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Galvanic Applied Sciences
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Galvanic Applied Sciences is a Canada-based company that has
facilities in Boston and England and representation all over the
world. The company develops electronic technology for Gas and
Liquids analysis.
Head Office
7000 Fisher Road SE, Calgary, Alberta, Canada
Website: www.galvanic.com
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Lead Acetate Tape
Analysers for Hydrogen
Sulphide and Total
Sulphur Determination
SRU Analysers for Tail Gas,
Sulphur Pits and Oxygen
Demand
Sulphur
Chromatograph
Gas Chromatograph for
BTU and Composition
measurement in Natural
Gas
Electronic
Volume
Correctors
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Acoustic and Optic
Analysers for Turbidity,
Color and Concentration
measurements.
Online Viscosity Analysers
Online Automatic
Titrators
Field
Programmable
UV Analyzers
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INDUSTRIALRESIDUESAPPLICATIONPRESENTATION
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INDUSTRIALRESIDUES
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INDUSTRIALRESIDUES
In an IndustrialProcess such as a
Refining or some
types of chemical
plants, there are
always byproducts
that derive from the
different
transformations and
separations that occur
within the plant.
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INDUSTRIALRESIDUES
These residues aremainly in three forms:
Gases.
Liquids.
Solid Waste.
Which are treated to
make the
environmetallyfriendly.
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Usually, after the treatment one, or some of thefollowing, may take place:
LIQUIDWASTE
- Remove Solids and/or Heavy metals.
- Remove Organics.
- Neutralize.
- Cool Down.
- Remove Color.
- Others that may apply.
GASES
- Remove poisonous gases.
- Remove flammable gases.
- Transform into Carbon Dioxide andMoisture (Combustion)
- Others that may apply.
SOLIDS
- Separate.
- Neutralize.
- Recycle or Send to Landfill.
- Others that may apply.
INDUSTRIALRESIDUES
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INDUSTRIALRESIDUES
Some of the most important contaminantsto be aware of are:
Sulphurs.
Ammonia. Heavy Metals.
Organic Materials.
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SULPHURRECOVERYPROCESS
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THESULPHURRECOVERYPROCESS
The Claus process, and itvariations, are the most significantgas desulfurizing processes forrecovering elemental sulfur fromgaseous hydrogen sulfide. Firstpatented in 1883 by the scientistCarl Friedrich Claus, the Clausprocess has become the industry
standard.
The multi-step Claus processrecovers sulfur from the gaseoushydrogen sulfide found in rawnatural gas and from the by-product gases containing hydrogensulfide derived from refining crudeoil and other industrial processes.
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THESULPHURRECOVERYPROCESS
The by-product gases mainlyoriginate from physical andchemical gas treatment units inrefineries, natural gas processingplants and gasification or synthesisgas plants. These by-product gasesmay also contain hydrogencyanide, hydrocarbons, sulfur
dioxide or ammonia.
Gases with an H2S content of over25% are suitable for the recoveryof sulfur in straight-through Clausplants while alternateconfigurations such as a split-flowset up or feed and air preheatingcan be used to process leanerfeeds.
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THESULPHURRECOVERYPROCESS
ClausReactorBFW
Steam
Air
Sour Gas
Gas
Condensed
Sulphur(CS)
Gas
Boiler
Feed
Water
(BFW)
BFW
Steam
Claus
Furnace
Stack
Sulphur Pit
BoilerCondenser
Reheater
Incinerator
ClausReactor
ClausReactor
Steam Steam
BFW BFW
GasGas
Gas
CSCS CS
The Claus Process
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THESULPHURRECOVERYPROCESS
Thermal Stage:The main feed of the plant is Air and the plant
sulphuric residue, which is called Tail Gas, mostly
comprised of:
H2S
SO2
COS
CS2Sulfur vapor
Ammonia BoilerFeed
Water
Steam
Air
Sour Gas
claus
Furnace
Combustion
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THESULPHURRECOVERYPROCESS
In the thermal stage, which consists of a burner with acombustion chamber and a waste heat boiler, the H2Spresent in the Claus feed gas is combusted to sulphur
according to
R-S + O2 SO2+ H2OH2S +
1/2O21/nSn+ H2O
Part of the sulphur reacts with the formed H2O to H2S andSO2according to the reversed Claus equilibrium reaction:
3/nSn+ 2 H2O 2 H2S + SO2
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THESULPHURRECOVERYPROCESS
APPLICATION:
SOURGASATPLANTINLET
The reason: Sulphur Recovery is a veryimportant process to control, measuring the
acid gas content of a stream helps prepare for
the process.
