Professional Documents
Culture Documents
Gerhard Bingel
Sr. Industry Development Manager MENA 1
Treated Sewage Effluent (TSE)
Challenges and Opportunities in DC
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NALCO ‐ Global Presence
Solving Customer Problems On‐Site worldwide
North America Europe, Africa & Middle East Plant
Employees 4,790 Employees 3,015 Countries of
Plants 18 Plants 11 Operation
Asia/Pacific
Employees 2,285
Plants 13
Latin America
2008 Sales $411mm
Employees 1,680
Plants 6
70,000+ Customers
7,000+ Sales and Service Professionals
Essential
Expertise •Improve oil reservoir use efficiency
for Water, •Produce in extreme environments
Energy •Treat “opportunity” crudes
and Air •Clean production water
Nalco, the logo, tagline, and 3D TRASAR are trademarks of Nalco Company. 4
©Nalco Company 2011
Innovation
Nalco Research and Development
Discovering new ways to treat the water used in
industrial processes which contribute to the
sustainable development of customer operations:
•Chemical solutions
•Non-chemical solutions
•Technology design
Nalco has over 500 research staff & spends over €100M
a year on R&D, resulting in more then 2000 patents
Nalco Customer
R&D Capabilities Sustainability
• Process Knowledge • Process optimization
• Chemical Products
• Energy reduction
• Equipment
• Water use optimization
• Analytical Services
• Reduction of emissions
• Automation
5
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Nalco’s Mission & Vision Statement
Our Vision is to earn customers for life & enhance the lives of our employees while protecting
the planet.
Nalco, the logo, tagline, and 3D TRASAR are trademarks of Nalco Company. 6
©Nalco Company 2011
What We Deliver to Our Customers We
We believe
believe in
in closing
closing the
the loop
loop
• Performance
– We optimize critical systems and
processes to minimize resource
consumption, emissions & waste
• Peace of Mind
– We quantify our Customers’ environmental
improvements and economic payback
• Measurable Results
– We communicate our results using a
measurement system called Environmental
Return on Investment (eROI)
Enhanced Asset Reliability
Competitive
Advantage
Decreased
ROI Total Cost
Of Operation
Minimized
Environmental Improved
Impact Operating
Health & Safety What Customers Receive
Concerns Efficiencies
Nalco, the logo, tagline, and 3D TRASAR are trademarks of Nalco Company. 7
©Nalco Company 2011
GCC District Cooling ‐ The Success Story
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District Cooling ‐ Water Demand
The Industry Trend goes to Alternative Water sources
- away from Domestic water usage:
• TSE – Treated Sewage Effluent
• Sea Water Cooling
• Blow-down Recovery
• Zero Liquid Discharge
Calculations basis:
•5.5 m3/1000 TR.hr
•40% average load
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TSE production in GCC
People need comfort cooling and domestic water – and produce Waste water
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TSE as Makeup in DC – The PRO & CONs
Advantages Disadvantages
• Co$t reduction • Water chemistry/quality
– Municipal compared to direct – Corrosive
TSE gives a factor 5‐6 in cost – Formation deposits
reduction – Microbiology
– Polished TSE around 1,5‐2 • Fluctuations in Quality
• Availability • Acceptance
– Domestic demand too high
• System Adaptation
• Sustainability issue
requirements
• Allows water cooling in
regions of water scarcity • TSE supply issue
>> higher energy efficiency • CAPEX Investment
• Legislation compliance for Polishing option
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Treated Sewage Effluent as Makeup in DC
Direct TSE ‐> cost 18‐30% of DEWA Polished TSE ‐> cost 50% of
DEWA
• No CAPEX needed
• CAPEX approx. 7 AED/m3
• No equipment foot print
and operation needed • WT plant & maintenance
• COC 3‐5 – medium water needed
• Higher Chemical cost and • COC 8‐10 – low water
Automation needed but concentrate
• Possible discharge issue discharge
of CT blow down • Low chemical cost but
• Potential microbio issue corrosion inhib. needed
when un‐treated • Possible discharge issue
– as concentrate needs
to be discharged as well
• UF – RO best practice 12
Facts About use of TSE as Make Up Water
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Issues using TSE in Cooling Systems
Mechanical
SScc
sio
aall
rro
ee
Co
BioFouling
BioFouling Operational
Chemical
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Typical TSE Quality
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TSE Challenges
• Corrosion Æ High concentration agressive anions like
Chlorides, Sulphates and Ammonia
– Online corrosion monitoring and control of a combination of
patented inhibitors and copper protection with Trasar®
– Ammonia elimination
>>> CHILLER Manufacturers limits need to be adopted!!
