advancement & digitalization in cooling water treatment to ...enterprise visibility of critical...
TRANSCRIPT
Presenter:
J. ANAND
Advancement & Digitalization in Cooling Water Treatment to have Informed Decision making
& Avoiding Microbiological fouling to improve the asset life and
Quality in Reverse Osmosis Membranes.
Agenda..
• Cooling Water Treatment Digitization• Traditional approach
• How Digital to help CWT automation
• What’s new in Market?
• Advancement in Cooling water treatment..• Acid free programme
• How it works & case studies
• Membrane Treatment• How to handle microbio fouling?
• What’s new in controlling micorbio fouling..
Cooling Water Treatment DigitizationDRIVE COMPELLING CUSTOMER BENEFITS; TRANSFORM HOW WE DO BUSINESS
5
CUSTOMER
AUTOMATION
Data Monitoring
and EnVision
GLOBAL
KNOWLEDGE
Traditional Approach to Cooling Water?
4
• Stress is the total of everything which can cause a loss of cooling efficiency in the system
• MECHANICAL Heat exchanger design & operation
• High temperatures or heat fluxes, low flow velocities
• Long Holding Time Indexes (HTI’s)
• OPERATIONAL Cooling water chemistry & control
• Poor or failed control/testing or dosing equipment
• CHEMICAL Raw water chemistry
• Variable water quality
• Phosphate added by water utility
• Suspended Solids
• Dependency on Water analysis,
• Pinks & Blues
• Grab Samples once per day, not representation of the day
• Reactive approach
• Mechanical & Operational Parameters
• The chemistries dosed on Ad-hoc basis
• The dosages not linked to real time corrosion & scale in system
• Not considering the above stress in the system
• Operations negligence on critical parameters etc.
What automation to do?
5
YOUR COOLINGSYSTEM
Best-in-Class Automation
Modeling &Optimization
On-Site TechnicalServices
Chemicals &Equipment
System Assurance
Center
CustomerData
Services
Providing visibility
via dashboards
to track system
performance and
benchmark
A team of experts
provides 24/7/365
monitoring of your
system
World-class service to
ensure we DELIVER
value to the customer
Technology to
DETECT upset
conditions
Proprietary algorithms
to DETERMINE
corrective actions
Continuously
monitoring:• Conductivity
• pH
• Turbidity
• Flow rates
• Corrosion
• Scaling potential
Deliver
Energy
SavingsWater
SavingsExpert Support
Asset
Longevity
Corrosion
control
Fouling prevention
maximizes heat
transfer efficiency
Higher cycles
minimizes water
discharge
Experts watch your
systems 24/7 for your
peace of mind
• Real-time scale and corrosion measurement with fluorescent Tagged Polymer
and proprietary Nalco Corrosion Monitor
• Direct measurement of bio-demand with bio-reporter technology
• Other system conditions monitored through conductivity, pH, ORP, temperature,
and turbidity
• Alarm conditions are reported instantly via email
Detect
Corrosion Microbiology Alarms on System UpsetsScale
Determine
• Built-in control algorithms determine chemical dosage and blow down response
• Proprietary dynamic algorithms based on Nalco Scale Index and Nalco Bio-
Index respond to variable stresses
• Remote monitoring by the Nalco 360 Expert Center enables proactive response
to system conditions
Special Algorithms Root Cause & Actions
Automation & Digital as a “solution”
COMPONENTS WITH DESCRIPTORS
Fingerprinting the Operational
parameters…
OMNI SimulatorSimulates the exact conditions (skin temperature
and water velocity) of the critical asset allowing to:
+ Quantify/Identify the type of fouling.
+ Quantify/Identify the type of corrosion.
+ Identify BioFilm events.
+ Corroborate effectiveness of passivation
procedures.
3D TRASAR Technology: Continuously monitors and detects changes in
system demand, determines potential causes of
variability, and delivers corrective action to bring
key system parameters under control:
+ Optimization of cooling water treatment,
+ Water chemistry KPIs,
+ Automation
+ Best in class chemistry.
