Presenter:

J. ANAND

Advancement & Digitalization in Cooling Water Treatment to have Informed Decision making

& Avoiding Microbiological fouling to improve the asset life and

Quality in Reverse Osmosis Membranes.

Agenda..

• Cooling Water Treatment Digitization• Traditional approach

• How Digital to help CWT automation

• What’s new in Market?

• Advancement in Cooling water treatment..• Acid free programme

• How it works & case studies

• Membrane Treatment• How to handle microbio fouling?

• What’s new in controlling micorbio fouling..

Cooling Water Treatment DigitizationDRIVE COMPELLING CUSTOMER BENEFITS; TRANSFORM HOW WE DO BUSINESS

5

CUSTOMER

AUTOMATION

Data Monitoring

and EnVision

GLOBAL

KNOWLEDGE

Traditional Approach to Cooling Water?

4

• Stress is the total of everything which can cause a loss of cooling efficiency in the system

• MECHANICAL Heat exchanger design & operation

• High temperatures or heat fluxes, low flow velocities

• Long Holding Time Indexes (HTI’s)

• OPERATIONAL Cooling water chemistry & control

• Poor or failed control/testing or dosing equipment

• CHEMICAL Raw water chemistry

• Variable water quality

• Phosphate added by water utility

• Suspended Solids

• Dependency on Water analysis,

• Pinks & Blues

• Grab Samples once per day, not representation of the day

• Reactive approach

• Mechanical & Operational Parameters

• The chemistries dosed on Ad-hoc basis

• The dosages not linked to real time corrosion & scale in system

• Not considering the above stress in the system

• Operations negligence on critical parameters etc.

What automation to do?

5

YOUR COOLINGSYSTEM

Best-in-Class Automation

Modeling &Optimization

On-Site TechnicalServices

Chemicals &Equipment

System Assurance

Center

CustomerData

Services

Providing visibility

via dashboards

to track system

performance and

benchmark

A team of experts

provides 24/7/365

monitoring of your

system

World-class service to

ensure we DELIVER

value to the customer

Technology to

DETECT upset

conditions

Proprietary algorithms

to DETERMINE

corrective actions

Continuously

monitoring:• Conductivity

• pH

• Turbidity

• Flow rates

• Corrosion

• Scaling potential

Deliver

Energy

SavingsWater

SavingsExpert Support

Asset

Longevity

Corrosion

control

Fouling prevention

maximizes heat

transfer efficiency

Higher cycles

minimizes water

discharge

Experts watch your

systems 24/7 for your

peace of mind

• Real-time scale and corrosion measurement with fluorescent Tagged Polymer

and proprietary Nalco Corrosion Monitor

• Direct measurement of bio-demand with bio-reporter technology

• Other system conditions monitored through conductivity, pH, ORP, temperature,

and turbidity

• Alarm conditions are reported instantly via email

Detect

Corrosion Microbiology Alarms on System UpsetsScale

Determine

• Built-in control algorithms determine chemical dosage and blow down response

• Proprietary dynamic algorithms based on Nalco Scale Index and Nalco Bio-

Index respond to variable stresses

• Remote monitoring by the Nalco 360 Expert Center enables proactive response

to system conditions

Special Algorithms Root Cause & Actions

Automation & Digital as a “solution”

COMPONENTS WITH DESCRIPTORS

Fingerprinting the Operational

parameters…

OMNI SimulatorSimulates the exact conditions (skin temperature

and water velocity) of the critical asset allowing to:

+ Quantify/Identify the type of fouling.

+ Quantify/Identify the type of corrosion.

+ Identify BioFilm events.

+ Corroborate effectiveness of passivation

procedures.

3D TRASAR Technology: Continuously monitors and detects changes in

system demand, determines potential causes of

variability, and delivers corrective action to bring

key system parameters under control:

+ Optimization of cooling water treatment,

+ Water chemistry KPIs,

+ Automation

+ Best in class chemistry.

