Culligan International. Sustainability Applications for Industry

Transcription

1 Culligan International Sustainability Applications for Industry

2 Why are we here? Introduce you to Culligan Industrial Provide an initial overview of Matrix Solutions Introduce new technologies Discuss possible sustainability solutions Determine if future discussion are needed to validate possible ROI projects 2

3 Culligan Fast Facts US and Worldwide Support and Expertise Largest Pure Water play company Over 1400 dealerships around the world - local service and support Service companies like Coca-cola, Toyota, John Deere, IBM and others Over 600 North American locations 200 U.S. patents 3

4 Culligan s Commercial & Industrial Heritage Culligan has a commercial and industrial water treatment history dating back to the 1950 s

5 Culligan s Industrial Matrix Solutions Modular Advanced Water Treatment Systems Pre-Treatment Membrane Technology Polish Storage Distribution Control, Instrumentation, Pre-Packaging and Skid Mounting Culligan Matrix Solutions is based on building blocks Large array of applications covered with just a few components Simple, check the box system design concept Or provides highly custom approach from the platform Each piece pre-engineered to work interchangeably Pick the appropriate size, and all the pieces easily interconnect Great platform to implement our technology & third party s Maximizes potential to capture spend

6 Industrial Plants Many Corporations have proactively developed Water & Energy Sustainability programs These programs have resulted in the development of plant metrics on water and energy use. Water and energy savings goals are often established as part of their sustainability goals The benefit of these actions has resulted in published savings Culligan s technologies offer a holistic approach to water system solutions are in line with your sustainability needs 6

7 Typical Water Uses Industrial Plant Boiler & Clean Steam Feedwater Cooling Tower Makeup Main Plant Feed Other Food Rinsing Bottle Washing Can Rinsing Truck Washing Crop Irrigation Tea Production Reclaimed Water Wastewater Treatment CIP Make Up Product Water Purification 7

8 Potential Plant Opportunities Culligan Technology Customer Benefit RO Boiler Make Up Energy ROI Softener Brine Reclaim > 20% salt savings Hot Water Carbon Sanitization Energy, Water and Improved Quality Mixed Oxidants (MOS) for CIP Energy, Water, Chemical & Production ROI MOS for Bottle Washing Chemical savings MOS for Inlet water & Cooling Tower Potential chemical savings High Efficient UV Energy, Footprint & Life Cycle ROI Nano / RO Brine Reclaim 50% water savings Gray Water Reclaim Water Savings Chlorine tolerant RO membranes Improved Life Cycle Costs Ingredient Water Better Yield / Better Quality 8

9 Boiler Savings Water, energy and chemical savings with boilers 9

10 RO Feed - Boiler Opportunity Plant Load Condensate Softener Reverse Osmosis Q Steam Rate DA Vent Make Up Steam Loss Deareator RO Reject Feedwater Storage Tank Plant Boiler(s) Blowdown 10

11 RO Make Up for Boilers Manufacture of Pet Food flavors Case Study Savings Energy $33,800/ year Savings Chemicals $12,500/ year Capital Costs: $38,000/ year Steam directly injected in product 50% Condensate Return 540 BHP Average Production 10.7% Blowdown $1.00/ Therm We have seen cases with savings as high as $300,000/ year 11

12 Softener Brine Reclaim Brine recovery and reuse 12

13 Culligan Softener Brine Reclaim System Sample Brine Discharge Curve Brine curve Brine Strength This system utilizes the excess salt brine needed to complete the resin regeneration and recycles this excess brine back the brine tank Cycle 2A Cycle 2B Cycle 2C Reclaim back to brine tank Finish Slow Rinse To Drain Time Brine Draw discharge to drain Slow Rinse to drain Advantages Average salt savings of 25-40% and up to 75%. ROI in salt savings justifies adder of brine recovery unit Reduction in waste water and salt discharge. Regeneration lockout isn t needed Dilution time can be minimized On multiple softener systems multiple brine tanks aren t needed Easy to switch back to non-reclaim May qualify for LEED credits 13

14 Brine Reclaim Retrofit Single Tank System 14

15 Hot Water Carbon Systems Non-chemical sanitizations

16 Hot Water Carbon Sanitizations 16

17 HOT Carbon - Benefits More thorough microbiological kill Meets tight bacteria limit of <10 CFU s per 10 ML Sanitization frequencies can be reduced (up to 80%) Faster bed heating Complete sanitation in 4 hours Reduces water usage by 75%. Eliminates potential for contamination from plant steam Completely automated (up to 6 vessels) Hot Water will not remove THM s from carbon only steam will 17

18 Mixed Oxidants Generators On-site disinfectant generation 18

19 Culligan - MIOX Culligan and MIOX have teamed together. MIOX provides the technology and Culligan provides sales, installation and maintenance support. Worldwide with over 1,500 Miox installations Treatment capacity over 6 billion gallons per day 600 Culligan Dealers in North America 19

