Ultrapure Water System Starting Up at Nanotechnology Center in Philadelphia

Res-Kem supplied, to a new nanotechnology center in Philadelphia, an ultrapure water system. The start up will commence this Monday. The system is designed to produce water with three different qualities to supply:

• 10 gpm to process cooling equipment
• 40 gpm to laboratory benches and humidification equipment
• 75 to 125 gpm to recirculation loop feeding process tools

Ultrapure Water System Produces a Maximum of 125 gpm of UPW

Ultrapure Water Loop Specifications

Parameter	Specification	Measurement Location	Instrument or Analysis Method
Resistivity (% of time)	< 18.2 M-ohm-cm (100%)	On-line	Thornton 770 MAX
TOC	< 2 ppb	On-line	Sievers 500RLE
Dissolved Oxygen	< 5 ppb average 10 ppb maximum	On-line	Swan Oxytrace
Particles	< 80 particles/liter >=0.05 micron	On-line	PMS Ultra D150
Bacteria	< 1 CFU/liter	Off-line	Low nutrient agar
Al, Ca, Co, Cr, Cu, Fe, K, Mg, Na, Ni, Pb, Zn	< 5 ppt	Off-line	IC
Boron	0.1 ppb maximum	On-line	Sievers
Dissolved Si as SiO2	< 50 ppt	On-line	Swan

The system is designed to allow for easy expansion to double the makeup rate to the ultrapure water recirculation loop.

For more Information:
Contact us if you would like presentation about this project
Modular Ultrapure Water Systems
On-line Industrial Water Treatment Catalog

Naturally Occurring Radioactive Material in Your Water

NORM means Naturally Occurring Radioactive Material and TENORM stands for Technically Enhanced Naturally Occurring Radioactive Material.   The USEPA states "TENORM is produced when radionuclides that occur naturally in ores, soils, water, or other natural materials are concentrated or exposed to the environment by activities, such as uranium mining or sewage treatment."  Res-Kem sees the potential for TENORM in filters and softeners treating well water in areas where naturally occurring radioactive materials NORM are found.

As a result, Res-Kem will be adding an additional test before we replace media or particularly when entering tanks. We will bring instrumentation to test for TENORM radiation.  Unfortunately, if we detect radiation, we will have to button the system back up and depart.

Again on the USEPA's website "NORM consists primarily of material containing potassium-40 and isotopes belonging to the primordial series. The principal primordial radionuclides are isotopes of heavy elements belonging to the radioactive series headed by the three long-lived isotopes uranium-238 (uranium series), uranium-235 (actinium series), and thorium-232 (thorium series). ... At background concentrations, the naturally occurring radionuclides in the uranium, actinium, and thorium series contribute about one-half of the natural background external radiation, and over 80 percent of the background including radon, to which all humans are continuously exposed."
  From a Clean Harbors bulletin on the subject, typical sources of NORM and TENORM wastes include

• Oil and gas industry
• Geothermal energy production
• Coal combustion
• Mining of uranium and metals
• Phosphate production
• Municipal water treatment
• Abandoned mines and processing facilities
• General manufacturing

Temporary Exchange Softeners for Unplanned Equipment Repairs

Temporary, skid mounted softeners can get you back up and running when unplanned repairs are required to your in-house zeolite softeners.   Depending on the extent of the problems, repairs can take several weeks or longer.  Tanks are simply hooked up to your water source via cam-lock connections and 2" industrial Goodall hose.  As the tanks exhaust, Res-Kem will bring new tanks with regenerated resin.  No backwash is required, no salt is required and no hard piping is required.  

Skid-mounted Exchange Water Softener form Res-Kem

In order for water tube or firetube boilers to operate efficiently they need low hardness quality feedwater. If you've recently had a boiler opening and discovered scaled boilertubes due to non-functioning boiler pretreatment zeolite softeners and ineffective boiler internal chemical treatment. Res-Kem can provide ASME code 100 psig temporary skid mounted softeners good for flow ranges- 15-120 gpm. These tanks can be provided within a 150 miles radius of our locations in near Philadelphia, PA, New Britain, CT, Avon, MA and Colonial Heights, VA.

The tanks are delivered via a Res-Kem truck with a liftgate for dock deliveries or ground deliveries.  We transport the tanks short distances within your plant to the point of use via a motorized pallet jack.

 

Failing Water Softener.  Look familiar?

