Maximize Your Cost Savings With a Properly Sized Sodium Cycle Condensate Polisher

Res-Kem’s Process Engineer Kevin Preising discusses their Boiler Feedwater Checklist and the 15 questions that will help properly size a Sodium Cycle Condensate Polisher (and generate the most payback) for your steam plant.  Please print out the checklist and follow along!

Dealkalizer Shipped to University in Massachusetts

A triple dealkalizer was shipped this week is the last major piece of equipment for a major steam boiler upgrade at a university in Cambridge, Massachusetts which included a new condensate polisher system Res-Kem provided, a deaerator and other major physical plant upgrades.  The months between the polisher shipment and the dealkalizer shipment were filled with activity in the steam plant.


Triple Dealkalizer System Being Prepared for Shipment

The shipment of the dealkalizer had to wait several months because the condensate polisher had to be moved into place, installed and started up.  Once this was completed, the deaerator was delivered and required installation and start up.  After that, the entire revamped boiler treatment system had to be tested, operating correctly and then operators needed to be trained.  Once everything was proven out to the satisfaction of the university, the old condensate polisher could be scrapped and the piping prepared for our dealkalizer which will be placed in the same location where the CP was.   

What a dealkalizer does:	A dealkalizer removes Alkalinity which breaks down in the boiler and generates CO2 and carbonic acid (H2CO3) in the condensate.  The removing of CO2 and Carbonic acid reduces corrosion rates within the condensate piping
Inlet alkalinity:	Average inlet M-Alkalinity- 40 ppm- 50 ppm
Savings the customer wants to achieve:	• Reduced Corrosion of steam condensate return piping • Lower return condensate iron levels in boiler feedwater and cleaner boiler tube surfaces • Lower Operating expenses on fuel with cleaner boiler tubes • Eliminating alkalinity via the dealkalizer allows for higher boiler cycles of concentration and lower fuel costs
Flow Operating Conditions:	Typical: 140 gpm typical Peak: 200 gpm Minimum: 40 gpm
System Configuration:	• Triple 42 " diameter X 72" ASME Code fiberglass tanks • Each tank has a front mounted/supported Pentair Fleck 3900 valve with NXT controller • All Interconnecting pipe is Schedule 80 PVC piping • Each tank is individually skid mounted
Control Valves:	Multi-Port Fleck 3900 valves side mounted and supported via welded steel frame
System Operation:	Progressive Flow and Demand Flow operations
Added Features:	Contacts on the Fleck valve indicate to the DCS that the unit is in operation, standby, or regeneration

Additional Information:
Technical bulletin for Res-Kem's dealkalizer equipment

Improving Efficiency of Water Softeners at a Hospital

A customer found they could reduce the salt and water costs of regeneration by 63% by having our service person diagnose the problems they were having and make changes to the system.

Situation:A hospital customer has a 20 cubic foot water softener used for domestic water.  The system was designed for run length of of 20,000 gallons between regenerations, but recent records indicate the run length has reduced to 10,000 gallons.  The hospital demand is approximately 10,000 gallons per day.  The following is the cost information:

• Water and Sewer Cost - $4.00/1000 gallons
• Salt Cost - $0.05/lb

Findings:
After inspection of the unit and analysis of resin samples, several problems were found:

• The softener had 7 cu ft missing in the softener
• The resin was fouled with iron
• The regeneration cycle needed to be adjusted

Changes:
The following changes were made:

• 7 cubic feet of cation softening resin was added to the softener
• The resin was cleaned to remove iron and a preventative maintenance program will maintain clean resin in the future
• The regeneration cycle was changed to the design conditions

Results:

The following are the benefits the customer realized by making the recommended changes:

• The number of regenerations dropped from 365 to 182 per year
• The salt use per regeneration dropped from 180 lbs to 120 lbs.
• The water use pre-regeneration decreased from 2590 gallons to 2090 gallons

Calculations:

Cost	Calculations	$/year
Salt Before	(180lb/regeneration)($0.05/lb)(365 regenerations per year)	$3,285/year
Salt After	(120lb/regeneration)($0.05/lb)(182 regenerations per year)	$1,092/year
Salt Savings		$2,193/year
Water Before	(2590 gallons/regeneration)($4.00/1000 gallons)(365 regenerations per year)	$3,781/year
Water After	(2090 gallons/regeneration)($4.00/1000 gallons)(182 regenerations per year)	$1,522/year
Water Savings		$2,259/year
Total Savings		$4,452/year

Water Reuse From Wastewater Using RO

Often we are asked to help with water re-use project.  From their research, prospective customers are often interested in using an RO system.  They want to take advantage of the key features which make RO a great technology for treating water entering their plant for process applications:

• The RO membrane is barrier between the treated and untreated water
• Reverse osmosis reduces the TDS (Total Dissolved Solids)
• RO systems and membranes are a robust, proven technology

These advantages have been quantified and defined when an RO system is desalinating water and treating municipal/well water.  More information is required before any RO is placed on a process waste stream.  Often a pilot is required.  Our parent company, Ecolab, has extensive experience with water treatment and reuse applications, but more information than a standard water test is needed to determine whether RO has a chance of working.

