Fertilizers Manufacturing. Wloclawek, Poland

Mexel products were employed to treat two cooling towers and associated water circuits at a fertilizer factory. The factory produced ammonia, nitric acid and ammonia nitrate with a total water flow of 110,000 gpm. The problems being experienced included corrosion induced leaks and excessive quantities of scaling and mud. Mexel proved successful in stopping the pitting, reducing biofouling, stabilizing pH and diminishing the sedimentation and metals’ discharge in two separate units with varying constituent metals.

Pernis Refinery

A large-scale refinery in Pernis, near Rotterdam in the Netherlands was experiencing problems with fouling resulting in diminished performance in the air compression equipment. Mexel was brought in for a full-scale trail on a variable brackish mix of water drawn from the Rhine River and North Sea which also contained dissolved and suspended solids at this major seaport. Two heat exchangers, an intermediate gas cooler and a final gas cooler were treated for mussels, biofouling, and corrosion. 

The tested unit was found to be free of fouling and no increase in water flow was needed to maintain the required discharge temperatures. The unit was clear of corrosion and other deposits and returned to service without any needed cleaning. Other units at the site are now treated with Mexel.

Orange Juice Factory

An Florida orange juice concentration plant was experiencing dramatic biofouling accumulation in the cooling tower serving a taste evaporator. Carry-over of nutrients from the evaporator entered the water-cooling system causing biofouling buildup. Previous treatment with chlorine and bromine was not successful. Chlorine dioxide was slightly effective but too costly. Mexel was brought in for testing for its potential to address the fouling in an innovative and economical manner.

Within hours of the initial treatment, substantial clumps of biomass became dislodged from the towers fill and were found floating in the basin. After three weeks of Mexel treatment, an estimated 75% the cooling tower’s biofouling had been dispersed and the biofouling growth rate was equal to the rate of clearing. It was further noted that the remaining deposits were loosened to such a degree that manual cleaning was successful.

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