Culligan International

Culligan International
Sustainability Applications for Industry
Why are we here?
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Introduce you to Culligan Industrial
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Provide an initial overview of Matrix Solutions
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Introduce new technologies
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Discuss possible sustainability solutions
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Determine if future discussion are needed to
validate possible ROI projects
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Culligan Fast Facts US and Worldwide
Support and Expertise…
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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
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Culligan’s Commercial & Industrial Heritage
Culligan has a commercial and industrial water treatment history
dating back to the 1950’s
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
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Large array of applications covered with just a few components
Simple, check the box system design concept
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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
Industrial Plants
Many Corporations have proactively developed Water &
Energy Sustainability programs
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These programs have resulted in the development of plant
metrics on water and energy use.
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Water and energy savings goals are often established as
part of their sustainability goals
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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
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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
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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
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Boiler Savings
“Water, energy and chemical savings with boilers”
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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
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RO Make Up for Boilers
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Manufacture of Pet Food flavors Case Study
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Savings Energy
$33,800/ year
Savings Chemicals $12,500/ year
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Capital Costs: $38,000/ year
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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
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Softener Brine Reclaim
“Brine recovery and reuse”
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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
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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
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Brine Reclaim Retrofit
Single Tank System
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Hot Water Carbon Systems
“Non-chemical sanitizations”
Hot Water Carbon Sanitizations
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HOT Carbon - Benefits
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More thorough microbiological kill
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Meets tight bacteria limit of <10 CFU’s per 10 ML
Sanitization frequencies can be reduced (up to 80%)
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Faster bed heating — Complete sanitation in 4 hours
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Reduces water usage by 75%.
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Eliminates potential for contamination from plant steam
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Completely automated (up to 6 vessels)
Hot Water will not remove THM’s from carbon
only steam will
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Mixed Oxidants Generators
“On-site disinfectant generation”
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Culligan - MIOX
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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
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On-site Generation Gives Power to the User
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Salt
+
Water
Power
Disinfectant
The amount you need, when and where you need it
Eliminates storage and handling of hazardous chemicals
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Basics of On-Site Generation Chemistry
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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+
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MIOX On-Site Generation Process
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Benefits of MIOX CIP
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Enhanced productivity via reduced CIP time
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Exceptional microbial control even at high pH
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Reduced chemical and energy costs
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Reduced water footprint
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Safe, green process
- 80% reduction in carbon emissions from transport
- 3-to-1 storage footprint reduction
- No cleaning/disposal of empty chemical containers
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Mixed Power Oxidants
Have Enhanced Oxidation
Ox i d at i on
S t r eng t h
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10
9
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Mixed
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Oxidants
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HYPO
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5
4
3
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2
1
0
Oxidant
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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
On-Site Generation
Is Safest for the Environment
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80% reduction in carbon emissions from transport
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3-to-1 storage footprint reduction
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No cleaning or disposal of
empty chemical containers
On-Site Generation is
Safest For The Environment
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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.
