-18 with ETP-UF-RO Avgerage
Recoverable Effluent WTP/Plant dr. 2377 2323 2323 1750 2.47% 2.06%
HRSCC+Mn Clf 3240 35 35 35 0.04% 0.04%
CWBD to CHP 6336 0 0 0 0.00% 0.00%
CW BD in AHP 17496 13068 11201 11201 11.91% 13.15%
Recovered Effluent WTP / Plant dr. 2377 2323 2323 2323 2.47% 2.73%
HRSCC+Mn Clf 3240 95 95 95 0.10% 0.11%
CWBD to CHP 6336 0 0 0 0.00% 0.00%
CW BD in Ash Water 17496 13068 11201 11201 11.91% 13.15%
AHP Requirement ETP and TT rejects 4584 4584 4584 4584 4.87% 5.38%
Excess CWBD to be drained out 15289 10807 8940 0 9.50% 0.00%
Sludge Clf+HRSCC Drain 360 0 0 0 0.00% 0.00%
COC 5 7.5 8 8 0.01% 0.01%
Water Balance
Analytics at 100%
PLF - synopsis
Water Balance – Design and initial
SWC = 2.8940
Water Balance Improved by monitoring and control
SWC = 2.064
Analytics
• This requires, that the water management team perform its monitoring activities at several different times over the
course of a year to capture the various plant operating scenarios of interest and collect the desired data.
• Off-design operating conditions, especially at multi-unit sites with integrated water and wastewater systems, often
can produce the most challenging water operating scenarios and can drive decisions related to equipment sizing.
Chart Contaminants:
• Once all flows have been charted, the second step is to understand the mass balance of contaminants present in the
plant water and wastewater streams. This will likely involve sampling and testing the internal streams that are not
normally monitored in order to paint a true picture of:
■ Where the plant is adding contaminants to the water streams or concentrating existing contaminants.
■ What contaminants are being added or concentrated.
■ In what concentration the contaminants are present in each stream.
Portable flow monitors and sample collection devices can be employed to monitor inlet and outlet flows and collect
water samples from locations that are not instrumented to capture this data currently.
Analytics
• Obvious examples of internal recycle/reuse opportunities include recycling reverse osmosis reject as cooling tower
makeup, collecting and reprocessing boiler or heat recovery steam generator blowdown water, and recycling cooling
tower blowdown as flue gas desulfurization makeup water.
• However, a close review of the plant water and mass balances can reveal quite a few opportunities for water reuse or
water conservation.
• Many of these internal recycle/reuse opportunities can be inexpensive and relatively simple to implement, involving
only piping and valving modifications, though some may involve the addition of treatment equipment such as
clarification or filtration to reprocess the wastewater streams to make them suitable for reuse.
• Determining the water quality of the wastewater stream contaminants, therefore, is a crucial early step in evaluating
wastewaters for reuse opportunities and performing a cost-benefit analysis.
Analytics
• Development of water and mass balances will also prepare a plant to intelligently evaluate the impact of and reaction
to potential modifications to the plant water balance that may occur due to regulations changes.
• The new proposed regulations may affect a plant’s cooling water systems, material-handling and conveyance systems,
and wastewater discharges.
• Potential changes such as the addition of wastewater treatment systems or the rerouting of wastewater streams can be
simulated to assess their effects on overall plant operations.
Analytics
Water Balance Water Balance Water Balance

