crm summary - rti services · rti developed the custom resin management (crm) program as a way to...

CRM Summary

RTI developed the Custom Resin Management (CRM) program as a way to help our customers see the economic value in maintaining their resin. CRM is a 3 Phase Program: Phase I Our customer sends in resin samples from their vessels. RTI analyzes the resin for salt split, total capacity and TOC. We then clean the resin and re-analyze it illustrating the “before” and “after cleaning” results on a formal report presented to the customer. Phase II RTI will look at historical throughput data provided by the customer. This will show if there are any trends we should be concerned with. RTI will then perform a Run Extension test. In order to run this test, the before and after resin samples are taken to the lab where they undergo a bench scale test which simulates a run. This will tell the expected increase in throughput from the fouled resin to the cleaned resin. This will be given as a % increase on the formal report presented to the customer. RTI then uses the % increase for our next report, Predictive EconoTrac. This report uses throughput to determine how much the water plant is spending to operate the system currently compared to how much they will spend to operate the system once the resin is cleaned and throughput increases. Phase III The final phase is to calculate the Return on Investment (ROI) from the project. Traditionally, RTI expects our customers to see a payback in 6-8 weeks based on the water plant’s lower operating costs. Lastly, once all the reports listed above are complete, RTI will furnish a plan to implement the CRM program. This plan will detail exactly what is recommended based on the analysis as well as the price to complete the project.

A Custom Collection of Information & Resources Tailored for Your Water Plant Needs…

Custom Resin Management Program

Because WATeR Makes the Difference™

Phase 1 System Questionnaire: Provides a complete overview of the water plant including the water source, number of trains, volumes of resin, throughput and any operational issues at the plant. This is the foundation for the resin maintenance program.

Resin Samples: Procure an actual resin sample from the beds to use for analysis and throughput extension testing. Resin Analysis: After the resin is received, RTI will perform a comprehensive analysis of the resin for basic health, organic and metals fouling, salt split and total capacities, plus particulates.

Client: Custom Resin Management (CRM) Program Better Than Simply Resin Cleaning… A Complete Water Treatment Strategy The NEW CRM Program is an innovative, tailored way that RTI can help you address your water purification needs. To get started, we need some information. Please take a moment to answer this short survey about your facility.

• What is the water source? o Well—indicate depth:

[ ] <100 ft. [ ] >100 ft.

o Surface—choose type: [ ] Lake [ ] River

o Municipal—indicate municipal source: [ ] Back to well [ ] Surface

o Other—enter type: _______________

• Number of trains: _______________

• What are the resin bed sizes? o Cation: ___________ ft3/vessel o Anion: ___________ ft3/vessel o Mixed Bed: ___________ ft3/vessel

• Who is the manufacturer of the resin? Enter manufacturer name(s): __________________

• Enter name & product # of resin (e.g., Amberlite IR-120)

[ ] Cation: _____________________________________________ [ ] Anion: _____________________________________________

• When was the resin purchased?

CATION ANION [ ] 1 year ago or less [ ] 1 year ago or less [ ] 1-3 years ago [ ] 1-3 years ago [ ] 4-6 years ago [ ] 4-6 years ago [ ] more than 6 years ago [ ] more than 6 years ago

• Do the trains run to chemical break or is there a set point? (please circle your answer)

Customized System Survey

• If there is a set point, why is the throughput set and why not go to chemical break? _____________________________________________________________________ _____________________________________________________________________ o Do you change the set point if the resin is replaced? [ ] yes [ ] no o Would you consider changing the set point if the resin were cleaned? [ ] yes [ ] no • Are there times when the regenerations stack up? [ ] yes [ ] no • Are there times when water production is less than the demand due to short runs? [ ] yes [ ] no • What is the throughput of each train? Enter throughput: ____________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ • Has the throughput dropped significantly since the resin was new? [ ] yes [ ] no • When was the last time the resin was removed and the vessels completely inspected? Enter date: _______________________ • Enter the system GPM: _______________________ • Enter gallons per cubic foot: _________________________ • What is the DI water used for?

[ ] Boiler (please specify header pressure: _______( PSIG) [ ] Process

Thank you for taking the time to complete this survey. The information you’ve provided will help us to create a customized plan for your resin management. Please return this survey any of these 3 ways: 1 – email it to us at [email protected] 2 – Fax it to us at 215-322-2250 3 – Mail it to us at the address below.