• Deposits Æ High concentration of Phosphate + Hardness
– Online deposit/scale tendency monitoring and patented
dispersant for calcium‐phosphate precipitates
• Microbiology Æ Health Issues and Slime formation
– Bioactivity monitoring and Biocontrol program
– TSE Storage tank preservation
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How to meet the Discharge Limits
At Cycles = 3, Dilution water = 50 to 100% of System Blow Down
!
If Dilution is made by fresh Water, TSE will save ~70% of Fresh Water …
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Direct TSE vs. Polished TSE – The FINANCIALS
• DC system 10.000 TR – 6800m3/h RR, 61,8 m3/h evaporation
DEWA @ 6 COC
Treatment cost 311.770
Water consumption m3 649.116 A cost factor of 3‐5 for
Cost per M3 8,8 DEWA ‐ direct TSE
Total water cost 5.712.220
TCO 6.023.992
TSE POLISHED @ 10 COC
Treatment cost 183.139
Water consumption m3 601.023
Cost per M3 4 *not incl. CAPEX for RO/UF ~+3
Total water cost 2.404.094
TCO 2.587.233 + 1.803070 = 3,6 M
TSE 100% @ 3.8 COC
Treatment cost 813.245
Water consumption m3 734.088
Cost per M3 1.2
Total water cost 880.905
TCO 1.694.151
All in AED TSE Polished TSE 100%
SAVINGS to DEWA 3.436.758 4.329.841 Approximately a cost factor of 2
SAVINGS to TSE Polished - 893.082 is between Direct ‐ Polished TSE
Plus CAPEX for UF/RO
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Global Experience with TSE
The Water treatment company with a long track record on direct TSE use
• US Æ North Carolina University and other campuses
• California Æ Refineries
• UK Æ Power stations
• Middle East Æ District Cooling in UAE and Saudi
– Dubai Festival City since 2007
– KKIA Riyad International Airport 2010
– DAFZA Dubai Airport Freezone 2010
– Projects in progress: KAFD, Madinat Jumeira, Palm DC, DA,
Emicool, EMPOWER, AUH university, etc.
– Other GCC countries follow soon with DC development
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Case History 1 – DFC (Al Futtaim Eng.)
TSE as Makeup in District Cooling
• District Cooling System in Dubai – 35.000 TR
• Annual average of 12.000‐20.000 TR
• Copper enhanced tubes chiller – YORK
• DC plant works at 0,87‐1,0 KWh/TR total plant
• Changed from DEWA water to TSE water as
MU
• Implementation started in June 2007 with
small percentages of TSE
• Evaluation of the parameters resulted in 100%
unpolished TSE as make‐up in January 2009 till
present 20
DFC – TSE Water Qualities
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Stepwise Implementation of TSE
• Installation of 3D TRASAR®
• Blending TSE with DEWA
– 25% TSE
– 42% TSE
– 50% TSE
– 75% TSE
– 100 TSE
• Interpretation of data
– Change of setpoints of chemicals
– Decrease blowdown rate (Increase conductivity)
• Visual Inspection of Chiller
• Corrosion rates On‐line and via coupons
• Tube wall thickness measurement – Eddy current
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Case History DFC ‐ UAE
DEWA vs TSE for 12.000 TR Chiller System with 6 CT
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Test Results
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Test Results – Corrosion Rates
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Corrosion Rates
• Additional corrosion coupons in the outlet of the Chiller at highest
temperature. We analyzed 2 periods of 80 days and 92 days
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Inspection of Chiller May 2009 and 2010
• No Slime formation visible – no increased approach
• No Scale formation visible – no de‐scaling or brushing needed
• No Corrosion visible – on inspection and corrosion rate < 1 mpy
• Edit Current – Cu tubes wall thickness measurement – 0,3% replaced
from 2000 tubes only 6 showed more than 10% loss after > 18 months with TSE
Customer confirmed results were better than in previous period with DEWA water and
below typical standard replacement values
• All data was recorded to have statistical process control capabilities
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Conclusion by DFC – Al Futtaim Eng.