Analytics at Analytics at 85% Analytics at 70%
100% PLF PLF PLF
Improvement Project to further reduce SWC
Note For
Approval Visit us at www.just-chemicals.com
Water Balance after measuring, monitoring, controlling + Recycling
SWC = 1.799
Challenges:
• The most difficult challenge in developing an accurate site water balance is collecting adequate data to
model the plant water and wastewater streams precisely.
• Using smart water meters and IoT with Analytics is the necessary system creation for sustainability
• Inclusion of seasonal and historical data and its impact on the plant water balance is desirable, such as
periodic degradations in water supply qualities that reduce cooling tower operating cycles.
• This water balance should include average daily usage rates as well as peak and minimum flows to create
an accurate picture of the plant’s water footprint.
• Reduced load operations (if they are relevant for a unit), partial plant operations (for instance, single-unit
operation in a two-unit plant), as well as other off-design operating scenarios should be evaluated, as
appropriate, to determine how they will affect water consumption rates and wastewater production.
Where is the bottleneck?
REACHING HIGH COC
In Cooling Water Systems
➢Operating recirculating cooling systems at higher COC helps us to gain many
economic and environmental benefits viz.:
• Reduction in pumping cost.
• Reducing depletion of natural resource, Reducing specific water consumption and water cost,
Station’s requirement to lower the operating cost/increase profitability
• Abiding environmental regulations
• Demonstration of corporate responsibility by conserving water.
➢Elevating COC can minimize operating costs through water savings and energy
savings.
➢While planning to operate at high COC, we need to study various technical

issues in order to prevent waterside problems.
Study on Water Chemistry:
CW MAKE-UP WATER ANALYSIS CONSIDERED
To understand the chemistry of our Parameters
Make up Water Parameter
As Min Max Avg
cooling water system we studied the pH 6.6 8.2 7.5
present system and operating Total Hardness PPM 30 50 40
Calcium Harness PPM 18 30 24
parameters for Calcium Hardness, TDS, Magnesium Hardness PPM 12 20 16
alkalinity and associated pH. M-Alk PPM 20 40 30
Chlorides PPM 15 25 20
Silica PPM 8 13 11
• LSI below 0.5 is corrosive and above 1.5 is scale Conductivity µs/cm 100 150 120
forming; 0.5-1.5 controllable Total Dissolved solids PPM 67 101 80
• RSI above 6.4 is corrosive and Below 5.4 is scale Turbidity NTU 4 20 7
forming; 5.4-6.4 controllable
Iron PPM 0.1 0.2 0.15
pHs (Saturation) 9.3 8.8 9.0
LSI Indices -2.7 -0.6 -1.5
RSI Indices 12.0 9.4 10.5
Relationship of Various parameters
• Evaporation Loss
E = 0.0018 x delta T x R x TF (Tower Factor)*
(T expressed in oC)
* Tower factor is based on (a) humidity% and (b) Tower Height (Considered during designing of the tower)
• Blowdown
B = Evaporation
COC-1
• Cycles Of Concentration
COC = Concentration in Recirculation
Concentration In Make-up