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CIP Application – Criteria & Results
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Biological criteria:
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Total Count < 25 CFU/mL
Coliforms 0 CFU/100mL
Yeast and Fungus < 10 CFU/100 mL
Mixed oxidant results:
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Total Count: Pass in 100% of trials
Coliforms: Pass in 100% of trials
Yeast and Fungus: Pass in 100% of trials
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MOS Corrosion Study
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Analysis of the corrosion rates of mixed
oxidant solution – 70 ppm (CIP solutions 4050 ppm)
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Two types of stainless steel materials used:
304 SS and 316 SS
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Study protocol was developed using ASTM
guidelines
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Fresh oxidant made every 24-48 hours
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The largest corrosion rate observed was 0.46
mils-per-year (mpy)
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The corrosion rate for 304 SS without
anticorrosion agents was 0.38 mpy
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The corrosion rate for 316 SS without
anticorrosion agents was 0.24 mpy
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Corrosion was only evident at or above the
waterline
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Mixed Oxidants in Botle Washing Provides a
Major Savings in Chemical and Energy Costs:
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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
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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
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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-83
392 kg
MOS
N/A
kg
Projected MOS Costs
Monthly
Monthly
Unit price
Monthly
usage
0.35 $/kg
cost
$16,51
3,978
0.35 $/kg
$1,376
0.00021
$1,219
11,750
0.00021
$1,074
kL
392 kg
$/L
2.74 $/kg
$2,437
3.16 $/kg
$1,235
392 kg
3.16 $/kg
$1,235
N/A
N/A
1800 kg
$1.51 /
$4,000
Unit price
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Total Monthly Cost: $20,041
30
kg
cost
$1,074
Total Monthly Cost: $10,122
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, 1996
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Bottling Plant Installation: Cali, Colombia
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Calcium hypochlorite replaced in
2007 with MIOX hypochlorite
generated on site
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Water from the municipality and
from a well site is mixed
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Disinfectant must be added
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Disinfection is for the following:
Before MIOX
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Beverages (dechlorinate afterwards)
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After MIOX
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Juice
Carbonated beverage
Bottled water
Filter backwash
Cooling towers
Thermal Chicago Cooling Tower
Algae and Biofilm Issues Solved
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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
UV Disinfection
“UV power enhancement”
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UV Chamber Forces Light Onto Bacteria
Polished stainless
chamber wall
UV Reflector
Water
4%
Lamp
100%
Bacteria
20%
Conventional Chamber
Low UV Reflection
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UVS Chamber
>99% UV Reflected
Chamber Wall Reflectance > 99% is
Necessary for maximum benefit
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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)
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Other High Reflectivity
Chambers - 2.5X better
than Conventional
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Conventional Chamber
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0.7
0.75
0.8
0.85
Reflectance
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0.9
0.95
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75% Decrease in Operating Footprint
Aquafine
50 GPM
UVSI
50 GPM
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Lower Cost to OEM & End User
$35,000
$30,000
$25,000
$20,000
AQ20R60
$15,000
UVS438
$10,000
500 gpm
$5,000
@99%UVT
$0
Capital Cost
Op. Cost (10 Yrs.)
50% Less
Capital Cost
90% Less
Operating Cost
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Nano / RO reject Reclaim
“Saving water on membrane rejection”
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
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85 GPM Reject to
Drain
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
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Boiler
Make Up
Storage
Gray water recycling
“Opportunities when dealing with gray water”
Recycle Water Opportunities
$
Sanitary Gray Water
Irrigation H2O
Utilities / Cooling H2O
Chemical Make Up
Cleaning Rinse
H2O
Process
$$$
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Dual Loop Cooling System
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Gray Water/ Recycle Water Equipment
Tubular UF
Spiral wound Micro,
UF and Nano Filtration
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Culligan’s Novotel Hotel Gray Water Project
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The Basis of Design for the Culligan
Grey Water/Blow Down
Treatment and Recycle Plant Quantity and Quality of Effluents:
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Grey Water:
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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
25 – 40 oC
pH
8–9
Cooling tower Blowdown:
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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)
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Chlorine Resistant Membranes (CRM)
“Avoiding RO membranes degradation”
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Major RO Membrane Issues
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Chlorine Degradation Mechanism
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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
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Sample CRM1: CRM membrane no pre-carbon
CRM Testing Conclusion
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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
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Process or Ingredient Water
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Higher purity water could improve yields, provide
consistent quality and have a return on
investment
Example
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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
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I hope we have demonstrated that…
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Culligan understands Industrial Plant needs
We have the technology, products and
services you need to:
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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.
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Ed Orvidas
Culligan International
Director North America C&I Sales
9399 W. Higgins Rd, Suite 1100
Rosemont, IL 60018
Office: (847) 430-1367
Cell: (847) 757-5940
Fax: (847) 430-2367
E-Mail: [email protected]
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