Case Study: Solid Water Treatment System Solves Poultry Processing Plant Water Treatment Problems

Problem

A poultry processing plant in the southwestern U.S. was experiencing severe problems in its 3,500- ton ammonia refrigeration system due to poor water treatment practices.

Since the evaporative condensers were located on the roof, poultrya liquid chemical water treatment program was not considered practical by plant personnel due to accessibility concerns. Instead, a “pulsed power” non-chemical water treatment device was used to treat one of the seven evaporative condensers, while the remaining six systems were only treated by heavy manual bleed.  These practices were not effective and allowed heavy scale deposits to form on the evaporative condenser tubes, which resulted in high condensing pressure and increased energy costs. Severe corrosion also occurred, which significantly reduced the life span of the evaporative condensers. The plant was considering an expensive coating to help avoid premature replacement of the corroded system.

Analysis

Although proven technology, plant personnel considered a traditional liquid chemical water treatment program too difficult and dangerous to implement. They were concerned about the safety and handling requirements associated with transporting and storing hazardous liquid water treatment chemicals on the roof. The limited space available for drum storage around the evaporative condensers and in the compressor room was also an issue. However, the high maintenance and operating costs associated with the current ineffective water treatment practices, along with the potential for production losses, begged for a better solution.

To address these concerns, our national partner recommended APTech Group’s blended solid concentrates. With blended solid concentrates from APTech Group, water treatment chemicals are provided as non-hazardous solid concentrates in recyclable plastic bottles rather than liquid in drums. The solids are dissolved as needed into a small plastic reservoir using a dissolving board. The feed solution is then pumped into the system being treated, as is done with liquid chemicals.

 

 

Solutionallproducts

The plant implemented the recommended blended solid concentrate system. The dissolving boards were installed inside an enclosure located on the roof near the condensers, and the blended solid concentrates were provided in 11-pound bottles that can be easily transported to the roof as needed. The blended solid concentrate system has provided an effective and reliable water treatment program that helped remove energy-robbing scale deposits from the condenser tubes while also controlling corrosion to extend the system’s life and reliability.

The blended solid concentrate system from APTech Group along with service from our national partner provided the poultry processing plant with the recognized benefits of a high- performance liquid water treatment program but in a form that affords several additional benefits, including:

  • Simplicity of use (solid concentrate is easily moved throughout the facility and product loading only requires handling a single bottle)
  • Reduction of splash and spill concerns
  • Elimination of drum handling, storage and disposal
  • Ideal for use in hard-to-reach locations
  • Reduction of fuel and greenhouse gas emissions associated with product delivery

The blended solid concentrate system by APTech Group provided an innovative and effective water treatment program that solved a difficult handling, space and storage issue for a hard-to-reach location.

Case Study: APTech Group’s Blended Solid Concentrates Program Helps Meet Corporate Sustainability Initiatives

Problembeverage-plant

A large soft drink bottling plant in the Midwestern U.S. was presented with corporate sustainability initiatives for their 300,000 square foot manufacturing facility, which prompted them to evaluate a range of measures to reduce their facility’s environmental impact. The refrigeration and boiler systems were targeted since they are major consumers of energy and water.

Analysis

The plant’s 1,600 ton ammonia refrigeration system consists of three evaporative condensers and eight compressors. A 550-HP boiler system provides 85 psi process steam. Reliable and efficient operation of these systems is required for plant production.

Our national partner’s liquid water treatment program was providing good results, but chemical storage, handling, and disposal presented sustainability concerns. APTech’s Solid Water Treatment System was introduced to address this.

With the APTech Solid System, chemicals are provided as solid concentrates rather than liquid in drums. APTech Solid Concentrates are dissolved as needed into a small plastic reservoir using the APTech dissolving board. The feed solution is then pumped into the system being treated.

Solution

The APTech Solid System was installed and provided the proven results of the previous high-performance liquid program. Furthermore, the APTech  System enabled the facility to meet its corporate sustainability initiatives by

  • Reducing splash and spill concerns
  • Reducing fuel and greenhouse gas emissions associated with product delivery
  • Eliminating drum handling, storage, and disposal
  • Reducing packaging requirements and landfill waste

The APTech Solid Water Treatment System proved to be an innovative technology that provided environmentally responsible water treatment and helped achieve corporate sustainability initiatives.