Recirculation Technologies, Inc. Suite 230 CenterPoint Office Center 626 Jacksonville Road Warminster, PA 18974 Ph: 215-682-7099

Recirculation Technologies, Inc.626 Jacksonville Rd., Ste 230Warminster, PA 18974215-682-7099rtiservices.com

Report Date:

Anion ResinSample Data Southern Power Plant Cleaning: week of

Procedure: Cleaning: Anion

Before After Spec. NewColor Very Dark Brown Light Yellow Light Yellow Light GoldSilt None None None None

Organic Fouling Very Heavy Light Light None

Analysis: Before After % Increase Spec. New

Salt Split 19.9 20.8 4% 25

Total Capacity 21.3 23.8 11% 25

Before After % Removal Spec. New

TOC 2860 369 87% <50

Before After

Comments:

(1) Anion resin health is determined by the salt split and total capacities. This resin is in good condition and will furnish many more years of useful service life if the organic fouling issue is attended to.(2) The level of fouling was very heavy; the "action" point where TOC starts to cause operating problems is 1500 ppm. Organics can cause short runs, long rinses, and high conductivity during service. (3) The resin responded very well to the ReStore + cleaning. (4) We look forward to working with the plant on the performance of the demin system after the cleaning.

Recirculation Technologies, Inc.626 Jacksonville Rd., Ste 230Warminster, PA 18974215-682-7099rtiservices.com

Report Date:

Cation ResinSample Data Southern Power Plant Cleaning: week of

Procedure:

CationBefore After Spec. New/Clean

Backwash Yellow Yellow GoldAppearance No Coating No Coating No Coating

Silt None None None

Analysis: Before After % ChangeGrams per Cubic Feet

Ca 184 1 99%

Mg 18.7 1.1 94%

Ba 0.5 0.1 80%

Fe 1.1 0.6 45%

Al 4.1 5.9 -44%

Moisture, % 50% 45% 45-55%

Before Cleaning After Cleaning

Comments:

(1) Cation resin health is measured by way of the moisture content. As cation resin ages or is destroyed, the moisture content increases until the resin starts to deform under pressure. This increases the vessel DP, and can lead to channeling and short runs. This resin is in excellent condition except for the internal hardness fouling.(2) RTI has discovered that cation hardness fouling prolongs the removal of acid from the resin during the cation final fast rinse, producing an acid tailing effect. This has little or no impact on the operation of the cation itself, but can seriously interfere with the anion. The anion uses cation effluent during its final rinse and the presence of the extra acid from the tailing effect can prematurerly use up anion capacity even before the vessel goes on line. Thus, the cation fouling problems shows up as an anion performance problem.(3) The cleaning quite effectifvely lowered the hardness fouling.



Phase 2 Throughput Analysis: RTI will review the throughput of the water plant by train based on data provided. A one-year time span is recommended to cover seasonal changes.

Run Extension Test: This is a test designed to demonstrate the ability of RTI to increase the throughput of anion resins with ReStore +™. The test is a side by side comparison of the plant resin sample before and after a cleaning with ReStore +. The test will provide the expected potential increase in throughput on strong base anion resin.

Predictive EconoTrac™: A proprietary software program that will track the monthly operational costs of the water plant. The predictive EconoTrac™ is designed to demonstrate the cost savings the plant could expect to see if the resin is cleaned by RTI. EconoTrac is based on the actual plant regen protocol and the results of the run extension test.


Southern Plant

City, SC

Demineralizer Throughput Analysis

The mill submitted throughput data in the form of DCS print outs for the year from 2/25/09 to 2/25/10. The graphs were scanned into a J-peg format and then digitized with GrabIt software. This program transforms graphs back into X/Y data sets in Xcel, where can then be further displayed and analyzed. Here the X is the date and the Y values are individual vessel throughputs. We found that displaying the graphs in conventional Xcel style was highly informative over the original DCS graphs, which used such a high degree of Y-axis (throughput) compression that meaningful structure was almost lost.

Cation Throughput Below is a composite of the throughput in 1000 gallons for Cation #1. The heavy blue line is a linear curve fit to the data set.

Universal Paper Cation #1

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General conclusions from the cation throughput analysis:

(1) A very wide scatter in the data indicates high variation among operators as to how the system should be run, and/or

(2) Inconsistent regenerations both between vessels and for a given vessel (3) Gradual decline in performance

Operation of the system can be stabilized by Operator Training, but if there are systemic problems, such as a poorly performing acid dilution skid, then that kind of problem should be resolved before training the operators for consistent performance. There could also be an underlying cation fouling problem which is exacerbating some of the other problems here. An analysis of Cation #1 last August confirms the presence of heavy particulate fouling, which can increase the operating DP of the vessels. High DP is a prelude to channeling, which shows up as shortened, highly variable run lengths, precisely the pattern seen here. We recommend a professional cleaning of this resin to remove the foulants.