Siemens Selling Water Treatment Business

The big news in the water treatment industry for this past week has been Siemens' announcement to sell the water treatment equipment and water systems service business.  Bloomberg announcement states that the Siemens Water Technologies division includes wastewater, municipal and industrial water purification services and membrane filtration systems.  Most of these technologies were parts of the former US Filter Corporation acquired by Siemens in 2004 from Veolia Environnement for $993 million.  

According to a statement by Siegfried Russwurm, member of the Siemens AG Managing Board and CEO of the Industry Sector, "This business shows only minor synergies with our industrial portfolio, as the skills for water treatment are primarily based on chemical expertise. Instead of investing into that business, we want to gear our resources toward our core portfolio."

In related news, Kemira Oyj, Europe’s largest supplier of chemicals to treat water, will not be bidding for the water business of Siemens AG.

Open For Business-Res-Kem Aston, PA & New Britain, CT

For Res-Kem Customers: Both of the Res-Kem regeneration facilities, Aston, PA and New Britain, CT are open for business!  Delivery services may be curtailed based upon local ordinances.

For Res-Kem Employees: If your State's roads are closed, then do not attempt coming in.  You must obey the laws as they apply.  If you are trying to get to work, please keep your safety paramount.  Use your best judgment of the road conditions.

Res-Kem New Britain, CT Remains Closed

Since the roads remain closed in Connecticut by order of the Governor, our New Britain, CT facility will remain closed until the roads are open for traffic.

If you need assistance, please contact our Aston facility at 800-323-1983 or send an email to sales@reskem.com.

Delayed Opening Res-Kem Aston, PA

Due to the hazardous road conditions from Hurricane Sandy, the Res-Kem Aston facility will have a delayed opening this morning, October 30. Some of our employes have already arrived, the balance will arrive by 10:00 AM.

If you need assistance, please leave a message at 800-323-1983 or send an email to sales@reskem.com. 

Res-Kem New Britain and Hurricane Sandy

Res-Kem New Britain will be pulling our Connecticut delivery drivers off of the road. The State of Connecticut is putting a truck ban into effect by 11:00 AM today for limited access highways.  At 1:00 PM, all CT state highways will be closed for all non-emergency personnel.  We will be closing the New Britain office at 12:00pm today.  We anticipate being open tomorrow.  As power permits, we are working remotely from our homes. You may leave a message on at 800-358-1983 or send an email to sales@reskem.com. We will respond as soon as possible.

For our DI exchange customers, we prepared for Hurricane Sandy by working additional shifts over the weekend. When we are allowed to be safely on the roads, we will resume deliveries. Thank you for your patience.

Res-Kem Aston and Hurricane Sandy

Due to the arrival of Hurricane Sandy, the Aston, PA office of Res-Kem will be closed on October 29.  We anticipate reopening on October 30. You are welcome to leave a message at 800-323-1983 or email us at sales@reskem.com.

Rental Condensate Polishers Now Available

Skid-Mounted, Rental Sodium Cycle Condensate Polishers are available for deployment with preconfigured systems in single, double, triple and quadruple module deisgns to treat condensate return for reuse as boiler feedwater. All wetted parts for Res-Kem Condensate Polishers are 316 stainless steel. Single units are rated for flows up to 210 gpm. Use multiple modules in parallel to treat flows up to 840 gpm. 

Res-Kem is offering a rental option because companies who want to immediately begin to saving money recovering waste heat, reducing water usage, and reducing water chemical usage may not have sufficient capital.

Res-Kem CPR-2 Rental Condensate Polisher
Designed to Treat up to 420 gpm

STANDARD FEATURES:

•Skid Mounted Units With Flows up to 840 gpm
•All 316L Stainless Steel Wetted Parts
•Welded Components Media Blasted and Passivated
•ASME Code Stainless Steel Vessel Designed for 100 psig
•Factory Assembled Schedule 40 316 Stainless Flanged and ASME Section IX Welded Valve Nest
•Stainless Hub and Wedge Wire Screened Lateral Underdrain
•NEMA 4XFG Electrical Enclosure
•Differential Pressure Switch
•Flow Sensor
•Automatic Fast Rinse and Backwash Flow Controller
•Separate Cold Water Connection for Regeneration Cycles
•High capacity, High Crosslinked Macroporous Cation Resin
•Stainless Steel Resin Trap
•Water Sample Cooler
•Manual Isolation Valves and Bypass Piping

