Case Study
İGSAŞ Increases Ammonia Production by 7% with Seawater ElectroChlorination
How on-site electrochlorination helped İGSAŞ prevent biological fouling, stabilize seawater cooling and increase ammonia production by approximately 7%?
Problem
Biofouling reduced efficiency and limited production.
Biological Fouling in the Seawater Line
Heavy accumulation of mussels and other biological growth in the intake line and on the plate heat exchanger surfaces was restricting the flow passages.
Falling Heat Transfer Efficiency
The fouling layer acted as an insulating barrier on the exchanger surface, driving up the temperature of the closed-loop cooling water.
Insufficient Inter-stage Compressor Cooling
Rising cooling water temperature pushed up the main compressors’ discharge temperature and compression work, raising specific energy consumption.
Capped Production Capacity
As process gas temperatures approached their limits, ammonia output had to be throttled back to preserve a safety margin.
Solution
Continuous Chlorination by Clorel®
Onsite Seawater ElectroChlorination
The most critical factor for achieving 100% biofouling control is continuous chlorine dosing which not only eliminates existing biofouling but also prevents the re-formation. And, the most efficient way to ensure uninterrupted dosing is through on-site chlorine generation.
To enable continuous dosing, İGSAŞ stopped purchasing chlorine externally and began producing its own chlorine on-site with Clorel, using only seawater and electricity.
Project Information
Sector
Ammonia Production
Application
Cooling Seawater Chlorination
Product & Model
Clorel LC 33000 UNO
End Product
NaOCl
Project FAC Capacity
33 kg/h
Project Year
2024
Results
Better Cooling. Lower Energy.
Higher Production.
Ammonia Production Increase
7%
New Jun–Sep Average
1070 t/day
Visible Exchanger Fouling
0%
Daily Average Ammonia Output — June / July / August / September
Prevented the formation of mussels and similar biological fouling
Seawater flow became stable
The heat exchangers began operating at their nominal heat-transfer capacity
Closed-loop cooling water temperatures could be kept under control
Intercooling efficiency increased
Compressor power consumption decreased
We would like to emphasize that the solution provided by Kemisan has played a critical role in the operational continuity and process safety of our facility. We thank Kemisan and everyone involved for this successful implementation and look forward to continuing our collaboration with the same success in the future.
A Ammonia and Auxiliary Units Chief Engineer
Other Benefits
Some Results Cannot Be Measured in Numbers,
But They Can Be Felt Everyday
Less Operator Intervention
PLC-controlled production and consumption reduce the need for manual intervention and simplify daily operations.
Eliminates Chlorine Gas Purchasing
On-site production eliminates the need to purchase, store and handle externally supplied chlorine gas. Eliminating chlorine transportation reduces the serious risks for not only factory but also all roads.
Lower Environmental Impact
Producing hypochlorite on-site from seawater eliminates the need for chemical transportation, reducing the logistics and emissions associated with chemical transportation
Protecting Energy Efficiency
Preventing fouling protects flow and heat-transfer performance, helping protect energy efficiency—for both the business and the environment.
No Cleaning-Related Shutdowns
With heat-transfer surfaces kept clean, production does not need to be interrupted for physical cleaning of the seawater lines and heat exchangers.
No Physical Cleaning Workload
Continuous biofouling control prevents mussel and biological growth, eliminating the need for routine physical cleaning of the seawater system.
Facing a similar cooling water
problem at your plant?
Let’s talk about how our Clorel range prevents biofouling at the source for facilities that cool with seawater.
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