20 On-site Generation Gives Power to the User + Salt + Water Power Disinfectant The amount you need, when and where you need it Eliminates storage and handling of hazardous chemicals 20

21 Basics of On-Site Generation Chemistry Anode Reaction (+ Side) 2 ClCl2 + 2 ecathode Reaction (- Side) 2 H2O + 2 eh2 + 2 OHChlorine Hydrolysis Reaction Cl2 + H2O HOCl + Cl- + H+ HOCl OCl- + H+ 21

22 MIOX On-Site Generation Process 22

23 Benefits of MIOX CIP Enhanced productivity via reduced CIP time Exceptional microbial control even at high ph Reduced chemical and energy costs Reduced water footprint Safe, green process - 80% reduction in carbon emissions from transport - 3-to-1 storage footprint reduction - No cleaning/disposal of empty chemical containers 23

24 Mixed Power Oxidants Have Enhanced Oxidation Ox i d at i on S t r eng t h Mixed 7 Oxidants 6 HYPO Oxidant 24 Chlorine-based, but more powerful disinfectant than conventional chlorine MIOX optimizes chemistry performance with a superior cell design and more energy applied Chlor-oxygen species: H2O + NaCl >> Disinfectants have been used for years No O3 or ClO2 EPA does not require DBP monitoring

25 On-Site Generation Is Safest for the Environment 80% reduction in carbon emissions from transport 3-to-1 storage footprint reduction No cleaning or disposal of empty chemical containers On-Site Generation is Safest For The Environment 25

26 Enhanced productivity via reduced CIP time Traditional Process: Effective, but more steps wastes time and money. CIP utilizing MIOX cuts the process by approximately 40%, reducing downtime and saving money. 26

27 CIP Application Criteria & Results Biological criteria: Total Count < 25 CFU/mL Coliforms 0 CFU/100mL Yeast and Fungus < 10 CFU/100 ml Mixed oxidant results: Total Count: Pass in 100% of trials Coliforms: Pass in 100% of trials Yeast and Fungus: Pass in 100% of trials 27

28 MOS Corrosion Study Analysis of the corrosion rates of mixed oxidant solution 70 ppm (CIP solutions 4050 ppm) Two types of stainless steel materials used: 304 SS and 316 SS Study protocol was developed using ASTM guidelines Fresh oxidant made every hours The largest corrosion rate observed was 0.46 mils-per-year (mpy) The corrosion rate for 304 SS without anticorrosion agents was 0.38 mpy The corrosion rate for 316 SS without anticorrosion agents was 0.24 mpy Corrosion was only evident at or above the waterline 28

29 Mixed Oxidants in Botle Washing Provides a Major Savings in Chemical and Energy Costs: Prior bottle washing operations used a multistep process where the active component of cleaning was four 5300 gal tanks of 3-4% NaOH heated to ~60 C Pilot testing indicates that this process can be replaced by one that uses three tanks of MOS at ~1000 ppm FAC and one tank of 1% NaOH at room temperature Left: Dirty bottle returned to the factory with dirt and mold covering the bottom of the bottle Right: Bottle cleaned with Mixed Oxidants with an FAC of 790 ppm 29

30 Economic Impact of Switching to Mixed Oxidants Based on fi lling the washer daily with 1,000 ppm Mixed Oxidants and double water usage, switching to Mixed Oxidants will reduce monthly costs by $9,919. Estimated Monthly Bottle Washing Costs Current Operation Chemical Monthly s NaOH usage 47,763 H2O 5,875 kl BacterRP 392 kg $/L 2.74 $/kg ALF kg MOS N/A kg Projected MOS Costs Monthly Monthly Unit price Monthly usage 0.35 $/kg cost $16,51 3, $/kg $1, $1,219 11, $1,074 kl 392 kg $/L 2.74 $/kg $2, $/kg $1, kg 3.16 $/kg $1,235 N/A N/A 1800 kg $1.51 / $4,000 Unit price 3 Total Monthly Cost: $20, kg cost $1,074 Total Monthly Cost: $10,122

31 Microorganism Kill in Simulated Cooling Tower Waters was Superior Using MOS Or g ani sms ( C F U / ml ) (10 minutes exposure) Larry Barton, PhD, University of New Mexico "Disinfection of Simulated Cooling Tower Water - March 4,

32 Bottling Plant Installation: Cali, Colombia Calcium hypochlorite replaced in 2007 with MIOX hypochlorite generated on site Water from the municipality and from a well site is mixed Disinfectant must be added Disinfection is for the following: Before MIOX Beverages (dechlorinate afterwards) o o o After MIOX 32 Juice Carbonated beverage Bottled water Filter backwash Cooling towers