• Using proper monitoring and control makes it possible to use
water qualities that otherwise cause severe problems.
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Case History – Ryiadh Airport
SAUDI Oger ‐ KKIA
• DC system – 35 m3/h max. evaporation
• Copper tubes – TSE 600‐800 µS/cm – COC4.5‐5
– TH: 150 ‐ Cl: 100 ppm – PO4: 0,5 ppm – NH4: 2 ppm
• Changed from RO permeate to direct TSE
water
• Implementation started in June 2010 with
100% TSE trial – from own WWTP
• Corrosion < 5 mpy on steel
• No Scale, slight silt fouling easy removed by
backwashing >> Side stream filter recommended
• 3 month trial evaluation resulted in full
implementation of unpolished TSE in
December 2010 by KKIA quality assurance
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Case History KKIA – Saudi Arabia
RO permeate vs TSE
100% RO 100% TSE
• Cost : 10.5 SAR/m3 • Cost : 1 SAR/m3
• CoC : 16 • CoC : 5.0
• MU : 36.8 m3/hr • MU : 43.5 m3/hr
• MU : 321,900 m3 RO • MU : 381,000 m3 TSE
• BD : 2.5 m3/hr • BD : 9 m3/hr
• WC* : 3,219,300 SAR • WC* : 385,950 SAR
• WT cost : 304,500 SAR • WT cost : 850,000 SAR
• 1 or 2 drum program • 3 drum program
Savings
~ 321,900 m3/Y of fresh Water = 5700 people equvivalent
TCO reduction of 2,288,000 SAR/Year
*WC = Water Cost Annually
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3D TRASAR ® – Key to a TSE success story
HIGH
•Expect to Reduce TCO
System Efficiency
HIGH
Total cost of Operation (TCO)
“Safe” control
…but costly
Time
“Average” control
Like a stopped clock
- only right when
it crosses the stress
System Stress
Line
Control
Measures stress and
adjusts set point
continuously
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3D TRASAR Technology
• Detect
– System Variability
– Changing Parameters
• Determine
– Compares Current Conditions to the standard
– Takes appropriate corrective response
– Expert Assistence/surveilance 24/7 ‐ Nalco 360
• Deliver
– Measurable Results (corrosion rates, scale/bio
index)
– Save Water and Energy
– Assures Environmental Compliance
– Contributes to Sustainable Development
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3D TRASAR – what it does
• Measures directly System condition & needs
via important KPIs
• On‐line Monitoring of:
• Scaling tendency – NSI
• Corrosion rates – NCM
• Bioactivity ‐ NBI
• Real time Demand based Treatment control – Adaptive
• Monitors and controls Corrosion/Scale Inhibitors On‐Line
• Full alarm and communication capabilities (Web, SMS, mobile)
• Alerts site personnel and Nalco during upset conditions
• Trends critical data on your customized extranet website
• Three months data recording for full statistical process
control
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3D TRASAR®
Monitoring and Control
Measured and logged parameters
• pH
• ORP
• Conductivity – Blow‐down
• Corrosion rate Steel and Copper
• Temperature
• Turbidity
• Inert Trasar (Corrosion inhibitor)
• Scaling Tendency (Dispersant)
• Fouling fluorometer cell
• Bio Index
• Analoge input signals
• Flow switch
• Timers of the biocides
• Alarm history
• Remote and plant access
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Introduction NALCO 360
Nalco 360™ Service provides
Peace of Mind
that your CT water system is being
monitored by a team of Nalco Experts,
24 hours a day, 7 days a week.
w ay
Gate
GSM
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Via
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TSE as Make Up Water
Conclusion
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Thank You
» QUESTIONS !
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