INCLUDED SERVICES:
•Monthly site service visit to insure proper operation
•Yearly resin cleaning to maximize system efficiency
•Resin replacement every three years included

ADVANTAGES:
•Quick ROI by Reclaiming Waste Heat and Increasing Cycles
•Cold Water Regeneration Saves Heated Water
•Standard Designs Reduce Cost and Delivery Time
•Passivated Flanged and Welded Piping for Corrosion Resistance
•High Strength Resin Selected for Long Life

OPTIONS:
•Pressure Relief Valve
•Allen Bradley PLC

For Additional Information:
Rental condensate polisher bulletin
Technical help sizing and selecting a condensate polisher
Entire Res-Kem Condensate Polisher Product Line

Arc Flash Training Held at Res-Kem

Arc flash training, an OSHA required session to help identify the risks around working with electrical and signal wires, was given to twenty people with our organization.  It helps the technicians fully understand the risks, and how to determine if there is any stored energy before starting work.

Injuries that can result from an arc flash:

• Burns
• Respiratory system damage
• Hearing damage
• Skin penetration from flying debris
• Eye and face injuries

We covered the risks with performing the work, Lock-Out Tag-Out (LOTO,) testing methods and Personal Protection Equipment (PPE). The twenty people trained included plant and field personnel that have not yet completed this certification class, including field service technicians, in-house assembly personnel, and field sales engineers.

What is an arc flash?

According to Wikipedia:

"An arc flash is an electric arc supplied with sufficient electrical energy to cause substantial damage, fire or injury. ...  Arc flash temperatures can reach or exceed 35,000 °F or approx 20,000 °C at the arc terminals. The massive energy released in the fault rapidly vaporizes the metal conductors involved, blasting molten metal and expanding plasma outward with extreme force. A typical arc flash incident can be inconsequential but could conceivably easily produce a more severe explosion ... .  The result of the violent event can cause destruction of equipment involved, fire, and injury not only to the worker but also to nearby people."

Industrial Water Softener Shipped to Repeat Food Flavorings Customer in New Jersey

Res-Kem recently shipped a second 84 inch industrial water softener to the same food flavorings plant in southern New Jersey. The water treated by the water softener is used to make steam to sterilize the raw plant material prior to extraction and to extract the flavoring. The softener is the replacement to a second existing tank which has failed after 40 years of service.

Second 84"Water Softener prior to Shipment to Food and Flavorings Plant

Emptying and Removal of Old System:
Before the system was shipped, our service team coordinated their work with the company's mechanical contractor to remove the resin and gravel from the existing, corroded system. Our service team brought our trailer mounted diesel vacuum system to remove the media and prepare for disposal by the customer. After we were finished, the old system was cut apart for scrapping by the contractor.

Vacuum Trailer used to Remove Ion Exchange Resin
and Gravel from Existing Water Softener

New System:

The new system is an 84" diameter steel vessel and is finished in an epoxy coated interior and exterior. The customer asked us to change our normal blue color to red.  We hope to provide the white tank next fiscal year (do you see the theme??)  We also were asked to change the face piping to Schedule 10 304 stainless steel. As before, the valves are Bray valves with Bray air-to-air actuators. The system is controlled by an Aquamatic 962 controller. At this point, regeneration will be initiated manually when production will allow. To handle the existing uneven floor, four jack legs were provided.

System Operating Parameters:

Since most of the steam ends up in the plant matter and the extracted flavor ingredient, very little steam condensate is returned. This make the makeup flow very large. Each of the three softeners operate at 200 gpm and 80 psig. Because to the system's age, corrosion of the tanks and piping have become a maintenance nightmare.

Second Condensate Polishing System Shipping to a North Carolina University

Res-Kem is shipping the second of two condensate polishing systems to a leading private university in North Carolina next week.  This is the second of two systems sold to this same university in the past year and a half.  This system treats 400 gpm of dirty condensate.

Res-Kem's Dual 54 inch Sodium Cycle Cycle Condensate Polishers

To improve the ROI, through energy savings, this system is designed with a separate source of cold water for backwash, brine draw and slow rinse.