The Benefit: SRU Reactor control, SRU Process
Control.The Instrument: BRM 961 AG.
961 AG
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THESULPHURRECOVERYPROCESS
APPLICATION
SILICAMEASUREMENTINWATERGOINGTO
THECONDENSER
The reason: Silica (SiO3) is the second mostcommon material on the surface of the Earth.
The molecule is too small to be detected using
electrochemical methods such as conductivity
measurements, and it can cause plugging and
corrosion.The Benefit: Process Control, Condenser
Integrity.
The instrument: Sentinel.
Sentinel
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THESULPHURRECOVERYPROCESS
APPLICATION
HEAVYMETALSINWATERGOINGTOTHE
CONDENSER
The reason: Heavy metals like Iron andCopper could cause corrosion or plugging
problems in a Boiler.
The Benefit: Process Control, Condenser
Integrity.
The instrument: Sentinel.
Sentinel
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THESULPHURRECOVERYPROCESS
APPLICATION
FREEALKALINITYINWATERGOINGTOTHE
CONDENSER
The reason: Alkalinity in water works as abuffer to avoid sudden changes in pH, this is
used as an indication of possible incrustation
or corrosion.
The Benefit: Process Control, Condenser
Integrity.The instrument: Sentinel.
Sentinel
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THESULPHURRECOVERYPROCESS
APPLICATION
HARDNESSMEASUREMENTINWATERGOING
TOTHECONDENSER
The reason: Hardness as Calcium Carbonatecould cause corrosion or plugging problems in
a Boiler.
The Benefit: Process Control, Condenser
Integrity.
The instrument: Sentinel.
Sentinel
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THESULPHURRECOVERYPROCESS
APPLICATION
MEASUREMENTOFACID/BASICIONSIN
WATERGOINGTOTHECONDENSER
The reason: Ions like Ammonium, Chlorideand Sodium could generate Hydrates or Acids
in the Boiler causing corrosion problems.
The Benefit: Process Control, Condenser
Integrity.
The instrument: Sentinel.
Sentinel
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THESULPHURRECOVERYPROCESS
Sulphur precipitates as it condenses andgoes into the sulphur pit.
Boiler
Feed
Water
Steam
Air
Steam
Condensed
Sulphur
Boiler
Feed
Water
claus
Furnace
Boiler/Condenser
Sulphur Pit
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THESULPHURRECOVERYPROCESS
APPLICATION:
H2S ORSO2INSULPHURPIT
The reason: Monitor the concentration of H2Sand SO2in either the sulphur pit vent gas or
the vapour space above the liquid sulphur
depending on the location of the sample
point.
The Benefit: Product quality, Process Control.The Instrument: BRM 201 SPX.
201 SPX
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THESULPHURRECOVERYPROCESS
Catalytic StageThe down-stream catalyticreactor stages furtherincrease the conversion tosulphur. A catalytic Clausstage consists of a reheater,
catalytic reactor and sulphurcondenser, that can be builtin a series to increasetransformation.
Condensation of sulphurafter a Claus reactor makesfurther production ofsulphur possible in the nextcatalytic stage
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THESULPHURRECOVERYPROCESS
APPLICATION:
H2S ORSO2INSULPHURPIT
The reason: Monitor the concentration of H2Sand SO2in either the sulphur pit vent gas or
the vapour space above the liquid sulphur
depending on the location of the sample
point.
The Benefit: Product quality, Process Control.The Instrument: BRM 201 SPX.
201 SPX
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THESULPHURRECOVERYPROCESS
To control de processefficiency is necessaryto control de amount
of SO2produced in theinitial Thermal Stage,to do this it ismandatory to controlthe amount of air
because the optimumconversion to sulphurwill occur at a H2S:SO2ratio of 2:1
Condensed
Sulphur
Gas
Boiler
Feed
Water
Steam
claus
Reactor Stack
Sulphur Pit
Boiler/Condenser
Incinerator
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THESULPHURRECOVERYPROCESS
APPLICATION:
H2S TOSO2RATIO(AIRDEMAND)
The reason: Monitor the concentration of H2Sand SO2to determine the Air Demand to
ensure the most efficient extraction of
sulphur.
The Benefit: Product quality, Process Control.
The Instrument: BRM 942 TGA
942 TGA
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THESULPHURRECOVERYPROCESS
Emission ControlEmissions, like in all
gas treatment
processes need to be
controlled to
acommodate to
international
environmentalstandards.