The combination of 3D TRASAR Technology, ECOLAB3D and OMNI™ Total Heat Exchanger Performance platform creates an unique visibility of the impact of

cooling water on the operation of your critical assets locally and across the enterprise.

HX Audit: A stress profile is created for each exchanger and Mechanical,

Operational and Chemical factors are analyzed that may impact

reliability or cost.

Real Time Monitoring: Performance Monitoring based on:

+ Trending of U-Value

+ U-Value

+ Water Velocity

+ Skin temperature

+ Heat flux

+ Approach Temps.

+ Cleanliness Factor.

+ Fouling Resistance.

Enterprise Visibility of critical Assets, Benchmark Performance of

Critical Assets, System Assurance Center, Value Tracking,

Improvements Impact.

+100 engineers monitor and give actionable Insights about Heat

exchanger performance and actions.

ON Site ExpertiseNalco Local service account reps and NALCO corporate account

managers will maintain tracks of dashboards to create and maintain

value.

Cloud Analytics

How to take informed decisions with

data…

OMNI simulator

SAC

Performance

Dashboards

Cloud Analytics

Advancement in Cooling Water

Treatment…

Cooling Water Treatment…

Generally of Phosphonates (HEDP/PBTC etc.)

as sequestrants & Ortho-Phosphates for

corrosion control.

The Blowdown discharged from CT’s rich in

Phosphates, which is food material for

Microbiology to grow.

Which turns the Public sewer, lakes with algal

bloom.

Demands lower pH operation to keep away

Ca3(PO4) scales – Acid dosing & corrosion

issues

Drivers for Non-PO4 Technology

Why Non-PO4 Programme

Regulatory compliance on P

Non acid or less acid

Multiple makeup sources or high

fluctuation in water quality

Regulatory compliance on zinc discharge

Historical zinc fouling issue

Calcium Phosphate scaling issue

Recycle cooling blown down with RO

Reduce biocides dosing

What’s Non-PO4 Programme?

• Cooling water direct discharge, save cost

for waste water treatment

• Using Carbonate – natural inhibitor to

support corrosion control

• Less/none acid - safety; low scaling

pressure, save energy and improve productivity

• Avoid scaling from Ca-PO4

• Avoid the interference of Ca-PO4 on RO

membrane while recycling cooling water

• Reduce nutrient for microbial, Better managing

microbio growth.

• Easy control

Model application

Provide programs;

Highlight risk

3D TRASAR Optimizer

m• Maintenance

Chemicals

3DT platform

Generate and

communicate timely,

affordable,

proprietary,

actionable

information

enVision

Organize and

Manage

Information,

Remote control

eROI & SAC

TCO tools (reduced

corrosion rate , save

water, reduced WWT cost)

24/7 remote expertise,

turning information into

results.

Non – PO4 program Offering

Pearl

Offering

enVision

Monitorin

g&

Control

Chemicals

Optimizer

eROI

& SAC

OMNI

Link water to

process KPIs.

Chemical Program Transfer from P Based

Current Program

No P ProgramNon-P under ‘Tag polymer’ control

pH Control needs to be adjusted

No Azole based product to be configured

Makes the chemical dosing simple

Cooling Tower Operation

Ac

id

Case Study from Field Trials with Non-PO4 chemistry

Case Study: Chemical plant. enVision Data for

New CPP Cooling Tower

Shutdow

n

Current COC

Higher COC

pH control maintained throughout the trial period

Steel corrosion rate reduced over time during trial

period

Product dosing maintained through ‘Tag’ control

~ 40 ppm

Conductivity increased over time due to COC

increase

Chemical plant - Water Savings and COC

Improvement

Blowdown savings > 450 m3/day

Sr. GM, Utilities & Energy, :

Post implementation of Pearl program for “COC : Cycle Of

Concentration” increase water treatment program w.e.f.

20th Apr’18, we have satisfactorily achieved the COC of all

the 11+1 Nos. of identified CT’s, wherein round the clock key

parameters online monitoring system i.e. 3D TRASAR has

been installed. During last 3 months, the COC levels has

been increased gradually from 6.6 to 9.2, wherein the CT

Sump make up water savings of @ 450+’ KLD has been

achieved.