What is the Res-Kem water treatment application?	Sodium cycle condensate polishing to remove iron and hardness
What are the operating conditions?	Flow: 400 gpm Pressure: 30-100 psi Temperature: 200F Continuous
What is the system configuration?	Dual tank, parallel operation 54” in diameter tanks
What ion exchange resin was used?	47 cubic feet of Purolite C-150 highly cross-linked macroporous cation exchange resin in each tank
Materials of construction?	316 SS ASME code with a 150 psig design pressure 316 SS Hub and Lateral 316 SS Subsurface Wash Distributor 316 SS Schedule 40 Welded face piping
Type of Valves and Actuators?	Bray McCannalok Series 41 with Series 93 pneumatic actuators with manual override
Special Features?	Subsurface wash Cold water used for separate source backwash, brine draw and slow rinse Condensate fast rinse 316 Stainless resin traps after each system

Additional Information:
Listing of Condensate Polishers Built by Res-Kem
Online Catalog of Res-Kem Condensate Polishing Equipment
Condensate Polisher Technical Bulletin
Condensate Polisher Application Checklist 
Purolite C-150 Technical Bulletin
For Technical Help From a Res-Kem Sales and Application Engineer

Amazing Craftsmanship of Condensate Polisher from Res-Kem

I need to acknowledge the excellent, American craftsmanship which goes into our condensate polishers!  It may be the engineer in me, because this is an amazing piece of work!  My kudos go to:

• Tony, our Lead Design Engineer who had to design the vessel, the vessel penetrations, pad flanges, internal clips and its internals with amazing accuracy (and I am certain a few sleepless nights!). 
• Shane, our Lead Assembly Person who had to go into this vessel and assemble Tony's creation, piece by piece day after day. 

This attention to detail is particularly admirable when it is likely no one will see ever see these distributors, header and laterals again! 

As we know, the things you cannot see separate the highest quality product from others.     



Condensate Polisher Internal Components in 316 L Stainless Steel from Res-Kem



 You are looking from the top of this photo to the bottom:

• Inlet distributor
• Brine Distributor
• Sub-surface was distributor
• Hub and Lateral underdrain

You have too realize everything you see takes place in a 54 inch diameter tank that is approximately 84 inches tall!  Shane had to squeeze through a 14 inch x 18 inch elliptical manway and Bill, who assisted Shane, had to give each piece to Shane through the same manway!

For more information:
Technical bulletin on Res-Kem's Condensate Polishers
Res-Kem's Condensate Polisher Portfolio Page of Recent Equipment
Checklist to Properly Size Your Condensate Polisher
If you need technical help

Growing DI Exchange Business Means Additional DI Tanks Needed

As the number of customers continues to increase for our deionized water exchange service, Res-Kem General Water continues to heavily invest in new DI (deionization) tanks and mixed bed ion exchange resin.  We just received our first of three shipments of our all stainless steel DI12 and DI30 tanks.  Res-Kem continues to have the largest fleet of stainless steel deionization exchange tanks on the East Coast.  

All Stainless Steel Service DI Tanks Received at Res-Kem for Growing DI Exchange Business

These exchange tanks and resin are used to produce high purity to ultrapure water for many industries including power, cogeneration, beverages, electronics, semiconductors, universities, corporate research campuses, pharmaceuticals, and manufacturers of most any type where high purity water is used in the product or touches the product.

Locations Served:
Res-Kem will use these primarily for customers in our southern region which includes New York, New Jersey, Pennsylvania, Delaware, Maryland, DC, Virginia and North Carolina out of our Aston, PA and Colonial Heights, VA locations.

Also, we have a large fleet of DI tanks serving our northern region New York, Connecticut, Massachusetts, Rhode Island, New Hampshire, Vermont, and Maine out of our New Britain, CT and Avon, MA locations.

For More Information:On Res-Kem General Water's DI Exchange Service
Technical and/or sales questions

Genetic Research Facility Will Reap the Benefits of Installing All Stainless-Steel Condensate Polisher

Kevin Preising shares how a large genetic research facility in New England will realize the benefits of a new Res-Kem single vessel Condensate Polisher. The unit will reduce the amount of iron deposits the facility was experiencing in their boiler tubes, which prolongs the life of the tubes and provides significant long-term fuel savings.
Get the full story –

For Additional Information:

For help sizing a system contact Kevin Preising
Condensate Polisher Checklist - Web Page
Condensate Polisher Checklist - Printable Version
CP Product Bulletin
View our CP System Portfolio

Greensand Filters Shipped to Western PA Water Plant

A western Pennsylvania, small private water utility, recently received four greensand filters to replace the filters that were failing.  Unable to get the original manufacturer to provide new, duplicate units, our customer found our website. 