33 Thermal Chicago Cooling Tower Algae and Biofilm Issues Solved 33 Basin cleared of algae and biofilm within 2 weeks; remaining biofilm cleared in 4 weeks No degradation of scale and corrosion inhibitors (phosphonates, polymer or azole) Low corrosion mild steel corrosion rates at 0.9 to 1.4 mpy, yellow metal corrosion at <0.1 mpy Excellent microbial control even at elevated ph Easy to operate and maintain Eliminated 28,500 lbs of sodium hypo and isothiazolin and subsequent disposal of 51 chemical drums

34 UV Disinfection UV power enhancement 34

35 UV Chamber Forces Light Onto Bacteria Polished stainless chamber wall UV Reflector Water 4% Lamp 100% Bacteria 20% Conventional Chamber Low UV Reflection 35 UVS Chamber >99% UV Reflected

36 Chamber Wall Reflectance > 99% is Necessary for maximum benefit 20 UV Sciences UVS Chambers >10X better than Conventional! 80% chamber coverage Relative intensity inside chamber 97% chamber coverage 100% chamber coverage Baseline (Stainless Steel Chamber) Other High Reflectivity Chambers - 2.5X better than Conventional 5 Conventional Chamber Reflectance

37 75% Decrease in Operating Footprint Aquafine 50 GPM UVSI 50 GPM 37

38 Lower Cost to OEM & End User $35,000 $30,000 $25,000 $20,000 AQ20R60 $15,000 UVS438 $10, gpm $0 Capital Cost Op. Cost (10 Yrs.) 50% Less Capital Cost 90% Less Operating Cost 38

39 Nano / RO reject Reclaim Saving water on membrane rejection

40 PFD Brine Reclaim Example Existing Nano Units Chemical Feed 367 GPM Product 275 GPM Inlet Supply Tank Product 367 GPM 275 GPM Nano Product Storage 185 GPM of Combined Reject Water New Brine Reclaim Unit Product Reject Storage 100 GPM Utility Water Storage 50% System Utilization Water Savings: 26 million Gallons /yr Dollar Savings: $244,000/yr GPM Reject to Drain

41 PFD Brine Reclaim Example Chemical Feed Existing RO Units Inlet Supply Tank 176 GPM Product 132 GPM 44 GPM of Reject Water RO Product Storage New Brine Reclaim Unit Product Reject Storage 22 GPM 22 GPM Reject to Drain Saved 11,500,000 gallons /yr of city water Boiler Blowdown reduced from 25% to 2% Netting: $61,000 per year in energy savings 50% Boiler Chemical savings 41 Boiler Make Up Storage

42 Gray water recycling Opportunities when dealing with gray water

43 Recycle Water Opportunities $ Sanitary Gray Water Irrigation H2O Utilities / Cooling H2O Chemical Make Up Cleaning Rinse H2O Process $$$ 43

44 Dual Loop Cooling System 44

45 Gray Water/ Recycle Water Equipment Tubular UF Spiral wound Micro, UF and Nano Filtration 45

46 Culligan s Novotel Hotel Gray Water Project 46

47 The Basis of Design for the Culligan Grey Water/Blow Down Treatment and Recycle Plant Quantity and Quality of Effluents: Grey Water: Total Grey Water Generated 230 m3/day Total Suspended Solids 100 mg/l Total Dissolved Solids 800- mg/l BOD 70 mg/l COD 100 mg/l Operating Temperature oc ph 89 Cooling tower Blowdown: Total Blow down Generated 40 m3/day Total Dissolved solids 1800 mg/l Total Suspended solids 50 mg/l Total Blended Waste water 270 m3/day (49 GPM) 47

48 Chlorine Resistant Membranes (CRM) Avoiding RO membranes degradation 48

49 Major RO Membrane Issues 49

50 Chlorine Degradation Mechanism 50

51 Municipal Water Membrane Results 0.4 to 1.0 ppm chlorine in feed water Sample 1: STD TFC membrane with pre-carbon Sample 2: STD TFC membrane no pre-carbon 51 Sample CRM1: CRM membrane no pre-carbon

52 CRM Testing Conclusion CRM RO membrane can extend membrane life 2-5 times where current RO s membranes are seeing premature failure due to chlorine/oxidation attack Pricing is competitive to TFC membranes There can be a slight trade off on water quality and production. Each application requires a Computer evaluation to ensure quality and quantity of water produced is acceptable 52

53 Process or Ingredient Water Higher purity water could improve yields, provide consistent quality and have a return on investment Example A leading Bread manufacture used a blended RO water stream to control inlet batch water quality Result - while improving yields and product quality, flour and yeast consumption were significantly reduced Total plant savings of $120,000 / year on a $60,000 investment Similar results in Pickle Manufacturing 53

54 I hope we have demonstrated that Culligan understands Industrial Plant needs We have the technology, products and services you need to: Reduce water consumption Save energy Improve product quality Improve safety and compliance Reduce onsite footprint requirements And have provided some ideas to help meet your sustainability goals. 54

55 Ed Orvidas Culligan International Director North America C&I Sales 9399 W. Higgins Rd, Suite 1100 Rosemont, IL Office: (847) Cell: (847) Fax: (847)