Case Study: Blended Solid Concentrate System Simplifies Water Treatment Pharmaceutical Facility

Problem

A pharmaceutical facility in the Southeastern U.S. used liquid chemicals in their four cooling towers. Due to limited space around the cooling towers there was great difficulty moving large drums of liquid product to the point of use. The cooling towers had to be hand fed several times a week due to the space constraints as well as lack of proper feed and control equipment. Furthermore, the cooling towers were not being properly treated for corrosion and microbiological fouling. The facility wanted to replace their problematic program with one that eliminated heavy drums and provided a feed system that would fit within their limited space.  pharma

Analysis

During the fall of 2012, one of APTech Group’s national partners suggested switching from liquids to a blended solid concentrate system by APTech Group. The compact size of this system would fit within the small space around the cooling towers and eliminate the need for hand feeding product. Automated controls were recommended to ensure proper chemical feed to handle the corrosion and microbiological fouling problems.

Solution

The blended solid concentrates from APTech Group and automated controllers were installed for each cooling tower in and have provided the proven results of a liquid program while allowing the facility to eliminate several challenges and safety hazards. This system’s simplicity of use

  • Reduced splash and spill concerns
  • Eliminated drum handling, storage, and disposal
  • Provided automated feed for a corrosion inhibitor, oxidizing biocide, and non-oxidizing biocide to enable proper treatment

The blended solid concentrate system from APTech Group proved to be an innovative technology that solved a space and storage issue for a hard to reach location while improving upon the overall water treatment program results.

Case Study: Cooling Tower Cleaning Job Leads to Blended Solid Concentrate Installation at Printing Facility

Problem

A 400,000 square foot printing facility in Ontario Canada with two cooling towers (approximately 1,200 tons) was operating using liquid water treatment products. The program was not being serviced well by the water treatment provider: the liquid chemical drums were often left empty, the area where the drums were kept was messy, and scale deposits had formed in the cooling towers.  printing

Analysis

The service team from one of APTech Group’s national partners initially contacted the printing facility to survey the cooling towers for cleaning. They performed the work over a holiday weekend to avoid unnecessary shutdown of the facility. A sales representative in the area assisted the crew with the tower cleaning to ensure the work was completed within a single day. The customer was very happy with the cooling tower cleaning and our national partner’s rep took the opportunity to suggest a blended solid concentrate water treatment program to replace the current liquid program.

Solution

The customer was interested in the blended solid concentrate system and agreed to have the installation performed. He was pleased with the change from a liquid to a solid program and especially appreciated the system’s simplicity of use.

  • Reduced splash and spill concerns
  • Eliminated drum handling, storage, and disposal
  • Provided a much cleaner and neater chemical storage area

The blended solid concentrate system from APTech Group provided an effective water treatment program that has kept the freshly cleaned cooling tower running efficiently.

Case Study: Blended Solid Concentrate System Simplifies Water Treatment in Large Property Management Facility

Problem

A large  property management facility in Ontario, Canada had a system filled with dirt and used liquid chemicals in their four cooling towers. Due to limited space in the control room there was great difficulty moving large drums of liquid product to the point of use. The cooling towers had to be hand fed several times a week. The facility wanted to replace their problematic program with one that eliminated heavy drums and provided a feed system that would fit within their limited space.property-management

Analysis

An APTech Group national partner suggested switching from liquids to APTech Group’s blended solid concentrate system with an advanced feed and control system. The compact size of this system would fit within the small space and eliminate the need for hand feeding product.

Solution

The blended solid concentrate system was installed allowing for accurate chemical feed and control leading to an increase in water and chemical savings of $23,000 over three years. Heat exchanger cleanliness and efficiency was also achieved during this period.  APTech Group’s blended solid concentrates provided the proven results of a liquid program while allowing the facility to eliminate several challenges and safety hazards. The system’s simplicity of use

  • Reduced splash and spill concerns
  • Eliminated drum handling, storage, and disposal
  • Provided automated feed for a corrosion inhibitor, oxidizing biocide, and non-oxidizing biocide to enable proper treatment

The blended solid concentrate system from APTech Group proved to be an innovative technology that solved a space and feed issue for a hard to reach location while improving upon the overall water treatment program results.