The combination of 3D TRASAR Technology, ECOLAB3D and OMNI™ Total Heat Exchanger Performance platform creates an unique visibility of the impact of
cooling water on the operation of your critical assets locally and across the enterprise.
HX Audit: A stress profile is created for each exchanger and Mechanical,
Operational and Chemical factors are analyzed that may impact
reliability or cost.
Real Time Monitoring: Performance Monitoring based on:
+ Trending of U-Value
+ U-Value
+ Water Velocity
+ Skin temperature
+ Heat flux
+ Approach Temps.
+ Cleanliness Factor.
+ Fouling Resistance.
Enterprise Visibility of critical Assets, Benchmark Performance of
Critical Assets, System Assurance Center, Value Tracking,
Improvements Impact.
+100 engineers monitor and give actionable Insights about Heat
exchanger performance and actions.
ON Site ExpertiseNalco Local service account reps and NALCO corporate account
managers will maintain tracks of dashboards to create and maintain
value.
Cloud Analytics
How to take informed decisions with
data…
OMNI simulator
SAC
Performance
Dashboards
Cloud Analytics
Advancement in Cooling Water
Treatment…
Cooling Water Treatment…
Generally of Phosphonates (HEDP/PBTC etc.)
as sequestrants & Ortho-Phosphates for
corrosion control.
The Blowdown discharged from CT’s rich in
Phosphates, which is food material for
Microbiology to grow.
Which turns the Public sewer, lakes with algal
bloom.
Demands lower pH operation to keep away
Ca3(PO4) scales – Acid dosing & corrosion
issues
Drivers for Non-PO4 Technology
Why Non-PO4 Programme
Regulatory compliance on P
Non acid or less acid
Multiple makeup sources or high
fluctuation in water quality
Regulatory compliance on zinc discharge
Historical zinc fouling issue
Calcium Phosphate scaling issue
Recycle cooling blown down with RO
Reduce biocides dosing
What’s Non-PO4 Programme?
• Cooling water direct discharge, save cost
for waste water treatment
• Using Carbonate – natural inhibitor to
support corrosion control
• Less/none acid - safety; low scaling
pressure, save energy and improve productivity
• Avoid scaling from Ca-PO4
• Avoid the interference of Ca-PO4 on RO
membrane while recycling cooling water
• Reduce nutrient for microbial, Better managing
microbio growth.
• Easy control
Model application
Provide programs;
Highlight risk
3D TRASAR Optimizer
m• Maintenance
Chemicals
3DT platform
Generate and
communicate timely,
affordable,
proprietary,
actionable
information
enVision
Organize and
Manage
Information,
Remote control
eROI & SAC
TCO tools (reduced
corrosion rate , save
water, reduced WWT cost)
24/7 remote expertise,
turning information into
results.
Non – PO4 program Offering
Pearl
Offering
enVision
Monitorin
g&
Control
Chemicals
Optimizer
eROI
& SAC
OMNI
Link water to
process KPIs.
Chemical Program Transfer from P Based
Current Program
No P ProgramNon-P under ‘Tag polymer’ control
pH Control needs to be adjusted
No Azole based product to be configured
Makes the chemical dosing simple
Cooling Tower Operation
Ac
id
Case Study from Field Trials with Non-PO4 chemistry
Case Study: Chemical plant. enVision Data for
New CPP Cooling Tower
Shutdow
n
Current COC
Higher COC
pH control maintained throughout the trial period
Steel corrosion rate reduced over time during trial
period
Product dosing maintained through ‘Tag’ control
~ 40 ppm
Conductivity increased over time due to COC
increase
Chemical plant - Water Savings and COC
Improvement
Blowdown savings > 450 m3/day
Sr. GM, Utilities & Energy, :
Post implementation of Pearl program for “COC : Cycle Of
Concentration” increase water treatment program w.e.f.
20th Apr’18, we have satisfactorily achieved the COC of all
the 11+1 Nos. of identified CT’s, wherein round the clock key
parameters online monitoring system i.e. 3D TRASAR has
been installed. During last 3 months, the COC levels has
been increased gradually from 6.6 to 9.2, wherein the CT
Sump make up water savings of @ 450+’ KLD has been
achieved.