Question: What is Best Element/chemical parameter?
Scaling/corrosion Propensity on Average Values
At Average Values
Parameters 5 COC 6 COC 7 COC 8 COC 9 COC 10 COC 11 COC 12 COC
pH 7.83 7.94 8.04 8.13 8.2 8.3 8.4 8.5
Total Hardness 200 240 280 320 360 400 440 480
Calcium Harness 120 144 168 192 216 240 264 288
Magnesium
Hardness 80 96 112 128 144 160 176 192
M-Alk 150 180 210 240 270 300 330 360
Chlorides 100 120 140 160 180 200 220 240
Silica 55 66 77 88 99 110 121 132
Conductivity 600 720 840 960 1080 1200 1320 1440
Total Dissolved
solids 402 482.4 562.8 643.2 723.6 804 884.4 964.8
Turbidity 35 42 49 56 63 70 77 84
Iron 0.75 0.9 1.05 1.2 1.35 1.5 1.65 1.8
pHs (Saturation) 7.4 7.2 7.1 7.0 6.9 6.8 6.7 6.7
LSI For Make up with
0.5 0.7 0.9 1.1 1.3 1.5 1.7 1.8
high Chlorides
RSI 6.9 6.5 6.2 5.8 5.6 5.3 5.1 4.8 use LaI
LSI below 0.5 is corrosive and above 1.5 is scale forming; 0.5-1.5 controllable
RSI above 6.4 is corrosive and Below 5.4 is scale forming; 5.4-6.4 controllable
Scaling/corrosion Propensity on Maximum Values
At Maximum Values
Parameters 5 COC 6 COC 7 COC 8 COC 9 COC 10 COC 11 COC 12 COC
pH
8.2 8.3 8.4 8.5 8.5 8.6 8.7 8.8
Total Hardness
250 240 280 320 360 400 440 480
Calcium Harness
150 144 168 192 216 240 264 288
Magnesium Hardness
100 96 112 128 144 160 176 192
M-Alk
200 180 210 240 270 300 330 360
Chlorides
125 120 140 160 180 200 220 240
Silica
65 66 77 88 99 110 121 132
Conductivity
750 720 840 960 1080 1200 1320 1440
Total Dissolved solids
502.5 482.4 562.8 643.2 723.6 804 884.4 964.8
Turbidity
100 42 49 56 63 70 77 84
Iron
1 0.9 1.05 1.2 1.35 1.5 1.65 1.8
pHs (Saturation) 7.2 7.2 7.1 7.0 6.9 6.8 6.7 6.7
LSI 1.0 1.1 1.3 1.5 1.6 1.8 2.0 2.1
For Make up with
RSI 6.2 6.2 5.8 5.5 5.2 5.0 4.8 4.5 high Chlorides
LSI below 0.5 is corrosive and above 1.5 is scale forming; 0.5-1.5 controllable use LaI
RSI above 6.4 is corrosive and Below 5.4 is scale forming; 5.4-6.4 controllable
RSI & Chemistry
All
LSI and
Saturatio
scaling
n indices
indices
Study Outcome / Analysis
▪ Considering the above, we shall always be in the range of 7 - 10 COC. Assuming that the system will
have max values (only in summers) also, a COC of 8.0 is ideal.
▪ RSI below 5.4 is scale forming but controllable till 4. RSI (Controllable with Chemical Treatment) above
6.4 is corrosive but controllable till 6 (Controllable with Chemical Treatment) Only, It is always better to
operate system in slight scale forming tendency than corrosive because scale can be removed but
corroded metal cannot be put back.
▪ For CW, where water velocity is >0.6 m/s, RSI should only be used.
Refer Nalco Water handbook Page 4.17.
Study on Environmental Impact:
• We will be complying by EC and Consent conditions by operating the CW
system above 5 COC as it says “COC of not less than 5 shall be adopted”,
• The water saving will be: Station Parameters for CW AT CYCLES OF AT CYCLES OF
System- CONCENTARTION 6 CONCENTARTION 7
CT blow down m3/year 3120938 2600781
CT Make Up Water Rate in 18725626 18205470
m3/year
Water Saving in M3/ year - 520156
• The Energy Savings will be:

