Water Treatment Improves pYour Bottom Line

DAVE PICOU – WATER CARE SERVICES DIVISION

JOHN SCHULTZ – TEXTILE CARE DIVISON

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Ecolab SummaryEcolab SummaryBoiler Operating CostsGas versus Electric Costs to Make SteamGas versus Electric Costs to Make SteamBoiler Damage From No Water Treatment ProgramPre-treatmentPre treatmentChemical TreatmentExcess Operating Costs From No Water Treatmentp gReducing Your Total Operating CostsQuestions and Answers

Ecolab, Inc.co ab, c

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.g y p g

Boiler Operating CostsBoiler Operating Costs

Electric Versus Gas Costsect c e sus Gas CostsELF is the Energy Loan Fund – data collected from the US EPA web-siteELF is the Energy Loan Fund – data collected from the US EPA web-site

Electric Boiler Savings in Alabama?

Electric Boilers Require Water Treatment Too!Treatment Too!

Fire Tube CorrosionFire Tube Corrosion

CorrosionCorrosionProblem: Oxygen PittingProblem: Oxygen PittingSolution: Scavenge all the oxygen from the boiler feedwater before it

enters the boiler.Problem: Low pHSolution: Maintain the pH of the boiler water between 10 0 and 11 5Solution: Maintain the pH of the boiler water between 10.0 and 11.5.

Scale DepositionSca e epos t o

Boiler Pre-treatment – Why i it d d?is it needed?

Under heat and pressure, Deposition & Corrosion are magnified. gFor this reason, the water used in the process must be treated both mechanically and chemically to prevent damage to the boilerboiler.

Pre-Treatment Removes S l F i H dScale 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 ironAlso handles up to ≈ 0.2 ppm iron

Exchange Ca/Mg ions for Na ions

Resin

Ca

NaResin

Hardness RemovalMg

Na

Chemical TreatmentTreatment chemicals include:

conditioning chemicals for scale controlalkalinity booster for corrosion preventiony poxygen scavenger to prevent corrosion and pittingamines for condensate return line corrosion control

Remove Scale On-LineWith P i i Pl ™With Precision Plus™

Improves heat transfer and energy savingsenergy savingsClean up a dirty boiler on-lineAvoid the expense of off line Avoid the expense of off-line cleanings

Do You Know ALL Your C t ?Costs?

You know your natural gas costsYou know your natural gas costsWhat you are paying for a scaled boiler?What About Water Costs? (Birmingham AL)What About Water Costs? (Birmingham, AL)

City Water – about $2.50 per 1,000 gallonsSewer charge – about $5.00 per 1,000 gallonsBOD, TSS, phosphate, and heavy metals surcharges – vary and can be expensiveBOD, 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?Are you inspecting your boilers?

Heat Transfer Inefficiency C tCosts

A 300 HP boiler operating at 100% load requires 10,043,700 BTU/Hr or 60,262,200

Scale Scale Gas Required Extra Fuel Cost Due toBuild Up Inefficiency (K, cu ft) Scale (@ $8.00 K, cu ft)

cubic feet of natural gas per year to produce ~8500 lb/Hr of steam at 100 psig..

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

50 HP Boiler Increasing C l f 1Cycles from 5 to 15

Total Savings $35 512Total Savings - $35,512$5,199 – sewer$2,262 – city water$28 051 natural gas$28,051 – natural gas

Based on:city water: $2.50 per 1,000 gallonssewer charge: $5.00 per 1,000 gallonsnatural 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

CondensateCondensate

Condensate is very valuable. It still contains much of heat used to d th t d it i f f i l t i t produce the steam and it is free of mineral contaminants.

It is important to capture as much condensate as possible and return it to the boiler for reuse.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.

Boiler Inspectionso e spect o s

Inspections lead to ll ki d f fi diall kinds of findings

Boiler Inspections

Should be conducted annuallyannuallyMost often required by insurance carriers

Questions and AnswersQuestions and AnswersSoftener

StSteam

Deaerator Boiler

Condensate Receiver Blowdown

Ecolab Points of Contactco ab o ts o Co tact

David S Picou: Water Care Specialist AlabamaDavid S. Picou: Water Care Specialist - Alabama

Cell phone: (256) 466-5388

E-mail: david.picou@ecolab.com

John J. Schultz: Director, Integrated Laundry SolutionsJohn J. Schultz: Director, Integrated Laundry Solutions

Cell number: (708) 308-6152

E il j h h lt @ l bE-mail: john.schultz@ecolab.com