Stack
Incinerator
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THESULPHURRECOVERYPROCESS
A flue gas stack is a type ofchimney, a vertical pipe,channel or similar structurethrough which combustionproduct gases called flue gasesare exhausted to the outsideair.
Flue gas is usually composed ofcarbon dioxide (CO2) and watervapor as well as nitrogen andexcess oxygen remaining fromthe intake combustion air. Italso contains a small
percentage of pollutants suchas particulate matter, carbonmonoxide, nitrogen oxides andsulfur oxides.
Stack
Incinerator
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THESULPHURRECOVERYPROCESS
APPLICATION:
CONTINUOUSEMISSIONMONITORING
The reason: Monitor the concentration ofSulphur Dioxide, Hydrogen Sulphide and other
gases exhausted to the air.
The Benefit: Environmental Protection.
The Instrument: BRM 991 EMX for SO2and
Flow, 903 for Hydrogen Sulphide.
991 EMX
903
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THESULPHURRECOVERYPROCESS
The claus SRP has some limitations relatedto the transformation of Sulphur
Compounds to elemental sulphur. To
overcome these limitations, two new claus-
based processes have come into the
market.
Super claus
Euro claus
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THESULPHURRECOVERYPROCESS
The Superclaus concept The Superclaus concept applies two main principles to
overcome the limitations of the Claus process:
Selective oxidation of H2S directly into elemental sulphur.
More flexible air to acid gas control.
For selective oxidation of H2S to sulphur, new catalysts
have been developed because available commercial
oxidation catalysts are all sensitive for water and establish
the Claus reaction.
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THESULPHURRECOVERYPROCESS
The Superclaus concept The developed catalysts possess some unique properties:
Oxidation of H2S for more than 85% to elemental sulphur in the
presence of excess air; further oxidation to SO2is minor.
Not sensitive to water.
The introduction of selective oxidation of H2S with these
catalysts in the Claus process contributes to a significant
increase in sulphur recovery. Moreover, the catalysts
allow a less stringent selective oxidation air control, as the
last reactor containing the selective oxidation catalyst cannow be operated with excess air.
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THESULPHURRECOVERYPROCESS
ClausR
eactorBFW
Steam
Air
Sour Gas
Gas
Condensed
Sulphur
(CS)
Gas
Boiler
Feed
Water
(BFW)
BFW
Steam
Claus
Furnace
Stack
Sulphur Pit
BoilerCondenser
Reheater
Incinerator
ClausR
eactor
Selective
Oxidation
Rea
ctor
Steam Steam
BFW BFW
GasGas
Gas
CSCS CS
Air
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THESULPHURRECOVERYPROCESS
From the analyticalmeasurement stand
point, the Superclaus
process is not very
different from theClaus process.
Gas
BoilerFeed
Water
Stack
Sulphur Pit
Boiler/Condenser
Condensed
Sulphur
BoilerFeed
Water
Steam
Selective
Oxidation
Reactor
Reheater
Air
Incinerator
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THESULPHURRECOVERYPROCESS
APPLICATION:
H2S TOSO2RATIODOWNSTREAMFROMTHE
SELECTIVEOXIDATIONREACTOR
The reason: Monitor the concentration of H2S
and SO2to determine the performance of the
Catalytic Reactor.
The Benefit: Process Control.
The Instrument: BRM 942 TGA
942 TGA
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THESULPHURRECOVERYPROCESS
APPLICATION:
CONTINUOUSEMISSIONMONITORING
The reason: Monitor the concentration ofSulphur Dioxide, Hydrogen Sulphide and other
gases exhausted to the air.
The Benefit: Environmental Protection.
The Instrument: BRM 991 EMX for SO2and
Flow, 903 for Hydrogen Sulphide.
991 EMX
903
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THESULPHURRECOVERYPROCESS
The Euroclaus (Extremely Upgraded Reduction Oxidation
CLAUS) process introduces a Catalytic Reduction Reactordownstream from the Claus Reactors to transform SO2intoelemental Sulphur as follows:
Claus reaction
2 H2S + 1 SO23/nSn+ 2 H2O Catalytic reduction of SO2 SO2+ 2 H2
1/nSn+ 2 H2O
SO2+ 3 H2 H2S + 2 H2O
SO2+ 2 CO 1/nSn+ 2 CO2
Selective oxidation of H2S H2S + 0.5 O2
1/nSn+ H2O (1)
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THESULPHURRECOVERYPROCESS
C
lausReactorBFW
Steam
Air
Sour Gas
Gas
Condensed
Sulphur
(CS)
Gas
Boiler
Feed
Water
(BFW)
BFW
Steam
Claus
Furnace
Stack
Sulphur Pit
Boiler
Condenser
Reheater
Incinerator
C
lausReactor
Selective
Oxidation
Reactor
Steam Steam
BFW BFW
GasGas
Gas
CSCS CS
Air
Cl
ausReduction
Reactor
Steam
BFW
Gas
CS
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THESULPHURRECOVERYPROCESS
The introduction of the ClausReduction Reactor increasesthe efficiency of the processto 99.5% approximately.
