manage your water systems for cost control & reliability
DESCRIPTION
This presentation was given at the 2012 PFMA Expo in Milwaukee, WI. The presenter was Thomas Christman, the Vice President at Watertech of America, Inc.The purpose of the presentation is to serve as brief discuss about why it is important to manage the water used in boiler and cooling tower applications.TRANSCRIPT
Manage Your Water Systems forCost Control and System Reliability
Presented by:Tom Christman, Vice President
Watertech of America, Inc.
March 1, 2012
Why Manage Water?
• Sustainability• Cost Control• System Reliability
Why Manage Water?
Sustainability The ability of the earth to continue to
support human life. The responsible use of natural resources - Water.
Water Stressed Areas of the WorldWhy Manage Water? Sustainability
Why Manage Water? Sustainability
• More than one-third of all counties in the lower 48 states will likely be facing very serious water shortages by 2050. Natural Resources Defense Council
• The average American uses 150 gallons of water per day, while residents of the U.K. only use 40 gallons per day and residents of China use just 22 gallons per day. CBS News
• In northern China, the water table is dropping one meter per year due to over-pumping
• Every single day Arizona and parts of New Mexico use 300 million gallons more water than they get in renewable supply.
• The Great Lakes hold one fifth of the world's (and 95% of the United States') fresh surface water .The Great Lakes Compact includes the 8 states surrounding the Great Lakes and two Canadian provinces and bans the export of water to outsiders - even to other U.S. states.
• Worldwide demand for fresh water tripled during the last century, and is now doubling every 21 years.
Why Manage Water? Sustainability
Regional Water Demand“Many Wisconsin communities are already facing serious water supply challenges caused by increasing customer demand, declining groundwater supplies, and aging utility infrastructure. The number of communities facing water challenges is expected to grow in the coming years.”
“The Milwaukee suburb of Waukesha, its deep wells contaminated with radium, is seeking permission to tap Lake Michigan under a compact signed by the region's eight states in 2005.”
32.3
5.1
27.5
23.5
9
0.9 0.019
Public Supply
Domestic
Industrial
Irrigation
Non-irrigation Agricultural
Commercial
Mining
Wisconsin Water Use - 2005
1,710.13 Mgal/d
Wisconsin Water Use by Category
Wisconsin Population and Water Use
Wisconsin Water Use by Source
Wisconsin Water Use by Source
Cost Control Water Costs –
• Relatively inexpensive but going up at record rates Chicago's city council unanimously passed the 2012 budget
which included a 70% rate hike over the next four years
• Conservation efforts = Catch 22 -per unit costs go up
• Trend to raise prices to encourage conservation by environmental groups
• Change in pricing structure – higher rates for higher use Rather than encourage usage with lower rates for more usage
Why Manage Water?
The next “Liquid Gold”
Rates for large industrial usersWhy Manage Water? Cost Control
Location Water costUS $/1000 gallons
Sewer costUS $/1000 gallons
Total Water & Sewer CostUS $/1000 gallons
Seattle, WA $6.19 $13.74 $19.93
Portland, OR $3.65 $9.42 $13.07
Los Angeles, CA $3.00 $4.00 $7.00
Cincinnati, OH $1.84 $4.93 $6.77
Wausau, WI $1.54 $3.45 $4.99
Green Bay, WI $2.65 $2.31 $4.96
Milwaukee, WI $1.58 $2.69 $4.27
Madison, WI $1.82 $2.31 $4.13
Spokane, WA $0.95 $2.19 $3.14
Related Costs
• Reduced electricity & fuel• Better heat transfer and reduced usage
• Pretreatment costs – Salt, etc.• Water Treatment Chemicals• Wastewater chemicals• Labor
Why Manage Water? Cost Control
Why Manage Water? Cost Control
Boiler Energy Loss Due to Scaling
1/64" 1/32" 1/16" 1/8" 1/4" 1/2" 3/4" 1"0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%Energy L...
Scale Thickness
Efficie
ncy
Loss
Why Manage Water? Cost Control
System Reliability Fewer failures Reduced downtime Extended asset life Reduced Liability
Why Manage Water?
Why Manage Water? System Reliability
Without a proper chemical treatment program, Scaling and Corrosion will occur = equipment failures, increased downtime, shortened equipment life
Why Manage Water? System Reliability
Public health and safety• Legionella
How Do I Begin Managing My Water?System-Wide Audit
– Conducting a survey is extremely important because every facility is different!!!