Case Study: APTech Group’s Blended Solid Concentrate System Simplifies Water Treatment in Large Casino Resort

Problem

A large casino resort in Ontario, Canada used liquid chemicals in their cooling towers. The liquids were kept in large storage tanks on the fifth floor and drums of chemical had to be hauled to the fifth floor feed station and transferred into the storage tanks. The storage tanks took up too much space to be located closer to the tower lines. The liquids were pumped via a long bypass loop to the cooling towers, however the line frequently clogged and needed regular cleaning, posing a safety issue for employees.  casino

Analysis

An APTech Group national partner took over the water treatment program and suggested switching from liquids to the APTech Group’s blended solid concentrates. The compact size of this install would allow the feed station to be located directly in front of the tower lines, considerably shortening the bypass loop and eliminating the hassle of drum transportation and storage. An eductor feed system was recommended to replace chemical pumps for inhibitor and biocide feed. This would enable a greater feed rate to accommodate the large system and also allow for balanced feed throughout the temperature changes of all four seasons.

Solution

The APTech Group blended solid concentrates and eductor were installed and provided the proven results of a liquid program while allowing the facility to eliminate several challenges and safety hazards. The system’s simplicity of use

  • Reduced splash and spill concerns
  • Eliminated drum handling, storage, and disposal
  • Provided solid concentrate cases that were easily moved throughout the facility on a hand truck or cart

The blended solid concentrate system from APTech Group proved to be an innovative technology that solved a space and storage issue for a hard to reach location while improving upon the overall water treatment program results.

Case Study: University Cooling Towers and Boilers

Situation: A large eastern university had been using liquid water treatment chemicals to treat the water in their cooling towers and boilers for a number of years. But in 2001, the university was faced with implementing a host of OSHA safety mandates associated with their water treatment program.  Among these were retention areas, eye wash stations and showers. Estimates for these improvements ranged from $30,000 to $70,000 each for the Main Campus and Medical Campus.

Solution: Prior to making a decision about funding the expensive OSHA mandated safety improvements, the university facility management team decided to do a one-year test to compare several water treatment methods. Solid water treatment chemicals from APTech Group was among the alternatives included in this test.

After a one year testing, the university decided to go with a solids water treatment program, with APTech Group solid products comprising a major component of the program. The following APTech Group solid products are being utilized as part of the program:

For Cooling Towers:

  • C20V-C – for scale reduction; contains Versaflex One, PBTC & HEDP phosphonate, HPA & POCA corrosion inhibitors, terpolymer, azoles; good for high hardness, temps and stressed systems

For Boilers:

  • BCO1 – oxygen scavenger containing catalyzed sodium sulfite
  • B-ACMDC-C – steam line, triple component Morpholine, Cyclohexylamine & DEHA amine product
  • B-ALK+ –  alkalinity builder containing a solid form of Hydroxide Alkalinity
  • B301-C – scale inhibitor for soft water, low-level phosphate-polymer and alkalinity builder

Results: With nine years of experience and performance data in hand, the results of the switch to the solids focused program on the main campus and subsequent addition of the Medical Center have been nothing short of dramatic.  The APTech Group solids program along with equipment control has produced significant savings; reducing total costs on water treatment by 80% compared to the previous liquids program. Plus, because of the transition, the university did not have to implement the OSHA mandated work, saving the university up to an additional $140,000 in investments for showers, eye wash stations and the like.

In addition to the financial payback, the university has benefitted from a significant reduction in required maintenance of equipment, meaning longer equipment life. For example, the boilers are inspected twice per year, with good results every time. In fact, according to one facility management team member, “the inspector said I’ve never seen boilers look this good.”

And finally, the facility management team has been impressed with how environmentally friendly the new system is. Comments from team members include:

  • “I was totally against it (changing to solids), but now I’m totally convinced.”
  • “Much easier to use than carrying or lifting drums.”
  • “The solids program is cheaper, more efficient, easier to operate.”

ct-and-boiler

Case Study: Large Commercial Center

Situation

A very large commercial center had been using liquid water treatment products for many years in its cooling system. The technical results had always been acceptable. In recent years, however, the management team of the commercial center had become more and more focused on environmental issues.

Solutionoffice

The management team worked with the water treatment partner to add sustainability areas of interest to the traditional water treatment and maintenance objectives to form a comprehensive, multi-directional series of goals for the new program.

