Dow Inc. · NYSE:DOW
Dow — Technical Presentation (June 2015)
37 slides from Dow's technical presentation, June 2015
Slide 1: Successful Cooling Water Systems Management
Successful Cooling Water Systems Management Tim Finley DOW RESTICTED
Slide 2: Successful Cooling Water Systems Management
Successful Cooling Water Systems Management Perspective from providing technical support to more than 275 Dow and Dow JV Partner Cooling Water Systems Cooling Tower System Inventory
Slide 3: Outline
Outline • What is a cooling water system? • What does my cooling water system do for me? • What is important? And why? • What can go wrong? • Thoughts on how to best manage/control these system? • Review of common pitfalls • Water conservation consideration
Slide 4: What is a cooling water system?
What is a cooling water system? Four Primary Components • Tower or Pond • Pumping System • Piping Network • Exchangers Schematic Compliments of Nalco
Slide 5: What does my cooling water system do for me?
What does my cooling water system do for me? • It rejects heat from process to the atmosphere!! What is important? • In addition to the primary function, the system must also: – Consistently cool water relative to wet bulb – Consistently distribute water to exchangers – Prevent debris and sediment f
Slide 6: The cooling water triangle
A closer look at water “the cooling water triangle” pH, Alkalinity, Mineral Content, Acid Feed, Corrosion Inhibitor(s), Scale Inhibitor(s) Scale Corrosion Biological
Slide 7: The cooling water triangle
A closer look at water “the cooling water triangle” But this is wrong, it is not a triangle!! pH, Alkalinity, Mineral Content, Acid Feed, Corrosion Inhibitor(s), Scale Inhibitor(s) Scale Corrosion Biological
Slide 8: It is "at least" a cooling water square
It is “at least” a cooling water square Heat Transfer Equipment Design pH, Alkalinity, Mineral Content, Scale Acid Feed, Corrosion Inhibitor(s), Scale Inhibitor(s) Corrosion Biological
Slide 9: A closer look at required systems with water chemistry control
A closer look at required systems - with water chemistry control in mind Water Treat Exchanger Monitoring Basic System DP Tower or Pond TT Pumping System Make Up TT Piping Network TT TT Blow Down Exchangers Flow Screens Water Management • Source Water Quality/Treatment • Make Up and Blow Down • Chem
Slide 10: What is important? Why?
What is important? Why? • Rule 1: Cooling water is a utility that should never limit production What is needed to prevent production losses? Why? Consistently cool water relative to wet bulb (Tower) Protect production capacity Consistently distribute water (Pumps, pipes, valves …) Prevents exchanger
Slide 11: Understanding potential expectation gap
Understanding potential expectation gap Typical Performance Objectives/Desires - Plant • Don’t allow exchangers to fail • Don’t allow exchanger fouling to limit production The real desires and • Control MB to prevent exchanger corrosion, tower fill fouling and expectations other undesirable situatio
Slide 12: What can go wrong? A partial list
What can go wrong? A partial list… • Multiple Sources Water • Deficient System Passivation • Poor Quality /Variable Source Water • Bi-metalic Exchangers • Exchanger Debris Fouling • Low Flow Exchangers • Acid Over/ Under Feed • Throttled Exchangers • Biocide Under/ Over Feed • Excess Heat Flux • Def
Slide 13: Cooling Water System Failures
Cooling Water System Failures Fe Corrosion Tower Structural Failure Cu/CS Bi-metalic Byproducts Tuberculation Pitting Example Fill Fouling CaCO3 Scale Phosphate Scale Chip Scale Debris Fouling Shell Side Scale/Fouling 16 Select Pictures Compliments of Nalco
Slide 14: Who gets involved?
