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