– Do you know how much water your facility is using??? Do you know how much water each process uses???
“You Can’t Manage What You’re Not Monitoring”
Managing My Water – Flow Diagram
Managing my Water
In some industries, Boilers and Cooling water systems can account for up to 90% of the water use. There is a tremendous potential for water savings in these areas that converts directly to dollars saved to your bottom line!
Hospitals Meat Proc Dairy Petroleum/Coal
Paper/Pulp0%
20%
40%
60%
80%
CoolingBoilers
Percent Boiler/Cooling Water use as Total Water Usage
AutomationManaging my Water
Managing my Water
www.wteservice.com Data Logging and Communications
Access to reports from anywhere via
the internet Real time availability of operator logs
and service reports Immediate access to MSDS,
equipment inspections, test procedures, and training materials
Detailed E-mail alarm notifications
Multiple security levels for various users
Secure data storage creating a permanent record
Graphing package for tests and logging Time and date stamp test results Ability to export test data
Automated Data Collection
Managing my Water
Cycles of ConcentrationBoiler and Cooling Towers
• Build-up of the concentration of dissolved solids in recirculating water = “cycling up”
• Determine the maximum number of cycles of concentration to run w/o forming deposits– Your Water Treatment Supplier is responsible for
this.
Water Use and Your Recirculating Cooling Water System
Before: Tower @ 3 Cycles
Make Up
Evaporation
3,000 GPM Recirc Rate
30 GPM
15 GPM 45 GPM
400 uS
Controller
Setpoint
= 3 Cycles
1,200 uS
Annual Make Up
Annual Bleed
22.86 MG 7.56 MG
$43,094 $19,656
Make Up
Evaporation
3,000 GPM Recirc Rate
30 GPM
8 GPM 38 GPM
400 uS
Controller
Setpoint2,000 uS
Annual Make Up
Annual Bleed
19.15 MG 4.03 MG
$36,389 $10,483
= 5 Cycles
After: Tower @ 5 Cycles
Make Up Flow Make Up Cost Bleed Flow Bleed Cost
3 Cycles 22.86 MG $43,094 7.56 MG $19,656
5 Cycles 19.15 MG $36,389 4.03 MG $10,483
Savings 3.71 MG $7,514 (-15.5%)
3.52 MG $9,173(-46.7%)
Chemical / Misc Savings = >$10,000 per year
Total Savings = ~$27,000
Summary of Cooling Scenarios
Effective Ways to Increase Cycles of Concentration Recirculating Cooling
Water1.Automate chemical feed and tower bleed2.Soften the makeup water3.Feed acid for control alkalinity and pH4.Look for a better source of makeup water5.Install “side-stream” filtration for solids
removal
Water Use and Your Boiler Water System
Make Up Condensate
Feed Water
Blowdown
50,000 #/hr Steaming
Rate
Setpoint
3,500 uS
Controller
850 uS
SteamHeat Exchanger67,925 GPD 92,455 GPD
160,380 GPD
16,495 GPD
Annual Make Up
Annual Blowdown
23.77 MG 5.77 MG
$45,170 $15,010
360 uS
= 9.7 Cycles
Before58%
Make Up Condensate
Feed Water
Blowdown
50,000 #/hr Steaming
Rate
Setpoint
3,500 uS
Controller
850 uS
SteamHeat Exchanger32,120 GPD 119,565 GPD
151,686 GPD
7,801 GPD
180 uS
= 19.4 Cycles
After79%
Annual Make Up
Annual Blowdown
11.24 MG 2.73 MG
$21,360 $7,098
Make Up Flow Make Up Cost Blowdown Flow Blowdown Cost
9.4 Cycles 23.77 MG $45,170 5.77 MG $15,010
19.7 Cycles 11.24 MG $21,360 2.73 MG $7,098
Savings 12.53 MG $23,810 (-52.7%)
3.04 MG $7,912(-52.7%)
Fuel Savings = $40,000 / year
Total Savings = $92,000 per year125 psi boiler operating at 80% efficiency, 2012 city of Milw. Water cost, $4.50/MSCF gas cost, 160 oF condensate temp.,
Chemical Savings = $20,000 / year
Effective Ways to Increase Cycles of Concentration Boiler Water Systems
1. Automate chemical feed and blowdown2. Return as much condensate as possible3. Improve makeup water quality through
advanced treatment Reverse Osmosis, Demineralizer,
Dealkalizers
Questions?
www.watertechusa.com
For a copy of this presentation, see Tom Christman or contact him at