In this way, an extremely
improved sulphur recoveryefficiency is made possibleby:
1. Bulk removal of Sulphur inthe Claus section,
2. Selective hydrogenationof the remaining SO2, and
3. Oxidation of H2S tosulphur.
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WASTEWATERTREARTMENT
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The main objective of industrial effluent treatment itto remove the solids, suspended hydrocarbons and
other physical, chemical or biological contaminats
that are suspendended in water, in order to return
the water to the environment safely.
WASTEWATERTREATMENT
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Waste Water
Effluent
SuspendedMatter
Removal
Biological
Treatment
ChemicalTreatment
Disinfection
Clean Water
Waste water plants usually have four stages:
WASTEWATERTREATMENT
Waste Water Treatment Plant
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It is very important to keep in mind that not alleffluents need the same treatment, depending on
the process they are attached to, they may or
may not require certain units.
Effluent
SuspendedSolids and
OilsRemoval
OrganicMatter
Removal
MetalsRemoval
ChemicalAdjustment
DisinfectionUsableWater
WASTEWATERTREATMENT
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WASTEWATERTREATMENT
Suspended Matter Removal: This is achieved through filtration. The
objective is to remove all mater suspended
in water, in this stage we want to remove: Solids (big and small).
Suspended Oil and Grease.
Sand.
Color (if possible)
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Depending on their use, filters could be categorized as follows:
SolidSettling
Gravel and Sand
Cartridge Filters
Press Filters
Combined
Color andOdour
Combined
Sieve
Crude Oil
WASTEWATERTREATMENT
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WASTEWATERTREATMENT
Solid Settling Filters: They usually consist of
a closed cylinder with
layers of different
filtering sieves or
sands to remove the
solids from the water.
Sieve
Water Inlet
Water OuletWash
Air Inlet
W W T
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WASTEWATERTREATMENT
APPLICATION:
TURBIDITYANDTOTALSUSPENDEDSOLIDS
The reason: Monitor the Turbidity and theamount of suspended solids in a sample to
insure the filters are working properly.
The Benefit: Product Quality and Process
Control.
The Instrument: MoniTurb Series (Dependingon Particle Size).
MoniTek
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WASTEWATERTREATMENT
Color and Odour removal:
Color in water is usually removed using a special sievethat traps the coloring particles suspended in thewater. Early stages of processing will tend to produce
smelly gasses, hydrogen sulphide being most commonin generating complaints from nearby areas.
Large process plants in urban areas will often contain
a foul air removal tower, comprised air circulators, acontact media with bio-slimes, and circulating fluids tobiologically capture and metabolize the obnoxiousgasses previously contained by reactor enclosures
W W T
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WASTEWATERTREATMENT
APPLICATION:
TURBIDITYANDTOTALSUSPENDEDSOLIDS
The reason: Monitor the Turbidity and theamount of suspended solids in a sample to
insure the filters are working properly.
The Benefit: Product Quality and Process
Control.
The Instrument: MoniTurb Series (Dependingon Particle Size).
MoniTek
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WASTEWATERTREATMENT
Oil Removal:Oil suspended on water
is removed by
decantation, oil stays
on the surface and is
removed mechanically
using different
methods like the API
Separator.
W W T
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WASTEWATERTREATMENT
APPLICATION:
OILONWATER
The reason: Monitor the amount of
suspended oil in a sample to insure the filters
are working properly.
The Benefit: Product Quality and Process
Control.
The Instrument: MoniTek with FlucomatSensor.
MoniTek
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Biological Treatment
The objective of this phase in waste water treatment is to degrade allorganic chemicals that are deemed as undesirable in the stream that isbeing treated.
Aereation PoolsAerobic
(Open exposure toatmosphere)
Anaerobic ReactorsAnaerobic(Closed Reactors)
WASTEWATERTREATMENT
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WASTEWATERTREATMENT
Aerobic Treatment:
Uses an aeration pool open toatmosphere where the waterflows continuously trough andas it does the bacteria withinthe basin interacts with thefluid consuming the organic
matter in it, usually they areslow treatments but are able toremove organic carbons amongother substances.