When looking at a water re-use project from wastewater, regardless of where the water re-use potential location is, it is essential that the water quality is considered both from a physical /chemical perspective but also from a biological perspective. What that means is analysis for parameters such as BOD / COD,( Biological Oxygen Demand / Chemical Oxygen Demand), turbidity , FOG ( Fats, Oils & Grease), NH3 /TKN ,( ammonia /total Kjeldahl nitrogen), NO3 and Total P as well as TSS ( Total Suspended Solids ) and conductivity or TDS( Total Dissolved Solids) should be added to the more typical water analysis list.  If your facility is a food and beverage plant, a microbiological assay should be done.

NOTE- most of these tests require special sampling methods and handling.  The WHO (World Health Organization) has an excellent paper on the subject "Water Quality Monitoring - A Practical Guide to the Design and Implementation of Freshwater Quality Studies and Monitoring Programmes".  Look at pages 17-18.

Additional Information:
Definition of Waste water quality parameters
The Kjeldahl test method used to determine the nitrogen concentration in a waste stream
Standard Methods For the Examination Of Water and Wastewater

Chloramine Removal With Catalytic Carbon

Is your carbon under attack? Have you chosen the correct carbon for chloramine removal? What carbon makes the most effective final barrier against chloramines?

Why use chloramination?Let's face it everyone, they're not making any more fresh water on this planet. Our fresh water is under continuous attack from man made substances and biological bad guys. To combat these contaminates, our municipalities are continually challenged to find the "right" treatment. For instance, good old chlorine was effective to combat bacteria and most disease. However, as our water systems with miles of pipe kept growing, chlorine's "staying power" was found to be less effective at the end of the line. And worse yet, chlorine would complex with organic matter (pipe sludge) or natural algae, to create disinfection by-products (THM's). Enter Chloramine. Some science guru dreamt up the idea that chlorine was more effective if they mixed in some Ammonia. Yes, ammonia. Chlorine+Ammonia = Chloramine

As you might imagine, chloramine wasn't the magic bullet bio fighting miracle. Needless to say, Chloramine, is better off in the street pipes than in you or in your ingredients. Ok? Now what? Since the invention of chlorine, man used activated carbon as the final barrier to remove it. Most activated carbon is manufactured from coal or coconut shells. Chloramine removal turned out to be a much trickier challenge. Here's why: Most drinking water is at pH 7 or above. At pH 7 chloramine forms into a monochloramine. Monochloramines are highly stable by nature making them very difficult to remove with traditional activated carbons. Calgon discovered if you manufacture carbon with catalytic functionality, it will remove the chloramine. Here's how: traditional carbon would do an excellent job of removing the chlorine portion, but leave a significant amount of ammonia. Catalytic enhancements to traditional carbon allowed the carbon to retain more oxygen. The oxygen acted as the needed catalyst to breakdown the ammonia. Simple 'eh?

Coconut vs Coal based carbon
YES you have a choice. This is America. It comes down to this: Our real world results have confirmed the coconut shell based catalytic carbons the clear winner.


Coconut vs Coal Chloramine Removal Comparison
from Jacobi CX-MCA Technical Paper

 I speculate that coconut shell carbons have a micro-pure structure that allows them to retain more oxygen, thus be more catalytic. Also, scientific proof tells us that the coconut shell carbon is physically harder than coal carbons. When dechlorinating, carbon gives up a structural molecule. Coconut shell's strength gives it an advantage in the long run.

For Additional Information:
If you are really into the technical wizardry, read what the really smart folks wrote:
Technical Bulletin for Jacobi Aquasorb CX-MCA Catalytic Coconut Carbon
Technical Paper "Treatment for Monochloramine Using Activated Carbon" by Jacobi Carbon

DI System Shipping to Washington Chemical Plant

Shipping today is a two bed (cation ion exchange tank followed by an anion ion exchange tank) demineralizer for a chemical plant in Washington State. This unit is a DI60072 and will be used in parallel with several other older systems currently installed at the same plant to increase treated water capacity.

150 gpm Demineralizer Showing NEMA 4X Control Panel with Panel View 300 HMI

The system will use the existing bulk acid and caustic for regeneration of the cation resin and anion resin respectively.

150 gpm Demineralizer Compact Design of Piping

System Design:

Normal Service Flow Rate:	150 gpm
Maximum Service Flow Rate:	230 gpm
Vessel Size:	60" x 72" Diameter x Straight side
Volume of Cation (SAC) Resin	66 cu ft
Volume of Anion (Type 1) Resin	77 cuft
Cation Vessel Internals:	Header Lateral Design PVC Schedule 80
Anion Vessel Internals:	Header Lateral Design 316L SS Schedule 10
Automatic Valves:	Butterfly valves 316L SS disc with Air to Open Spring to Close Actuators
Controls:	Allen Bradley Micrologix PLC Panelview 300 HMI NEMA 4X FRP panel
Instrumentation:	Signet Flow meter Totalizer Thornton Conductivity Meter

Additional Information:
For our complete demineralizer/deionizer product line.
For help sizing a DI system, please contact us.

