Gulf Coast Chemical Company

Gulf Coast Chemical Company
Case History
# 0-47
FlexPro® CL Provides Solutions For High Temperature Heat
Exchanger Fouling
Background
A cooling tower at a large Gulf Coast chemical plant was
operating at 9 cycles on clarified Sabine River water, which is
relatively corrosive water. Under the previous phosphate-based
treatment program, corrosion control had been adequate but
they had been experiencing calcium phosphate deposition
issues. The plant suffered from fouling problems in the tower
fill and in several high-temperature heat exchangers. Deposition in the shell side heat exchangers led to
a decrease in heat transfer efficiency, thus greatly increasing approach temperatures. Furthermore, the
ceramic material that comprises the heat exchangers was prone to thermal cracking when deposition
occurred. Offline cleaning was needed to correct this, thus plant downtime was significant. Despite
cleaning, several heat exchangers did fail, and maintenance costs grew. Each exchanger replacement
cost the plant $100K plus downtime.
Solution
Results
Although the corrosion rates had been
Corrosion coupons have shown excellent results,
acceptable, the plant wanted to use a more
with mild steel coupons remaining around
forgiving, non-fouling program.
ChemTreat’s
1 mpy or less. Calcium phosphate deposition
solution was FlexPro® CL, a phosphate and
has been eliminated, and heat exchanger
zinc-free product designed for corrosive-
approach temperatures have remained flat.
to-moderate waters.
FlexPro® CL is a
For two years, the plant has gone without a heat
breakthrough innovation in cooling water
exchanger failure. Because of the phosphate-
treatment that offers superior deposition
free technology, FlexPro® CL also enabled
and corrosion control. By eliminating added
water treaters to reduce the amount of biocide
phosphate, deposition risks are greatly reduced.
needed for the tower by 70 percent. The plant
Phosphate also contributes to environmental
is thrilled, and has since switched three other
hazards, such as algae blooms, and promotes
towers to FlexPro® CL technology.
microbiological growth within the tower.
FlexPro® CL offers an exceptional alternative to
phosphate-based treatment, while maintaining
superb corrosion and deposition control.
© 2 0 1 5 C h e m Tr e a t , I n c .
/
5640 Cox Road
/
Glen Allen, Virginia 23060
/
www.chemtreat.com
Case History
# 0-47
Initial 99-day steel coupon
0.32 mpy
Initial 35-day steel coupon
1.07 mpy
Heat Exchanger Approach Temperatures
80.00
Approach Temperatures, (F°)
70.00
60.00
50.00
40.00
HX #1
HX #2
30.00
HX #3
20.00
10.00
0.00
-10.00
1
11
23
31
27
18
14
11
20
22
17
14
26
51
Days
Summary
Previously the plant had to replace at least one exchanger bundle per year at a cost of approximately
$100K plus downtime. Since switching to ChemTreat’s FlexPro® CL over two years ago, they
have gone without any failures. The program has also enabled the reduction of biocide usage by
70 percent. The plant has been so pleased with the results of FlexPro® CL that they have expanded
the use of the program to other cooling towers at this facility.
Have more questions? Contact us by visiting
http://go.chemtreat.com/speak-to-a-support-staff
© 2 0 1 5 C h e m Tr e a t , I n c .
/
5640 Cox Road
/
Glen Allen, Virginia 23060
/
www.chemtreat.com