Anion Throughput

Below is the throughput graph for Anion #1 at the mill. The heavy blue line indicates a linear curve fit for the periods in question.

Universal Paper Anion #1

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The pattern of the general drop-off in throughput is consistent with organic fouling for the following reasons:

• The drop-off is gradual, rather than sudden • The drop-off seems to have started in September, when fall rains often flush out

organics into the surface water supplies Granted the drop-off is not uniform across the system. That could reflect different usages of the vessels by the operators, different day-by-day changes in organic loading, different regeneration practices between the vessels. The high degree of scatter in the throughput seems to occur throughout the past twelve months and does not seem particularly associated with the organic fouling, although some vessels show sharp drop-offs in throughput, a phenomenon recent since last fall. The bottom-line conclusions here are the following:

(1) The overall performance of the anion system is clearly being strongly impacted by organic fouling. This can be remedied by a cleaning of the resins.

(2) The performance of a given vessel is subject to several factors which contribute to the high variability. This can be remedied by a Technical Audit of the system to uncover the source(s) of the variation, as well as Operator Training to have everyone “on the same page” as far as how to manage the system.

► We strongly urge the mill to sample the anion (and cation) vessels. Authentic samples will allow RTI to assess the condition of the resin, identify if there are capacity problems, and try test cleaning protocols on the resin. We have been very successful in restoring cation and anion resin back to “as new” operation. We have had particular success with the ReStore + procedure for handling organic fouling on anion resins.

3

Run Extension Test RTI has developed a sensitive test to measure the effect of an increased availability of strong base capacity in resins cleaned by ReStore +. Extensive prior testing of resins from field cleanings has consistently shown an increase in operating capacity of the cleaned resins. The run extension test measures the increased throughput expected from cleaning the resin with ReStore +. The new test also uses a realistic field dosage of caustic for the regeneration, rather than the very high levels of caustic used in the lab to measure ultimate strong base capacity. The original and cleaned resins were regenerated side by side with a caustic dosage of 6 lbs/ft3, rinsed to <10 μS conductivity, and then challenged with a dilute salt solution to measure the strong base capacity of the resins. The conductivity results are shown below. Note the ability of the cleaned resin to treat considerably more solution before reaching exhaustion (which is identified as approaching the starting conductivity value, shown in red).

Southern Power Plant – Anion D

Starting Conduct

In a study like this, which goes back to baseline, the break through point is the midpoint in the curve. The visual midpoints are shown for each curve by the colored arrows pointing down. Comparing the two, the before-cleaning sample broke at 175 ml, the after-cleaning sample broke at 235 ml. This represents a gain of 34%. That is, all other factors being equal, cleaning the resin with ReStore + should result in a 34% increase in field throughput. This directly translates into a 34% drop in operating costs, due to the decreased number of regenerations. We note that Anion D has the least organic fouling in the system. For RTI, William E. Bornak, VP Technology

Plant Info Train Detail

Plant name: Southern Power PlantTrain

Caustic injection

rate (lbs/min)

Caustic per

regen (lbs)

Acid injection

rate (lbs/min)

Acid per regen

(lbs)

Date

Cleaned

Address: 1 3,984 3,360 2/1/2010

City: Sweeny 2 3,984 3,360 2/1/2010

State: TX 3 3,984 3,360 2/1/2010

Zip: 4 3,984 3,360 2/1/2010

5 3,984 3,360 2/1/2010

Cost of Caustic ($ per ton): $300

Caustic %: 50%

Cost of Acid ($ per ton): $100

Acid %: 93%

Optional Parameter Required Parameter

*Please input EITHER the Injection rate or the Total for both caustic and acid.

