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Water Treatment Improves pYour Bottom Line
DAVE PICOU – WATER CARE SERVICES DIVISION
JOHN SCHULTZ – TEXTILE CARE DIVISON
Agendag
Ecolab SummaryEcolab SummaryBoiler Operating CostsGas versus Electric Costs to Make SteamGas versus Electric Costs to Make SteamBoiler Damage From No Water Treatment ProgramPre-treatmentPre treatmentChemical TreatmentExcess Operating Costs From No Water Treatmentp gReducing Your Total Operating CostsQuestions and Answers
Ecolab, Inc.co ab, c
Ecolab, Inc.
As the global laundry experts, Ecolab provides full cycle solutions designed specifically to meet your laundry challenges, help reduce total operational costs
and give you a competitive advantage.g y p g
Boiler Operating CostsBoiler Operating Costs
Electric Versus Gas Costsect c e sus Gas CostsELF is the Energy Loan Fund – data collected from the US EPA web-siteELF is the Energy Loan Fund – data collected from the US EPA web-site
Electric Boiler Savings in Alabama?
Electric Boilers Require Water Treatment Too!Treatment Too!
Fire Tube CorrosionFire Tube Corrosion
CorrosionCorrosionProblem: Oxygen PittingProblem: Oxygen PittingSolution: Scavenge all the oxygen from the boiler feedwater before it
enters the boiler.Problem: Low pHSolution: Maintain the pH of the boiler water between 10 0 and 11 5Solution: Maintain the pH of the boiler water between 10.0 and 11.5.
Scale DepositionSca e epos t o
Boiler Pre-treatment – Why i it d d?is it needed?
Under heat and pressure, Deposition & Corrosion are magnified. gFor this reason, the water used in the process must be treated both mechanically and chemically to prevent damage to the boilerboiler.
Pre-Treatment Removes S l F i H dScale Forming Hardness
Hardness Calcium (Ca) & Magnesium (Mg) ions
Hard water passes through vessel filled with resin beads
Very strong attraction to hardness ions
Also handles up to 0 2 ppm ironAlso handles up to ≈ 0.2 ppm iron
Exchange Ca/Mg ions for Na ions
Resin
Ca
NaResin
Hardness RemovalMg
Na
Chemical TreatmentTreatment chemicals include:
conditioning chemicals for scale controlalkalinity booster for corrosion preventiony poxygen scavenger to prevent corrosion and pittingamines for condensate return line corrosion control
Remove Scale On-LineWith P i i Pl ™With Precision Plus™
Improves heat transfer and energy savingsenergy savingsClean up a dirty boiler on-lineAvoid the expense of off line Avoid the expense of off-line cleanings
Do You Know ALL Your C t ?Costs?
You know your natural gas costsYou know your natural gas costsWhat you are paying for a scaled boiler?What About Water Costs? (Birmingham AL)What About Water Costs? (Birmingham, AL)
City Water – about $2.50 per 1,000 gallonsSewer charge – about $5.00 per 1,000 gallonsBOD, TSS, phosphate, and heavy metals surcharges – vary and can be expensiveBOD, TSS, phosphate, and heavy metals surcharges vary and can be expensive
How much condensate are you returning to the boiler?Are you inspecting your boilers?Are you inspecting your boilers?
Heat Transfer Inefficiency C tCosts
A 300 HP boiler operating at 100% load requires 10,043,700 BTU/Hr or 60,262,200
Scale Scale Gas Required Extra Fuel Cost Due toBuild Up Inefficiency (K, cu ft) Scale (@ $8.00 K, cu ft)
cubic feet of natural gas per year to produce ~8500 lb/Hr of steam at 100 psig..
Build Up Inefficiency (K, cu ft) Scale (@ $8.00 K, cu ft)1/32” 7% 64,480 $33,747
1/20” 11% 66,891 $53,031
1/16” 13% 68,096 $62,673, ,
1/9” 16% 69,904 $77,136
50 HP Boiler Increasing C l f 1Cycles from 5 to 15
Total Savings $35 512Total Savings - $35,512$5,199 – sewer$2,262 – city water$28 051 natural gas$28,051 – natural gas
Based on:city water: $2.50 per 1,000 gallonssewer charge: $5.00 per 1,000 gallonsnatural gas: $10.00 per deca-Therm (1,000 cubic feet or 1 MMBTUs)
The savings in this example would pay for pre-treatment equipment, chemical treatment program and still have over $20,000 left-over
CondensateCondensate
Condensate is very valuable. It still contains much of heat used to d th t d it i f f i l t i t produce the steam and it is free of mineral contaminants.
It is important to capture as much condensate as possible and return it to the boiler for reuse.return it to the boiler for reuse.By returning condensate to the boiler, operational costs are reduced by minimizing the requirement for energy, water, and chemical treatment.
Boiler Inspectionso e spect o s
Inspections lead to ll ki d f fi diall kinds of findings
Boiler Inspections
Should be conducted annuallyannuallyMost often required by insurance carriers
Questions and AnswersQuestions and AnswersSoftener
StSteam
Deaerator Boiler
Condensate Receiver Blowdown
Ecolab Points of Contactco ab o ts o Co tact
David S Picou: Water Care Specialist AlabamaDavid S. Picou: Water Care Specialist - Alabama
Cell phone: (256) 466-5388
E-mail: [email protected]
John J. Schultz: Director, Integrated Laundry SolutionsJohn J. Schultz: Director, Integrated Laundry Solutions
Cell number: (708) 308-6152
E il j h h lt @ l bE-mail: [email protected]