Four New Greensand Filters and Greensand Media Ready for Shipment to Water Utility



Because of State regulations, the systems and their operation needed to be as close to the original as possible, otherwise new permits would be required.  Since Greensand is in very, very short supply, the media was changed to Greensand Plus from the same manufacturer.  Sodium hypochlorite is used to continuously oxidize dissolved iron in the water coming into the filters.  Also, these filters are very unique because they are much shorter than we normally manufacture.  Our normal tank straightside is 60".  These tanks are 36" straightside.  

Three of Four Existing Manual Greensand Filters Showing Tank Corrosion

What does the company do? Public water

What is the Res-Kem water treatment application? Green sand filter to removed dissolved iron


What are the savings and/or ROI the customer wants to achieve? Not applicable.  The customer is replacing old existing system with identical system


What are the operating conditions, e.g. flow, temp, continuous, etc.? 60 gpm, Well Water Intermittent Flow

What is the system configuration, e.g. # of tanks, standby units, etc.? Four greensand filters in parallel operation


Materials of construction of tanks, piping, valves, frame, etc.? ASME Code Steel Tanks, 6’ Diameter X 36” Shell straight-side , PVC glued with manual ball valves


Type of valves and actuators? Manual ball valves


Control philosophy? Backwash as required based upon differential pressure

Special Features? Short fat tanks, required to fit tight area

For Additional Information:
Greensand Filter Technical Bulletin
Greensand Plus Technical Data
For help sizing a new filter
For help repairing or rebedding a Greensand Filter

Dual Parallel Condensate Polisher Will Help Large New York University Prolong Life of New Boiler

A well-known university in upstate New York that was in need of a Condensate Polisher recently reached out to Res-Kem for help. Kevin Preising discusses how Res-Kem worked closely with the university’s chief engineer and another local firm to help specify and size the unit, which will help prolong the life of the university’s new boiler.
Listen now –

For Additional Information:
For help sizing a system contact Kevin Preising
CP Checklist - Web Page
CP Checklist - Printable Version
Condensate Polisher Bulletin
View our Condensate Polisher Portfolio

Iron and Manganese Removal Filter Shipped to Westchester County HQ

Res-Kem recently shipped a 52 gpm dual tank greensand filter to a Westchester County New York corporate headquarters campus.  This filter uses greensand to remove dissolved and precipitated iron and manganese from the water coming from the local public water system.

Dual 36" Greensand Filters with
Bray 31 Valves and Bray Series 93 Pneumatic Actuators

Water Problem:

At a Westchester County corporate headquarters campus, about 4 to 5 times a year, our customer experiences water quality and quantity problems. The campus receives its water from a local public water supplier. High levels of iron and manganese are present within the public water distribution system, and peak flow events such as hydrant flushing or firefighting activities have caused brown water to be drawn into their water system. What exacerbates the problem is the campus is at the end of the water distribution system without looping.

Therefore, iron and manganese laden sediment accumulates the piping and is drawn into the campus drinking water system. Res-Kem designed and constructed a filtration system to remove iron and manganese from the drinking water, as well as a storage tank. The volume of the tank is 150,000 gallons which provides two days of storage in the event of a water emergency with the water supply.


System Solution:

Inlet Iron and Manganese:	Average Inlet Iron 0.22 mg/l Average Inlet Manganese 0.11 mg/ml
Flow Operating Conditions:	Typical: 52 gpm typical
System Configuration:	Dual Parallel 36" diameter ASME Code, carbon steel tanks Epoxy Lined, NSF 61 certified Schedule 80 PVC face piping Differential Pressure Switch initiated backwash Greensand Plus filtration media
Control Valves:	Bray Series 31 valves with Bray Series 93 actuators
System Operation:	Differential Pressure Switch initiates backwash cycle
Added Features:	Domestic water booster pumping system brings filtered water backwash to system Sodium Hypochlorite (NaOCL) serves as the chemical oxidant for the removal of iron and manganese in the filtration system. The NaOCL will be injected immediately upstream on the system influent piping header. Chemical dose will flow paced based from the signal from the filtration systems influent flow meter.