Case study: Soft Water as Make up
16
Background:
• Chemical plant with strict regulatory limit on P discharge in this region
• System heat loading fluctuation
• To use recycled water as makeup to save water
• Old plant with pipeline leakage
Problems:
• Require non-P for P discharge compliance
• Big water fluctuation in system
• Multiple makeup sources with high microbial risk
• Corrosion control challenge
Solutions:
• New No P program of Nalco Water
• 3D TRASAR controller & enVision
Improvement:
✓ Can discharge CW blowdown directly to save WWT cost
✓ Use recycled water as makeup to save fresh water46653 tons/year
✓ Reduce general corrosion rate 30%
eROI:✓ Reduce cost for fresh water & WWT, save 22.8K
USD/year
✓ Extend asset lifetime, save 6.7K USD/year
✓ Reduce maintenance Manpower, save 1K USD/year
New No P program
6 weeks: 0.34mpy
3 months: 0.24mpy
NCM probe after 4
months:~0.1mpy
Trial startup
Large water fluctuation in system
Membrane Cleaning – New approach to
Microbio fouling
17
Different foulants in Membranes
Bio-fouling43%
Organic Fouling
15%
Colloidal Fouling
18%
Silica13%
Other Inorganics
6%
Coagulants5%
Bio & Organic fouling
leads to ~ 70% failure
across all end use
sectors
Advanced Microbial Management
Oxy membrane cleaner❑ Continuous dose or shock dose
❑ Acts before biofilm formed
❑ Removes existing biofilm
Biofilm can be developed in 24 hrs.
DBNPA ❑ Acts only on mature bio-film
❑ Microbes develop resistance
PermaDUO
Cell Population over Time
Advanced Benefits of Oxy membrane cleaner
• Dual stabilized biocide - compatible with polyamide RO membranes
• Two drum approach efficient bio-management
• Acts during microbe growth phase (proactive control)
• Can act on mature bio-films better than DBNPA
• Provides deep cleaning and thereby leading to complete removal
P
D
Trial Summary – India (Surface Water)
KPI BaselineWith PC-22 &
PC-80
Reduction in
alkaline
frequency
Every
alternate dayWeekly once
Reduction in
MCF
replacement
Every 3 -4
daysEvery 20 days
Reduction in
CIP frequencyMonthly once
Every 60 days
(and more)
This paper plant has a raw water RO. Due to high microbial contamination in the incoming stream, this RO plant was struggling with severe bio-fouling related concerns.
• Raw water and treated water savings in the
tune of 18,000 m3/ annum
• 5 times improvement in MCF life has led to
savings of 15K USD per annum
• Handling of aggressive chemicals reduced by
50% - annual impact is ~ 16K USD
CH-2031Energy savings is also significant –
could not be captured due to
mechanical limitations
Trial Summary – GC (Waste Water)
▪ CIP interval extended by 100%
▪ MCF life improved by 50%
▪ Total annualized saving $30,100/year
▪ Ecolab revenue of 88K USD @ 78% GMAfter
Before
Customer Impact SPI Economic Results
Increase in WW treatment by 30K
M3/annum - Increase in recycled
water by 14K M3/annum
Savings of 11.2K USD / annum
Improved membrane and MCF lifeConsumable savings ~ 14K USD /
annum
Extend CIP interval - 200 man hours &
handling of CIP chemical reducedSavings ~ 5K USD / annum
CH-1949CN
Summary
Cooling Water Treatment
• Synergize the chemistry with Automation, helping to take informed decisions.
• It’s high time to reduce the blowdown discharged from Cooling tower and the quality of the blowdown discharged too.
• Increase the opportunity of Recycling, wherever possible.
Membrane Treatment
• Let’s no more live with the micro-bio fouling problem in the Membranes.
• New innovation on cleaners helps to retain the % recovery for longer period.
Questions & Discussion
Questions ?