Water Treatment Improves Your Bottom Line DAVE PICOU WATER CARE SERVICES DIVISION JOHN SCHULTZ TEXTILE CARE DIVISON

Transcription

1 Water Treatment Improves Your Bottom Line DAVE PICOU WATER CARE SERVICES DIVISION JOHN SCHULTZ TEXTILE CARE DIVISON

2 Agenda Ecolab Summary Boiler Operating Costs Gas versus Electric Costs to Make Steam Boiler Damage From No Water Treatment Program Pre-treatment Chemical Treatment Excess Operating Costs From No Water Treatment Reducing Your Total Operating Costs Questions and Answers

3 Ecolab, Inc.

4 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.

5 Boiler Operating Costs

6 Electric c Versus Gas Costs ELF is the Energy Loan Fund data collected from the US EPA web-site

7 Electric Boiler Savings in Alabama?

8 Electric Boilers Require Water Treatment Too!

9 Fire Tube Corrosion

10 Corrosion Problem: Oxygen Pitting Solution: Scavenge all the oxygen from the boiler feedwater before it enters the boiler. Problem: Low ph Solution: Maintain the ph of the boiler water between and 11.5.

11 Scale Deposition o

12 Boiler Pre-treatment Why is it needed? d? Under heat and pressure, Deposition & Corrosion are magnified. For this reason, the water used in the process must be treated both mechanically and chemically to prevent damage to the boiler.

13 Pre-Treatment Removes Scale 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 iron Exchange Ca/Mg ions for Na ions Ca Mg Resin Na Hardness Removal

14 Chemical Treatment Treatment chemicals include: conditioning chemicals for scale control alkalinity booster for corrosion prevention oxygen scavenger to prevent corrosion and pitting amines for condensate return line corrosion control

15 Remove Scale On-Line With Precision i Plus Improves heat transfer and energy savings Clean up a dirty boiler on-line Avoid the expense of off line Avoid the expense of off-line cleanings

16 Do You Know ALL Your Costs? You know your natural gas costs What you are paying for a scaled boiler? What About Water Costs? (Birmingham, AL) City Water about $2.50 per 1,000 gallons Sewer charge about $5.00 per 1,000 gallons BOD, 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?

17 Heat Transfer Inefficiency Costs A 300 HP boiler operating at 100% load requires 10,043,700 BTU/Hr or 60,262,200 cubic feet of natural gas per year to produce ~8500 lb/hr of steam at 100 psig.. Scale Scale Gas Required Extra Fuel Cost Due to 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

18 50 HP Boiler Increasing Cycles from 5 to 15 Total Savings - $35, $5,199 sewer $2,262 city water $28,051 natural gas Based on: city water: $2.50 per 1,000 gallons sewer charge: $5.00 per 1,000 gallons natural 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

19 Condensate Condensate is very valuable. It still contains much of heat used to produce the steam and it is free of mineral contaminants. t It is important to capture as much condensate as possible and 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.

20 Inspections lead to all kinds of findings Boiler Inspections s

21 Boiler Inspections Should be conducted annually Most often required by insurance carriers

22 Questions and Answers Softener Steam Deaerator Boiler Condensate Receiver Blowdown

23 Ecolab Points of Contact David S. Picou: Water Care Specialist - Alabama Cell phone: (256) david.picou@ecolab.com John J. Schultz: Director, Integrated Laundry Solutions Cell number: (708) john.schultz@ecolab.com h l