For Additional Information:
Technical bulletin on Res-Kem's Greensand/Greensand Plus filters
Online catalog for Greensand Filter Systems
Technical bulletin on Greensand Plus filtration media for iron and manganese removal

Condensate Polisher Install Saves University Big Bucks on Annual Boiler Maintenance

Kevin Preising discusses how the installation of a Condensate Polisher at a large midwestern university allowed them to meet ASME guidelines for boiler feedwater and significantly reduce the amount of time and money spent on annual cleaning of their boiler system.

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.

Condensate Polisher Product Bulletin Updated

Res-Kem has updated the features list of our standard condensate polisher product line because we had important ones which we did not tell anyone about!

For example:

• All of the welded stainless steel piping and tank components have always used the expensive and necessary bead blasting and passivation, for long condensate polisher system life
• All our stainless steel piping is welded per ASME Section IX
• All our laterals use wedge wire screeening

Duplex Alternating 48" Condensate Polisher
with Optional Bray Valves

Stainless Steel Header & Wedge Wire Lateral Distributors
Installed Above
Stainless Steel Hub & Wedge Wire Laterals

Also, one common option customers have asked for is to provide stainless steel headers.  For most multiple unit systems we have sold, we have provided the inlet, outlet, brine, sub-surface wash and drain headers.  We needed to add this information to the bulletin as well.

Additional Information:
New Condensate Polisher Bulletin

Downloadable CP Checklist

Need help sizing a Condensate Polisher

400 gpm Multi-Media Filters Shipped to Brewery in Pennsylvania

Res-Kem shipped a dual alternating multi-media to a brewery in northeastern Pennsylvania.  The each multi-media vessel has a design flow rate of 400 gpm and a peak flow rate of 510 gpm.  The system filters all the municipal water entering the plant for all applications including brewing.   



Dual 84" Diameter Multi-Media Filters

Design Features:

• Two 84" diameter ASME code vessels rated at 100 psig.  The internal coating is an FDA epoxy
• Aquamatic diaphragm are used
• External piping is Schedule 80 black iron pipe
• Each filter is controlled using an Aquamatic 948 controller which backwashes on a time basis

Closeup of Multi-Media Filter Before Shipment

For additonal information:

Res-Kem's Multi-Media Filter System Bulletin
Res-Kem's Complete Media Filtration Product Line
Need technical assistance and/or system pricing?

Three Duplex 80 gpm Multi-Media Filters Ready for Shipment

Res-Kem is has delivered 20 of the 40 customized, duplex multi-media filters for mobile enhanced oil recovery trailers. The Res-Kem multi-media filters are sized to continuously produce 80 gpm of water to downstream equipment including steam generators.  The trailers generate steam which is injected into wells to recover more oil. The system started out as one of our customizable standard duplex multi-media filters.

Three Duplex Multi-Media Filters Being Prepared for Shipment

We added the following features to meet the customer's requirements:

• UV resistant tank coating for enhanced tank life
• Welded Schedule 10 stainless steel face piping for corrosion resistance
• Skid mounting on stainless steel frame
• Custom configured inlet and outlet piping locations to minimze piping between  other equipment on trailer
• Bray butterfly valves with position indicators and limit switches
• All valve solenoids and limit switches are wired to a single NEMA 4X stainless steel box to be interfaced with PLC which will control all equipment on the trailer
• Resin trap on the product line of each filter to protect downstream equipment

For additonal information:

Res-Kem's Multi-Media Filter System Bulletin
Res-Kem's Complete Filtration Product Line
Res-Kem's other industrial water treatment equipment
For technical assistance and system pricing

Q&A on Condensate Polishers with Res-Kem’s Kevin Preising

While dirty condensate clean-up can be an energy buster in most processing plants, one cost effective solution is to polish contaminated condensate for re-use. Condensate polishers use a simple ion exchange technology that is easy to operate, easy to maintain and economical to use – less make-up water is required which leads to lower chemical and energy consumption.

Here is a brief Q&A video with Res-Kem’s Process Engineer Kevin Preising that addresses some of the most common questions about Condensate Polishers. Kevin touches on the following points:
• The difference between sodium condensate polishers and water softeners
• The life expectancy of a condensate polisher
• What plant utility services are required for condensate polishers
• Why a sub-surface wash is important
• The advantage of using a sample cooler
• The type of instruments on a condensate polisher

Watch it now!