Energy savings (KwH)Clarified - 95709
water
Energy Saving (KwH) CT - 52016
Pumping
Total energy Saving(KwH) 147724
• Reduction in CO2 emission will be: 125 tons per year
Further Analysis:
Hydraulic factors:
1. Hydraulic factor (CH) of a tower is used to determine the efficiency of water use. It is represented as:
CH = ∑MUR/∑BDR
Where MUR = Total make-up rate and BDR = Total blow-down rate.
1. Both the makeup and blow-down flow rates are comprised of controlled and unintentional components.
The effective blow-down loss rate is the metered blow-down and unmetered streams such as drift, leaks,
filter backwash and removal of CW from the system for other uses. Our CW systems have almost negligible
unintentional water losses to limit the COC; thus COC of 14 is achievable.
2. Drift is the water lost from the tower as a liquid droplets entrained in the exhaust air. This loss is not
dependent on evaporation rate. Drift loss rate is normally expressed in percentage of the recirculation rate
(ranging 0.1% to 0.02%). The drift loss rate depends on the system-specific factors like design of the tower,
age of the tower, types and age of the drift eliminators. Our drift loss is around 0.02%.
3. Unintentional and uncontrolled water losses could be the SS filter backwash, leakages from pump(s) glands
or other equipment(s), cooling tower basin overflows, water tapping from return line for other use/purpose
etc.
Further Analysis:
Time-related factors:
Increase in Holding time index (HTI) is one of the major problem associated with high COC. The HTI is defined as the
half-life of an ion in the system. This is equated as:
HTI Vs Cycles
HTI = 0.693 VT / BT
Where VT is the system volume and BT is total water loss. 300
HTI in hrs
200
100
0
2 4 6 8 10 12 14 16 18 20 22
Cycles
HTI
Above figure illustrates the impact of increased cycling on the HTI of a typical cooling tower system. Increasing the COC
from 5 to 15 effectively triples the HTI, increasing the average time a molecule spends in the system by a factor of three.
This can affect the efficacy of the scale and corrosion inhibitors.
The HTI in our system: at 6 COC is 217 Hours, at 7 COC is 261 Hours and at 8 COC is 305 Hours.
As the HTI increases the stress on the organic portion (polymer, phosphonates, azoles) of the treatment regime
increases. In this case the treatment-program active components must stay active for longer periods of time before
being replaced. With current treatment regime, HTI of 300 Hrs is achievable. For going beyond 300 hrs HTI; advanced
high stress polymers may be used. Visit us at www.just-chemicals.com
Further Analysis:
Weighing of credits and debits:
• Some of the credits will be less water usage, reduced blowdown and decrease in energy consumption.
• At 8 COC or below there is no debit.
• Going beyond 8 COC may call for advanced high stress polymers and advanced phosphonates.
Setting rational goals:
• In the beginning, detailed water balance and inventory of the water consumption in the system was performed.
• This includes makeup to cooling tower, evaporation losses and blowdown.
• By far the biggest problems which may hinder the rising of CoC is unintentional losses or use with tapping from
ACW/CW system.
• After this, a plan is formulated with a review plans for gains, necessary to evaluate the success of this upgrade. After this
is complete (1 yr), increasing COC to 8 was evaluated.
• As the progress should be evaluated on a stepwise basis, the system were to go to 8 cycles from a starting point of 6
cycles, a reasonable goal for the first one year would be operate successfully at 7 COC.
• If corrosion and scale are well controlled, an increase to 8 cycles can follow with evaluation of success again after a
significant period of time.
Further Analysis:
Choosing a compatible treatment program:
This includes a combination of stress tolerant treatment actives and heat transfer monitoring (viz. TTD, LMTD, CT efficiency,
Approach etc.). The treatment programs may be based on a stabilized phosphate or alkaline phosphate approach, the
current treatment regime satisfies this condition.
Above 8 COC: Stress compatible inhibitor technology:
The best approach should be to design on-site the specific inhibitors need through a flexible product addition regime.
Recently developed stress-tolerant inhibitors are part of this approach. New dispersants have been shown to work under a
variety of stress conditions like high Ca (>1500 ppm as CaCO3), higher water temperature, extended HTI (> 350 hrs), etc.
These dispersants allow operation at lower dosages and provide better performance. New corrosion inhibitors have also
been found that are stress-tolerant. Some materials demonstrate high halogen resistance and remain stable under long
HTI (>350 h) conditions.
Diagnostic tools:
At high COC and stressed conditions, treatment programs and cooling water systems is to be used within recommended
guidelines. For this, the cooling water system is properly characterized. This involves evaluating the following key
operating parameters:
• Total blow-down rates (including drift loss);
• Holding time index;
• True COC based on Mg or Na (not Silica/Chloride.TH) ;
• Heat exchanger performance (TTD, LMTD & ‘U’ values). Visit us at www.just-chemicals.com
Further Analysis:
Measurement and control:

In addition to measuring and adjusting system-operating parameters, online monitoring and control of
treatment dosages may be installed to operate at high COC at optimal cost and performance.
Monitoring process:
Once desired COC is achieved, maintenance of high COC is required to realize water and energy
savings. Routine evaluation of the system control equipment and monthly logs are important to monitor
and document water quality and usage over time and through seasonal variations.
Further Analysis:
Measurement and control:

In addition to measuring and adjusting system-operating parameters, online monitoring and control of
treatment dosages may be installed to operate at high COC at optimal cost and performance.
Monitoring process:
Once desired COC is achieved, maintenance of high COC is required to realize water and energy
savings. Routine evaluation of the system control equipment and monthly logs are important to monitor
and document water quality and usage over time and through seasonal variations.
CW Monitoring Tools
• Online Chemistry Analyzers like (This can be developed in an Economical Solution)

• Corrosion coupons - indicate corrosion rate in mils (thousandth of an inch) per year (MPY)
• Corrator inbuilt in Online Analyzer
• Deposit monitor - visual indication of deposit formation and heat transfer loss indication
• Bio-fouling monitor - indicate loss of pressure due to biofilm or slime build-up
• Corrosion meter
• Test heat exchanger
CW Monitoring Tools
• Online Chemistry Analyzers like (This can be developed in an Economical Solution)

• Corrosion coupons - indicate corrosion rate in mils (thousandth of an inch) per year (MPY)
• Corrator inbuilt in Online Analyzer
• Deposit monitor - visual indication of deposit formation and heat transfer loss indication
• Bio-fouling monitor - indicate loss of pressure due to biofilm or slime build-up
• Corrosion meter
• Test heat exchanger
Interlinked Process Flow
Cooling
Tower
Heat Water
Exchanger Chemistry
Interlinked Process Flow
Cooling
Tower
CWT Design
Methedology and
Heat Water guidelines
Exchanger Chemistry
Impoundments and Storm Water
• Operators and owners tend to focus primarily on the quality of water coming into the plant and the wastewater quality
going out of the plant, as required to meet their plant discharge permits.
• In contrast, knowing exactly what is going on within the power plant boundaries in impoundments and process sumps is
not always as clear, especially in older facilities, where upgrades and plant modifications have considerably altered the
plant water picture over the years.
• Also, in many coal-fired power plants, coal combustion waste ponds and impoundments are utilized for equalization and
treatment of numerous plant wastewater streams, complicating the plant’s ability to easily assess the potential for reuse
of each individual stream.
• However, with some of the proposed regulation changes, coal-fired power plants may be required to do just that.
Segregation and separation of plant wastewaters can minimize the volumetric flow rate that requires additional treatment
to meet the proposed regulations.
• For instance, at one facility where we been assisting with water and mass balance activities in preparation for expected
Pollutant Discharge Elimination System permit changes, the engineering team was able to reconfigure portions of the
wastewater collection system.
• It segregated storm waters into contact and noncontact storm waters and separated mixed process water streams,
allowing the plant to reuse a fair portion of its previously discharged wastewater.
• As a result, the facility significantly reduced the potential treatment costs associated with meeting new permit
requirements and realized an overall cost savings. Visit us at www.just-chemicals.com
Get Prepared
• Especially in light of the upcoming regulation changes and the expectation that additional levels of
wastewater treatment will be necessary to meet some of the new discharge limits, any plant likely to be
affected should explore the potential for internal recycling or reuse of plant wastewaters and
minimizing water waste in order to keep wastewater treatment costs as low as possible.
• Starting now, evaluating the current plant water and wastewater conditions, conducting sampling and
flow measurement programs, and assessing current wastewater treatment systems are key to
development of a baseline and plan of attack for dealing with the impending regulation changes.
• Knowing exactly where your plant’s starting point is and developing a solid data history is crucial to
determining what you may need to do to meet changes in regulatory requirements.
Replace conventional Side Stream Filtration
• Use side Stream filter with continuous filtration

• 2 - 5 % of circulating water
• Saves manpower
• Continuous – no infringement
• Saves water – water wastage down to 3% against 10% in
conventional filters
• Down to 5/10/20 microns against 50 microns with
conventional filters
• Polymers used as dispersants
Discussion: Decide, whether you want