It is very effective againstAmines and Heavy Metals like
Iron as well as in trapped gaseslike Carbon Dioxide.
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WASTEWATERTREATMENT
Anaerobic TreatmentUses a closed reactor andit is a batch process, it isfaster than an aerobictreatment but it cant
handle big amounts ofwater, they are usually pHdependant and generatetoxic gases andcombustible gases that
need to be exhausted tothe atmosphere or thatcould be used as biofuel.
WASTE WATER TREATMENT
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WASTEWATERTREATMENT
APPLICATION:
TOTALORGANICCARBON
The reason: TOC is measured to determine if
the fluid is suitable to continue treatment, or
if it isnt, also this is the indication that the
sludge needs regeneration.
The Benefit: Product Quality and Process
Control.
The Instrument: FPA 4100
FPA 4100
WASTE WATER TREATMENT
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WASTEWATERTREATMENT
APPLICATIONHEAVYMETALSINWATER
The reason: Heavy metals like Iron and
Copper could cause corrosion and are
poisonous to humans and the environment.
The Benefit: Process Control, product quality.
The instrument: Sentinel.
Sentinel
WASTE WATER TREATMENT
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WASTEWATERTREATMENT
APPLICATIONAMMONIAINWATER
The reason: Ammonia could cause corrosion
and is poisonous to humans and the
environment.
The Benefit: Process Control, product quality.
The instrument: Sentinel.
Sentinel
W W T
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WASTEWATERTREATMENT
Secondary Filtration and/or ClarificationIt takes place with the use of Chemicals called
Flocculants. All suspended solids are cleared
from the stream in the form of floccules.
WASTE WATER TREATMENT
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WASTEWATERTREATMENT
APPLICATION:
TURBIDITYANDTOTALSUSPENDEDSOLIDS
The reason: Monitor the Turbidity and the
amount of suspended solids in a sample to
insure the filters are working properly.
The Benefit: Product Quality and Process
Control.
The Instrument: MoniTurb Series (Dependingon Particle Size).
MoniTek
W W T
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Chemical TreatmentIts objective is to stabilize the fluid so that it is compatiblewith the environment, or with the application downstreamfrom the Waste Water Plant. It usually involves a cation oranion removal which is done through Softening, IonicExchange Resins or Reverse Osmosis.
WASTEWATERTREATMENT
W W T
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Softening
It consists on removing Hardness from water (Hardness in water isdefined as the presence of multivalent cations. Hardness in water cancause water to form scales and a resistance to soap. It can also bedefined as water that doesnt produce lather with soap solutions, butproduces white precipitate or scum).
The process uses a filter that traps the cations and keeps the away fromthe water.
WASTEWATERTREATMENT
WASTE WATER TREATMENT
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WASTEWATERTREATMENT
APPLICATIONHARDNESSINWATER
The reason: Hardness could cause corrosion
and plugging and it must be kept under certain
controls for different applications.
The Benefit: Process Control, product quality.
The instrument: Sentinel.
Sentinel
W W T
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WASTEWATERTREATMENT
Ionic ExchangeIonic Exchange removes Ions from water that couldlater become corrosive acids, salts or hydrates.
It is done through resins that react with water and
clear all free Ions.
WASTE WATER TREATMENT
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WASTEWATERTREATMENT
Reverse Osmosis
A Reverse Osmosis filterremoves salts fromwater and could replacean Ion exchange unit
depending on the typeof salts.
Water is pushedthrough a SemiPermeable Membrane
leaving salt on the otherside of the membrane,like a net.
WASTE WATER TREATMENT
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WASTEWATERTREATMENT
APPLICATIONSALTINWATER
The reason: Salts could cause corrosion and
plugging and it must be kept under certain
controls for different applications.
The Benefit: Process Control, product quality.
The instrument: Sentinel, depending on the
salt.Sentinel
WASTE WATER TREATMENT
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WASTEWATERTREATMENT
DisinfectionThis is the final stage
in water treatment,
the remaining bacteria
is cleaned from waterusing chlorine.
Chlorine is added to
oxydize the water andtherefore kill all
bacteria.
WASTE WATER TREATMENT
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WASTEWATERTREATMENT
APPLICATIONCHLORINEINWATER
The reason: Chlorine is used for water
disinfection and it must be measured to insure
that water could be used for other
applications.
The Benefit: Process Control, product quality,
Process Economy.
The instrument: Sentinel, FPA 4100.(Application Dependant)
Sentinel
FPA 4100
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INDUSTRIALRESIDUESAPPLICATIONPRESENTATION