Downloadable Catalog of Water Treatment Equipment Updated

For 2012, we updated our downloadable industrial water treatment catalog.  (Given the number of equipment choices we provide, the catalog file is very large, so please be patient during the download.)



Res-Kem's Industrial Water Treatment Equipment Catalog for 2012

 In addition to the updated XL, CL and ML Series RO system bulletins list in my previous post, we have updated the two bed demineralizer sections of our catalog to include all of the standard sized DI systems up to 96" in diameter.

To many water treatment system choices?  Contact us for help!

Industrial RO System Information Updated

Bulletins on the RO systems Res-Kem provides have been updated. These bulletins include the most up to date standard and custom features of the XL, CL, and ML series RO systems.

Reverse Osmosis Systems
Type	Single System Capacity*	Controller	File
Res-Kem XL RO Systems	9,650-698,400 GPD (6.7-485 GPM)	Allen Bradley PLC with Panelview Touchscreen HMI	Res-Kem XL RO Brochure
Res-Kem CL RO Systems	3,150-22,300 GPD (2.1-15.5 GPM)	Allen Bradley PLC with Panelview Touchscreen HMI	Res-Kem CL RO Brochure
Res-Kem ML RO Systems	1,050-8,380 GPD (0.7-5.8 GPM)	Digital Microprocessor	Res-Kem ML RO Brochure
* If you have required flow rates above those listed in each category, multiple units can be used.

Res-Kem XL Series RO Systems

Contact us for Help:

• Sizing a new RO System
• Maintaining an existing RO System
• Renting a Mobile or Skid Mounted RO System
• Getting Exchange DI Services after an RO System

Condensate Polisher "Portfolio" Added

A sodium cycle condensate polisher "portfolio" page was added to the Res-Kem website.  As you have seen, I have used this blog to highlight the systems we have designed, manufactured and shipped to companies throughout North America.  Given the large number of systems we have manufactured, a consolidated list of these systems would be helpful rather than hunting through the blog. 

As you will see, Res-Kem has a base standard design that we have customized to meet the requirements of their facility or process.  Contact us if you want more information on a specific system you see or one you are contemplating.  I will add detailed information on each system in the coming weeks.  Also, I will continue to update this page with new systems we have sold.

Water Softener vs. Condensate Polisher – Knowing the Differences Can Help you "Get Greener"

Many companies are on a constant quest to run their business in the most energy-conscious, money-saving way possible. For those whose operations involve a low-pressure boiler system environment, investing in a condensate polisher is one of the easiest ways to “get greener” through energy efficiency and dollar savings.

In most every boiler plant, cold water softeners are used to treat boiler water makeup. What’s less common is the use of a condensate polisher which treats condensate return for resuse as boiler feedwater. There are several differences between a water softener and a condensate polisher. Let’s look at a few:

Water Softener vs. Condensate Polisher
Installion – a water softener is typically installed “upfront” with the boiler system in order to meet the ASME/manufacturer’s water quality specifications. A condensate polisher is often an “add-on” to an existing boiler system once steam traps, condensate piping, and condensate receivers age and form deposits (such as iron, copper, and magnesium) that cause thermal resistance to drop.

Materials of construction – water softeners are constructed of epoxy coated tanks or poly-lined FRP tanks, with cast iron or PVC valves and black iron or PVC piping. Res-Kem’s standard condensate polisher systems are fabricated completely with stainless steel. This all stainless steel construction is the best material choice for safe operation over a long time.

Temperature & flow rate – condensate polishers are built to operate at a much higher temperature and flow rate. Where water softeners operate below 80 degrees F, polishers operate substantially above 120 degrees F. The higher temperature and flow rate allow a polisher to acts as both an ion exchange device AND filter, removing copper and iron oxides that cause scale buildup. This oxide removal is not possible with a water softener system, which act only as an ion exchange device with limited filtering capabilities.

Stainless steel surface preparation – condensate polishers are passivated. After fabrication, to further enhance the corrosion resistance of our stainless steel components, all of our welded stainless steel piping and tanks are passivated. This is an expensive, multi-step process which includes bead blasting and passivation, for the longest condensate polisher life.

So what do all these differences ultimately mean for a customer who invests in a condensate polisher?

1) Fuel savings – a condensate polisher saves fuel by allowing higher boilerwater cycles of concentration by reducing the Fe and Cu oxides that cause scale buildup. Fuel savings is also realized through the reuse of heat in the steam condensate.

2) Reduced chemical usage – because of the reduction of oxides and scale buildup in the steam loop, less investment is needed in internal boiler treatment chemicals that are used to remove buildup.

3) Longer and safer service life – a condensate polisher’s passivated, stainless steel construction ensures optimal operation for many years, with minimal routine maintenance. The typical life expectancy of a condensate polisher is 10-20 years.

Learn more about the customizable standard features and specifications of eight of Res-Kem’s recently manufactured condensate polisher models. Download our brochure today, then give us a call to see how we can help you “get greener” with more energy efficiency and more money in your pocket.