Investment vs Operating cost • The average 800,000 ft² Property has • • $24,000,000.00 replaceable physical plant. The cost of water treatment is $0.02 - $0.04/ ft² to protect this investment. The industrial market costs are higher. A 200,000 square foot plant may have roughly $100,000,000 in replaceable physical plant. Water treatment cost may be in the vicinity of $0.10-$0.20 / ft² The owner loses $6 million per year (at 6% cost of money) for every year of lost life as a result of poor water treatment. Who is in charge of your Investment ??? • The Treatment Supplier tells you what your problems are. • Then they tell you what chemicals to use. • Then they tell you how much they will cost. • Then they tell you when it is working. • You know when its not working when something fails. Why treat the water? Corrosion Scaling Deposition Microbiological Cooling Tower 50 100 200 250 300 400 500 600 700 750 800 1000 1250 1500 2000 2 1.5 3 6 7.5 9 12 15 18 21 22.5 24 30 37.5 45 60 3 0.75 1.5 3 3.75 4.5 6 7.5 9 10.5 11.25 12 15 18.75 22.5 30 Tons [Enter]: Old Cycles [Enter]: New Cycles [Enter]: Savings (Gal./Day): Savings (Gal./Year): Cycles of Concentration 4 5 6 0.5 0.37 0.3 1 0.75 0.6 2 1.5 1.2 2.5 1.87 1.5 3 2.25 1.8 4 3 2.4 5 3.75 3 6 4.5 3.6 7 5.25 4.2 7.5 5.62 4.5 8 6 4.8 10 7.5 6 12.5 9.37 7.5 15 11.25 9 20 15 12 2000 4 8 16,560 6,044,400 Bleed Rt. 20 8.5 7 0.25 0.5 1 1.25 1.5 2 2.5 3 3.5 3.75 4 5 6.25 7.5 10 Gal./Day 28,800 12,240 8 0.21 0.425 0.85 1.06 1.27 1.7 2.12 2.55 2.97 3.19 3.4 4.25 5.31 6.37 8.5 Bleed Rate (Gal./min.) Tower Tonnage Water Savings Based on Tower Tonnage and Cycles of Concentration Gal./Year 10,512,000 4,467,600 Economics • General cooling economics • Effect of scale, deposits, and Bio on efficiency and heat transfer POTENTIAL LOSSES • Biofouled Condenser Tubes – 10% • Scaled Condenser Tubes – 15% • Scaled Boiler Tubes – 8-16% • Equipment Losses - $ millions • Piping Losses - $ millions • Downtime - $ priceless What you are Buying? Service (70% cost of your program) Chemicals (Only 20-30% Cost of program) Intent What you should Expect. • Service Defined • Visits • Testing • Recordkeeping • Inspections • Qualifications • Additional Services CORROSION CONTROL Tower Corrosion Inhibitors • Mild Steel – Phosphates • Phosphonates • Polyphosphates • Ortho-phosphates – Molybdenum – Zinc – Silicates – Others – Blends • Copper – – – – – Tolytriazole BT MBT HRA Others? Closed Loop Corrosion Inhibitors • Mild Steel – – – – – Molybdenum Nitrite Silicates Others Blends • Copper – Tolytriazole Corrosion Control. Corrosion Rates Less than 1.0 mils/yr for steel and less than 0.1 mils/yr. for copper. Less than 0.5 mils/yr. for steel and less than 0.1 mils/yr. for copper. PHOTO MICROSCOPY REPORT 120 DAYS MILD STEEL CHILLER 102 CW 0.62 MILS/Y DATE INSTALLED: 6/15/98 DATE REMOVED: 10/12/98 120 DAYS MILD STEEL CHILLER 102 COND 1.38 MILS/Y DATE INSTALLED: 6/15/98 DATE REMOVED: 10/12/98 120 DAYS MILD STEEL CHILLER 103 CW 0.64 MILS/Y DATE INSTALLED: 6/15/98 DATE REMOVED: 10/12/98 120 DAYS MILD STEEL CHILLER 103 COND 1.53 MILS/Y DATE INSTALLED: 6/15/98 DATE REMOVED: 10/12/98 DEPOSITION CONTROL Deposition Control. • What is deposition. • Control with cycles. • Control with polymeric dispersants. – – – – – Polyacrylates Sulfonated Copolymers. Copolymers Terpolymers Quad Polymers • Filtration Microbiological Control Microbiological Control • Aerobic Bacteria – slime • Anaerobic Bacteria – SRB, IRB • Algae • Legionella Bacteria – 7 different sero groups • Dual Alternating Biocide Program Types of Biocides • Oxidizing – Chlorine • Sodium Hypochlorite – Bromine • Liquid Bromine • Sodium Bromide – Bromine/Chlorine Donors (solids) • Hydantoin, Others • Ozone, chlorine dioxide, chlorine gas • Non-oxidizing – – – – – – Glutaraldehyde Isothiazolone DBNPA Ethylene Chloride Carbamates Quaternary Ammonium Compounds Field Testing Bacteria Performance • Aerobic Bacteria should at or less than 10,000 cells/ml in open condenser water systems • Bacteria should be at or less than 1,000 cells/ml in closed loops. • Anaerobic Bacteria at or below 50 cells/ml SCALE CONTROL Scale Inhibitors and Control • REALLY DEPENDING ON THE HARDNESS + • ALKALINITY TO PROVIDE THE MILD STEEL CORROSION CONTROL. YOU WORK ON DEPOSITON CONTROL. • Phosphonates – HEDP – PBTC • Carboxylic Acid Industry Changes • Companies/People • Tubes • Environmental • Service Industry ENHANCED TUBES What you should know about enhanced tubes and package units? • They need flow to be protected. • They need the correct biocide program. • They need adequate copper protection. • They need proper brushing. • They need to be inspected with proper equipment. • They need to be eddy current tested. Underdeposit Corrosion ENHANCED TUBE BRUSHES Rat Race System Cleaning • New Systems – Proper Cleaning – White Rust – Filters – First Year Chiller Maintenance • Eddy current • Corrosion • Inspections White Rust “GREEN TALKING POINTS” Water Based Systems Water Conservation Energy Conservation Environmental Impact Natural Resource Stewardship Human Impact www.homeyer.com