Solving Cooling Water Acidity Issues: Preventing Corrosion in Manufacturing Plants

Background

A reliable cooling water system is essential to maintain the performance and longevity of manufacturing equipment. Precise control of cooling water parameters is critical for uninterrupted and efficient production.

Cooling water system showing grounding method to prevent pipe corrosion

The Challenge

Rising Water Acidity and Corrosion The manufacturing plant faced persistent water acidity issues impacting the effectiveness of the cooling water system. Frequent water replacements became necessary, each requiring costly and disruptive plant shutdowns, significantly affecting productivity and operational budgets.

Initial Approach

Previously, acidity levels were managed by adding basic chemical compounds. However, this approach inadvertently increased water conductivity, eventually necessitating water replacement anyway, perpetuating a costly cycle without resolving the underlying problem.

Root Cause Analysis

Corrosion in Cooling Water Pipes Employing PRIZ’s structured problem-solving methodology, the team pinpointed corrosion as the primary cause for the increasing cooling water acidity. Corrosion was triggered by electrochemical reactions between different alloy pipes within the system, driven by potential differences between metal alloys.

Solution Implemented

Grounding to Stop Pipe Corrosion To directly address the identified root cause, grounding the metal pipes was implemented. This eliminated the potential differences causing electrochemical reactions, thereby completely halting corrosion.

Impact and Results

The grounding solution successfully stopped corrosion, significantly reducing the rate of water acidity increase. This resulted in fewer cooling water replacements, minimized costly plant shutdowns, and substantial operational efficiencies, achieving an impressive annual ROI of approximately $10 million.

By addressing corrosion—the true source of water acidity issues—the plant transitioned from temporary symptom management to a robust, long-term, sustainable solution.

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