1 Recirculation Technologies, Inc.

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Remove Outliers

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Southern Power Plant EconomicsTrain_5

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Southern Power Plant CostsTrain_5

$ Caustic $ Acid $ Total


Start Date: End Date:

1/1/2010 2/1/2010 3/1/2010 4/1/2010 5/1/2010 6/1/2010 7/1/2010 8/1/2010 9/1/2010 10/1/2010 11/1/2010 12/1/2010

Totals Max Cost: $240,773 Monthly Cost $240,773 $178,860 $178,860 $178,860 $185,739 $199,498 $206,377 $213,256 $227,014 $233,894 $247,652 $261,411

Monthly Savings $0 $61,913 $61,913 $61,913 $55,034 $41,275 $34,396 $27,517 $13,758 $6,879 ($6,879) ($20,638)

Cumulative Savings $0 $61,913 $123,826 $185,739 $240,773 $282,048 $316,444 $343,961 $357,720 $364,599 $357,720 $337,082

Train_1 Start Date: 2/1/2010 Monthly Cost $48,155 $35,772 $35,772 $35,772 $37,148 $39,900 $41,275 $42,651 $45,403 $46,779 $49,530 $52,282

Max Cost: $48,155 Monthly Savings $0 $12,383 $12,383 $12,383 $11,007 $8,255 $6,879 $5,503 $2,752 $1,376 ($1,376) ($4,128)














**User may override these values

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Southern Power Plant Savings

Monthly Cost Savings Cumulative Savings

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Phase 3 ROI: RTI will calculate the return on investment based on the above tests and water plant economics.

Program Implementation: After analyzing all the above data, RTI will recommend a plan specifically designed to meet the needs and resolve the issues of the water plant. The plan includes the cost of cleaning the resins; free resin sampling valves for each vessel; a free, one-day technical audit of the design, operation, and regeneration protocol used at the water plant; and one year of EconoTrac™ support.


ROI Southern Power Plant

Current Annual Operating Costs $2,880,000 Future Operating Costs $2,552,154 Initial investment $80,000

Cost Savings from Project

Month 1 ($18,078) Month 2 $43,826 Month 3 $105,739 Month 4 $160,773 Month 5 $202,048 Month 6 $236,444 Month 7 $263,961 Month 8 $278,719 Month 9 $284,598

It will take approximately six weeks to recoup your investment of $80,000 for the resin cleaning, this is based on increased throughput from maintaining the resin. The project will net total operating cost savings of $284,598. This savings comes from the reduction in acid and caustic needed to regenerate the resin over the nine months.

SAMPLE IMPLEMENTATION

Date: April 7, 2010 Address: Southern Paper Mill 215 Highway 50 Birmingham, AL 36426 Contact: Craig Smith Re: CRM Program Implementation CRM Program Implementation Includes:

• Clean the anion resin of 2 units, holding approximately 350ft³ of resin each, out of vessel in its on-site trailer, for the removal of interior and exterior fouling, using ReStore + cleaning protocol

• Clean the cation resin of 2 units, holding approximately 350ft³ of resin each, out of vessel in its on-site trailer, for the removal of interior and exterior fouling, using ReStore CAS cleaning protocol

• Resin Sample Ports • One Day Technical Audit as follow up • One Year EconoTrac Report for water plant monitoring

It will require RTI to be on site for 3 days to clean resin as described above. The total cost to clean all the resin is $40,000, plus a 3% fuel surcharge that will be added to the invoice. ROI is expected to be 8 weeks based on increased throughput and low regenerant costs. See demurrage for additional costs, if any. The inspection of the vessels is gratis, at the request of customer, a service of RTI when cleaning resin. This pricing is turnkey and includes the cost of supervision, labor, travel, equipment and chemicals. Time Frame RTI has not put the work on its schedule. Once a date is agreed upon, we would appreciate a purchase order to confirm and hold the date, assign personnel and equipment and arrange for the timely delivery of chemical to the site.

1

All RTI field personnel have Basic +™ and confined space training and are current. We should require only site specific prior to starting work at the site. Once the site specific is complete RTI will come to the site, set up and take the first vessel the following morning. Demurrage: If the cleaning operation is interrupted at the request of the plant and out of the control of RTI, there is a demurrage charge of $500/hour, not to exceed a daily cost of $4,000. An interruption of two (2) hours or less, with a maximum of two (2) hours per day, engenders no demurrage. With an interruption exceeding two (2) hours, demurrage begins with a three (3) hour charge. This also applies to start of work in the morning when the RTI crew arrives. If the cleaning is interrupted or delayed at RTI’s decision, there is no demurrage charge. We look forward to serving you.

Sincerely, Maxine L. LeBouef Manager, Customer Service [email protected]

Enclosure (Utilities/Benefits) cc: Robert J. Finley, President [email protected]

John Finley, General Manager [email protected]

2

mailto:[email protected]

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crm summary - rti services · rti developed the custom resin management (crm) program as a way to...

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