To address these topics of interest, the facility management team worked with their water treater partner to install APTech Group blended solid concentrate water treatment products for their five cooling tower and chillers, each with 1,000 tons of refrigeration, with slightly soft municipal water for make-up.

Results

With the blended solid concentrate product implementation, cycles of concentration were increased from 5 to 10, which enabled significant water savings and reduced chemical usage. Additionally, PLC controllers were installed to allow for automatic, ongoing corrosion measurement without the need for corrosion coupons and automatic control of the number of operating chillers needed at any one time. The system uses “bleed and feed” method to deliver the blended solid concentrate water treatment products.

Over the following six months after installation, the blended solid concentrate product installation provided as good as or better system protection as the previous system for the following categories of measurement as tracked by the commercial center’s facility management team. Included among these are the more sustainability focused metrics as established by and of importance to the facility management team, based on the 5-star rating system the team developed.

Case Study: Process Cooling Tower Application

Situation:

Barnes Aerospace, headquartered in Windsor Connecticut, has a manufacturing facility located in Southern Ohio which uses four cooling towers (total capacity – approximately 400 tons) in support of their manufacturing and production processes.

This Barnes Aerospace location had been utilizing liquid chemical treatment for their cooling towers, but they were interested in making a change to a more sustainable, environmentally friendly solution, as this is a direction their headquarters had been espousing.

Solution:

productThe APTech Group solid chemical program was focused on meeting the following business goals:

  • Maintain the same or better level of system cleanliness
  • Eliminate chemical drum handling/disposal
  • Reduce inventory and related storage issues
  • Reduce costs and environmental concerns of, and need for containment areas

The installation of the new APTech Group solids system was completed in early July, 2010 along with a closed loop cleanup. A Tower Descaling was performed in late August on one of the cooling towers.

The following products are being used as part of the APTech Group solids program at Barnes Aerospace:

  • C20V-C – for scale reduction; contains Versaflex One, PBTC & HEDP phosphonate, HPA & POCA corrosion inhibitors, terpolymer, azoles; good for high hardness, temps and stressed systems
  • CPEN-C –  dispersant and penetrant; DTEA II (Non-EPA Registered)
  • Biobrom C-100 – DBNPA – EPA registered Biocide

Case Study: Federal Building Success

Situation

One of APTech Group’s partners began treating systems at a large federal facility in January, 2008. At the time of start-up, the cooling towers and chillers were six months old. The commercial center had just replaced 2 x 800 ton chillers and a 300 ton chiller with two new 900 ton chillers and a 400 ton chiller. They also replaced the cooling towers with new stainless steel Marley cooling towers. After only six months of operation, the cooling tower fill had accumulated 1/4″ of scale in some areas (Photos 1, 2). So much scale had built-up inside the fill that it began to crumble and stack up at the bottom near the basin due to the weight (Photo 3). The basin of the tower, below the water line, and the cooling tower hot distribution decks were also very scaled (Photo 4).

olc

Solution

It wasn’t until the following year that our partner was able to see the inside of the chillers.  They began using the OLC-STX in the beginning and then later switched to feeding the OLC-C from a solid feeder.

Results

They began seeing results almost immediately. Within a couple of months, the scale got thinner inside the fill. After about five months, the scale that had formed on the cooling tower basin had also started to become thin and even began flaking from the basin. After a little over one year the cooling tower fill was almost completely clean and the basin scale had gone from 1/4″ in thickness to eggshell-thin and flaking away (Photos 5, 6, & 7).

olc1

APTech’s partner was present when the chillers were opened for an annual inspection the following year. Although it was evident that the scale deposits were being removed, the two 900 ton chillers were still badly scaled. These two chillers alternate, so they are not always running. The 400 ton chiller is the most active. It is loaded almost constantly and is even used as the after-hours chiller. Our partner was pleased to see it completely clean when it was opened for PM and inspection. It looked amazing! Due to the 400 ton chiller’s percent load, the OLC-C was able to remove the deposits and scale build-up.

GSA was extremely impressed, to say the very least. Our partner has since been awarded 14 additional buildings due largely in part to the success we have had in with the towers and chillers at this commercial center. It has been over five years since the OLC product started being used at this facility. Although there are some small areas on the basin that still have thin scale present, the towers are in great shape.