EPSCO Ltd Energy Sector –
Cooling System Solutions
EPSCO
Chemically Engineered
Solutions, Practically Applied to Solve Emission and
Efficiency-Related Problems in Cooling Systems
Common Problems
• Biological Fouling
– biofilms formed by organics, fungi and bacteria in circulating water
• Sedimentary and Scaling Deposits
– solids naturally present in water form surface deposits
Effects
• Restricted Contact Between Air and Water – reduced heat transfer
– decrease in condenser performance
• Spiralling Build Up from Deposits – significant weight on
pack
– system contaminants
• Exhaust steam not
sufficiently cooled
• Air & water flow restrictions
Impacts of Effects • Increasing water treatment
costs
• Pack collapse
Warmer Water
Temperature
Decreased
Water Flow
Restricted
Air Flow
Reduced Condenser
Performance
Fouled Fill-Pack
Warmer Water
Temperature
Decreased
Water Flow
Restricted
Air Flow
Reduced Condenser
Performance
Fouled Fill-Pack
Potential Costs & Risks
• Maintenance Issues – costly pack repairs and replacements – excessive downtime
• System Inefficiencies – increase in fuel usage – decreased condenser performance
• Environmental Concerns – surplus water usage – increased carbon emissions – increased plume
• Health Concerns – airborne particulates (bacteria and water
treatment chemicals) • impacts on company employees and local residents
Traditional Methods of Cleaning Cooling Towers
• High Pressure Water Jetting
– causes irreparable damage to pack and drift eliminators
– damages the surface of timber structures
– removes wet rot protection
– substantial down-time
- largely ineffective
Traditional Methods of Cleaning Cooling Towers
• Changing the Pack – results in substantial down-time
– incurs the cost of new pack
– disposal cost of old pack
– access and handling Health & Safety concerns
• Biocide Dosing – prolonged, regular treatment required
– does not remove existing deposits or bio-film
– limited ability to stop build-up
Patented EPSCO System
Patented EPSCO System
• Initial No-Obligation Survey –pack assessed by our operatives
–samples taken for laboratory analysis
–specifically tailored to individual towers and cells
– tower/cell mapped due to variation of deposit accumulations
–chemical solution determined by survey and laboratory analysis
Patented EPSCO System
• Downtime Minimised – 12 days for hyperbolic towers, 3-4 hours
for conventional forced draft cells – un-treated towers or cells may remain
active – minimum disruption to production – non-intrusive
• A Fraction of the Cost of Pack Replacement – temperature difference improved by up to
3-4°C – cost of treatment recouped in around 6
months from resulting efficiency gains
Patented EPSCO System
• Tangible results of EPSCO treatment
• Weight reduction in 15m³ section of pack = 1448lbs/658kg
• Pack condition returned to as good as new
Pre v's Post Treatment
0
500
1000
Pack LayersWei
gh
t (p
ou
nd
s)
Pre Treatment
Post Treatment
Pre
Treatment
214 522 548 576 563
Post
Treatment
197 195 191 197 195
1 2 3 4 5
Note: Results from a 5-layer system
EPSCO – Cost Savings
• Significant Efficiency Gains
– temperature reduction minimises plume
• less requirement to introduce make-up water into the system as less water is discharged into the atmosphere
–drastic improvements in condenser efficiency
•generating greater power output from the same fuel usage
Summary
•Level of IPPC Compliance is Increased
•EPSCO Treatment will Save Money