Who gets involved? …Dow Design and Support Participation Map 17
Slide 15: Managing for success
Managing for success • Maintain Knowledgeable Staff and Support Resources • Establish Clear Design Expectations …Design it right !!! • Start-up, Commissioning & Passivation …Treat it right from the start • Treatment Vendor Selection/Management …Use Reputable/Experienced Vendor • Chemical Program Sel
Slide 16: Basis knowledge – understand M&EB
Basis knowledge – understand M&EB Schematic Compliments of Nalco
Slide 17: Managing/controlling water chemistry
Managing/controlling water chemistry Parameter Why Monitored Controlled by pH pH has strongimpacts on corrosion, fouling and scale Acid or caustic addition Dispersant Levels set to prevent scale formation Wet chemical tests or polymer controller Corrosion Levels set to minimize corrosion. Wet chemic
Slide 18: Water chemistry control on line
Water chemistry control on line Mild P Steel E Make-up G Yellow 000 Metal 90 Day Continuous Water Flow Cond Coupon Rack VOC F TT Blow Down Cond Flow Bypass RETURN Side Stream Filter 5% recirculation Emerg. Cell #1 Cell #2 Cell #3 Backwash flow Blowdown D C SUPPLY P LT A B LT 000 000 P P P P FIRE PRO
Slide 19: Managing cooling tower performance
Managing cooling tower performance • Control water flow to get even water distribution • Observe falling water pattern to evaluate air flow uniformity • Look for structural defects, sags or other signs of developing structural issues • Conduct structure inspections – understand what components can n
Slide 20: Managing heat exchanger performance
Managing heat exchanger performance • Manage water to quality speciation 24/7 - 365 days per year • Understand risks and performance history for exchangers • Understanding exchanger risks (example criteria) H M L B • Velocity … Keep to > 3 FPS 2-3 3-5 5-7 7-10 • Heat Flux … Limit to <10000 BTU/Ft /h
Slide 21: Tracking critical exchanger performance and controlling fouling
Tracking critical exchanger performance monitor and control fouling •Define Exchangers as Critical Due To: Production Impact, Low Flow, High Temperature •Track Common Exchanger Design Factor: U factor, Fouling Factor •Track and Trend Water Side Fouling: “C” Factor (orifice equation) •“C” Factor Calc
Slide 22: Common pitfalls to avoid
Common pitfalls to avoid • Debris Plugging of Exchanger Tube Sheet • Throttling Exchanger • Stagnant Water Induced Corrosion Issues • Poor or Highly Variable Source Water • Acid Overfeed Due to Deficient Design • Poor Chemistry Control/Underfeeding Chemicals • Ineffective Microbiological Control • S
Slide 23: Water conservation consideration
Water conservation consideration • Increasing cycles is often the easiest approach to water conservation • Utilizing stronger dispersants, acid feed or softening to reach higher cycles • Take care not to over cycle • Understand the limiting returns, not much benefit to > 6 cycles • Water savings ben
Slide 24: Dow Freeport saves 1 B gal/yr by optimizing cooling tower cycles
Dow Freeport saves 1 B gal/yr by optimizing cooling tower cycles • Dow Applies for 2008 EPA Water Leader Minimization Award • “Savings achieved through chemistry changes and Nalco 3DT Advanced Water Control” • Exchanger cleaning costs were reduced by more than $4 million/yr • Nalco and Dow receive a
Slide 25: Dow Chemical utilizes treated municipal effluent for cooling in Tarragona Spain
Dow Chemical utilizes treated municipal effluent for cooling in Tarragona Spain
Slide 26: Reduction of fresh water intake enabled by municipal wastewater reuse
Reduction of fresh water intake for industrial use enabled by municipal wastewater reuse Camp de Tarragona plant (ACA) is a prime example how wastewater can be used to increase the industry sustainability and support industrial growth in water scarce regions. Fast Facts RO Technology Used Location:
Slide 27: Questions & Discussion
Questions & Discussion DOW RESTICTED
Slide 28: Upcoming Webinars
Upcoming Webinars DOW RESTICTED
Slide 29: Thank You
Thank You
Slide 30: Cooling water value background
Cooling water value background • Water treatment is provided to protect asset capability and to extend the life of the asset • To maximize equipment life and asset capability water quality needs to be control 24/7 365 days per year • Price of treatment and service is important but secondary to the p
Slide 31: Cooling water management value map
Cooling water management value map Capital Cost Routine Operating Cost Failure Cost 100 x 1) Capital Cost of Tower 1) Inhibitor/Dispersant Costs Lost Production AC (Limited Capacity) 2) Capital Cost of Exchanger 2) Vendor Service Monitoring Labor Cost 5-20+ x Lost of AU (Days of Lost Production) 3)
Slide 32: Cost dynamic of water management
Cost dynamic of water management The impact of Water Management on Asset Capability and the life of the asset? The life of a water management asset is result of both the acute and chronic management issue experienced in the system. Some events like an extreme low pH and the redistribution of copper
Slide 33: The Value of Leveraging MET Controls for Process Cooling Asset
The Value of Leveraging MET Controls for Process Cooling Asset? We know that major production and asset investment losses have resulted from poor water quality management. On a group of 10 process units we would anticipate a major loss > $2 MM, every 2-3 years and certainly smaller losses and avoida
Slide 34: Freeport MET Improvement Impact (macro metric)
Freeport MET Improvement Impact (macro metric) Freeport Exchangers Cleaned / Quarter 180 160 >$ 2 MM/Yr Value Estimated Impact 140 120 100 80 60 40 20 0 2005 2006 2007
Slide 35: Midland MET application example 4D exchanger improvements
Midland MET application example 2 4D exchanger improvements $0.25 MM/Yr Value Impact
Slide 36: Key challenges to address in cooling water treatment
Key challenges to address in cooling water treatment Problem to Impact DW&PS Solution & DMC Solution & Mechanism DO&G Solution & Prevent Mechanism Mechanism Corrosion •Reduced heat exchange Biocides provide good biofouling control at much Secondary benefit from select “P” efficiency ($) lower corros
Slide 37: Thank You
Thank You