engineering control or Chemistry Control?
Given the following benefits, it’s easy to see why self-cleaning filters are the overwhelming choice of
consulting engineers, property management companies and building owners.
• Self-cleaning…requires no regular maintenance
• Self-cleaning…assures optimal filtration efficiency
• Self-cleaning…reduces energy cost.
• No monitoring – No manpower
• Only 3% water wastage
• As filter media accumulates suspended contaminants, the pressure drop across the filter increases and
flow rate decreases. The filter consumes the same power, but does less work.
• Self-cleaning…extends media life, (five to ten years typical).
• Our experience indicates that the necessary disciplined, routine maintenance required for manual
filters is the exception, not the rule. As a consequence, the filter media overloads with contaminants
and thereafter, backwashing is less effective in removing accumulated solids.
• Self-cleaning …is cost effective, No manpower required for backwashing.
• The retrofit fit cost is more than the initial incremental cost for self-cleaning
Reduction of Evaporation loss from Reservoirs
The floating discs were discs of 0.2m diameter and 0.02m thickness that covered 91% of
the water surface. The results have shown that evaporation from the covered reservoir was
reduced by about 80% relative to the uncovered water surface.
Shade balls are plastic Eco-friendly balls that could be used in lakes, ponds stream and dams.
The Department of Water and Power (LADWP) has first used these balls in California, to
prevent the evaporation. A study was conducted in the Nehru pond at Namakkal district. They
used 4 inch black balls from high density polyethylene (HDPE) and carbon black to cover the
reservoir. This study showed that the shade balls reduced 43-45% of evaporation in the
reservoir.
Shade-cloth are suspended structures installed over water surfaces with supporting poles and
steel cables. This cover reduces the action of wind and blocks incoming solar radiation,
therefore, it reduces the evaporation rates from water surfaces. Shade-cloth is economically
used for small reservoirs that are less than 10 hectares in area. The main disadvantage of this
method is the relatively high capital cost for construction but this has now been overridden in
Malaysia owing to a new shade-cloth knitting machine, which will produce wider rolls and,
therefore, reduce the number of installed cables.
A study carried out under summer conditions in Southern Spain shown that shading covers led to decrease the evaporation by about 80% for
the colored-polyethylene covers. Another study was conducted in Australia to estimate the benefits of shade-cloth covers for water
reservoirs. The study has shown that evaporation rate was reduced by about 90% and the shade-cloth reduced maintenance costs because
they delay the growth of aquatic plants at the bottom of the storages. Visit us at www.just-chemicals.com
Floating Solar Plant: “Europe’s largest floating solar plant opens in France”
French
English, Case
of USA
Reach us,
Juschem Solutions Pvt. Ltd
A108, SV Heights, Whitefield, Bangalore – 560066. KA
Email: sbanerjee@just-chemicals.com
Phone/WhatsApp: +91 7985635683
website: www.just-chemicals.com
Follow us at https://www.facebook.com/powerplantchem
https://www.linkedin.com/in/juschem-solutions-private-ltd-63a997165
https://www.youtube.com/channel/UC1Jt3imL-WtfkiRgI01sGZg
YouTube Channel Juschem Solutions Pvt. Ltd.
Part 2:
Steps for Designing Cooling Water Treatment for high COC.
Cooling Water Treatment Designing – Steps
Cooling Water Treatment Designing – Step 1
Reach us
Juschem Solutions Pvt. Ltd
A108, SV Heights, Whitefield, Bangalore – 560066. KA
Email: sbanerjee@just-chemicals.com
Phone/WhatsApp: +91 7985635683
website: www.just-chemicals.com
Follow us at https://www.facebook.com/powerplantchem
https://www.linkedin.com/in/juschem-solutions-private-ltd-63a997165
https://www.youtube.com/channel/UC1Jt3imL-WtfkiRgI01sGZg
YouTube Channel Juschem Solutions Pvt. Ltd.

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How To Achieve The Lowest Specific Water Consumption (SWC) In Hinterland

Audit criteria – what should be and what is?

Audit finding – what is compared with what should be?

Defining process, SWOT and Planning improvement projects

Estimate likely DELTA of Improvements, KIZEN

Design Measure Manage

Feedback to hold gain

What is being Measured?

Summer Yearly Winters

Summer Yearly Winters

Water Balance Water Balance Water Balance

➢While planning to operate at high COC, we need to study various technical

Question: What is Best Element/chemical parameter?

• The Energy Savings will be:

• Reduction in CO2 emission will be: 125 tons per year

Measurement and control:

Measurement and control:

• Online Chemistry Analyzers like (This can be developed in an Economical Solution)

• Online Chemistry Analyzers like (This can be developed in an Economical Solution)

• Use side Stream filter with continuous filtration

• Polymers used as dispersants

Discussion: Decide, whether you want

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