Case study: Soft Water as Make up

16

Background:

• Chemical plant with strict regulatory limit on P discharge in this region

• System heat loading fluctuation

• To use recycled water as makeup to save water

• Old plant with pipeline leakage

Problems:

• Require non-P for P discharge compliance

• Big water fluctuation in system

• Multiple makeup sources with high microbial risk

• Corrosion control challenge

Solutions:

• New No P program of Nalco Water

• 3D TRASAR controller & enVision

Improvement:

✓ Can discharge CW blowdown directly to save WWT cost

✓ Use recycled water as makeup to save fresh water46653 tons/year

✓ Reduce general corrosion rate 30%

eROI:✓ Reduce cost for fresh water & WWT, save 22.8K

USD/year

✓ Extend asset lifetime, save 6.7K USD/year

✓ Reduce maintenance Manpower, save 1K USD/year

New No P program

6 weeks: 0.34mpy

3 months: 0.24mpy

NCM probe after 4

months:~0.1mpy

Trial startup

Large water fluctuation in system

Membrane Cleaning – New approach to

Microbio fouling

17

Different foulants in Membranes

Bio-fouling43%

Organic Fouling

15%

Colloidal Fouling

18%

Silica13%

Other Inorganics

6%

Coagulants5%

Bio & Organic fouling

leads to ~ 70% failure

across all end use

sectors

Advanced Microbial Management

Oxy membrane cleaner❑ Continuous dose or shock dose

❑ Acts before biofilm formed

❑ Removes existing biofilm

Biofilm can be developed in 24 hrs.

DBNPA ❑ Acts only on mature bio-film

❑ Microbes develop resistance

PermaDUO

Cell Population over Time

Advanced Benefits of Oxy membrane cleaner

• Dual stabilized biocide - compatible with polyamide RO membranes

• Two drum approach efficient bio-management

• Acts during microbe growth phase (proactive control)

• Can act on mature bio-films better than DBNPA

• Provides deep cleaning and thereby leading to complete removal

P

D

Trial Summary – India (Surface Water)

KPI BaselineWith PC-22 &

PC-80

Reduction in

alkaline

frequency

Every

alternate dayWeekly once

Reduction in

MCF

replacement

Every 3 -4

daysEvery 20 days

Reduction in

CIP frequencyMonthly once

Every 60 days

(and more)

This paper plant has a raw water RO. Due to high microbial contamination in the incoming stream, this RO plant was struggling with severe bio-fouling related concerns.

• Raw water and treated water savings in the

tune of 18,000 m3/ annum

• 5 times improvement in MCF life has led to

savings of 15K USD per annum

• Handling of aggressive chemicals reduced by

50% - annual impact is ~ 16K USD

CH-2031Energy savings is also significant –

could not be captured due to

mechanical limitations

Trial Summary – GC (Waste Water)

▪ CIP interval extended by 100%

▪ MCF life improved by 50%

▪ Total annualized saving $30,100/year

▪ Ecolab revenue of 88K USD @ 78% GMAfter

Before

Customer Impact SPI Economic Results

Increase in WW treatment by 30K

M3/annum - Increase in recycled

water by 14K M3/annum

Savings of 11.2K USD / annum

Improved membrane and MCF lifeConsumable savings ~ 14K USD /

annum

Extend CIP interval - 200 man hours &

handling of CIP chemical reducedSavings ~ 5K USD / annum

CH-1949CN

Summary

Cooling Water Treatment

• Synergize the chemistry with Automation, helping to take informed decisions.

• It’s high time to reduce the blowdown discharged from Cooling tower and the quality of the blowdown discharged too.

• Increase the opportunity of Recycling, wherever possible.

Membrane Treatment

• Let’s no more live with the micro-bio fouling problem in the Membranes.

• New innovation on cleaners helps to retain the % recovery for longer period.

Questions & Discussion

Questions ?