Ming-Kai Hsieh

Escalating water demand for energy production and the potential for use of treated municipal wastewater.

To ensure sufficient thermoelectric power production in the future, the use of alternative water sources to replace freshwater consumption in power plants will be required. The amount of municipal wastewater (MWW) being produced and its widespread availability merit the investigation of this potential source of cooling water. This is particularly important for thermoelectric power plants in regions where freshwater is not readily available. Critical regulatory and technical challenges for using MWW as makeup water in recirculating cooling systems are examined. The existing regulations do not prohibit wastewater reuse for power plant cooling. The challenges of controlling corrosion, mineral scaling, and biofouling in recirculating cooling systems need to be carefully considered and balanced in a holistic fashion. Initial investigations suggest that many of these challenges can be surmounted to ensure the use of MWW in recirculating cooling systems.

Control of mineral scale deposition in cooling systems using secondary-treated municipal wastewater

Secondary-treated municipal wastewater (MWW) is a promising alternative to freshwater as power plant cooling system makeup water, especially in arid regions. A prominent challenge for the successful use of MWW for cooling is potentially severe mineral deposition (scaling) on pipe surfaces. In this study, theoretical, laboratory, and field work was conducted to evaluate the mineral deposition potential of MWW and its deposition control strategies under conditions relevant to power plant cooling systems. Polymaleic acid (PMA) was found to effectively reduce scale formation when the makeup water was concentrated four times in a recirculating cooling system. It was the most effective deposition inhibitor of those studied when applied at 10 mg/L dosing level in a synthetic MWW. However, the deposition inhibition by PMA was compromised by free chlorine added for biogrowth control. Ammonia present in the wastewater suppressed the reaction of the free chlorine with PMA through the formation of chloramines. Monochloramine, an alternative to free chlorine, was found to be less reactive with PMA than free chlorine. In pilot tests, scaling control was more challenging due to the occurrence of biofouling even with effective control of suspended bacteria. Phosphorous-based corrosion inhibitors are not appropriate due to their significant loss through precipitation reactions with calcium. Chemical equilibrium modeling helped with interpretation of mineral precipitation behavior but must be used with caution for recirculating cooling systems, especially with use of MWW, where kinetic limitations and complex water chemistries often prevail.

Corrosion control when using secondary treated municipal wastewater as alternative makeup water for cooling tower systems.

Secondary treated municipal wastewater is a promising alternative to fresh water as power plant cooling water system makeup water, especially in arid regions. Laboratory and field testing was conducted in this study to evaluate the corrosiveness of secondary treated municipal wastewater for various metals and metal alloys in cooling systems. Different corrosion control strategies were evaluated based on varied chemical treatment. Orthophosphate, which is abundant in secondary treated municipal wastewater, contributed to more than 80% precipitative removal of phosphorous-based corrosion inhibitors. Tolyltriazole worked effectively to reduce corrosion of copper (greater than 95% inhibition effectiveness). The corrosion rate of mild steel in the presence of free chlorine 1 mg/L (as Cl2) was approximately 50% higher than in the presence of monochloramine 1 mg/L (as Cl2), indicating that monochloramine is a less corrosive biocide than free chlorine. The scaling layers observed on the metal alloys contributed to corrosion inhibition, which could be seen by comparing the mild steel 21-day average corrosion rate with the last 5-day average corrosion rate, the latter being approximately 50% lower than the former.

Control of biological growth in recirculating cooling systems using treated secondary effluent as makeup water with monochloramine.

Secondary-treated municipal wastewater, an abundant and widely distributed impaired water source, is a promising alternative water source for thermoelectric power plant cooling. However, excessive biological growth is a major challenge associated with wastewater reuse in cooling systems as it can interfere with normal system operation as well as enhance corrosion and scaling problems. Furthermore, possible emission of biological aerosols (e.g., Legionella pneumophila) with the cooling tower drift can lead to public health concerns within the zone of aerosol deposition. In this study, the effectiveness of pre-formed and in-situ-formed monochloramine was evaluated for its ability to control biological growth in recirculating cooling systems using secondary-treated municipal wastewater as the only makeup water source. Bench-scale studies were compared with pilot-scale studies for their ability to predict system behavior under realistic process conditions. Effectiveness of the continuous addition of pre-formed monochloramine and monochloramine formed in-situ through the reaction of free chlorine with ammonia in the incoming water was evaluated in terms of biocide residual and its ability to control both planktonic and sessile microbial populations. Results revealed that monochloramine can effectively control biofouling in cooling systems employing secondary-treated municipal wastewater and has advantages relative to use of free chlorine, but that bench-scale studies seriously underestimate biocide dose and residual requirements for proper control of biological growth in full-scale systems. Pre-formed monochloramine offered longer residence time and more reliable performance than in-situ-formed monochloramine due to highly variable ammonia concentration in the recirculating water caused by ammonia stripping in the cooling tower. Pilot-scale tests revealed that much lower dosing rate was required to maintain similar total chlorine residual when pre-formed monochloramine was used as compared to in-situ-formed monochloramine. Adjustment of biocide dose to maintain monochloramine residual above 3mg/L is needed to achieve successful biological growth control in recirculating cooling systems using secondary-treated municipal effluent as the only source of makeup water.