ultrasound for cooling water application · treatment due to poor biocide selection or incorrect...

WINTECS

Ultrasound for Cooling Water Application

February 2, 2007February 2, 2007WINTECS CORPORATIONWINTECS CORPORATION

Consultant & EngineeringConsultant & Engineering

WINTECS

Cooling water System on Air conditioning

Chiller

Drift with Legionella Bacteria

Cooled air

AHU (Air handling unit)

Cooling tower

Cooling water

Chilled water

WINTECS

Cooling Tower (Hospital) Drift

Inside of Tower

Circulating water : 1,000 tons/hHolding water : 25m3

WINTECS

Scale & Deposit problem

Scale formed in condenser tube

Heavily scaled pipeHeavily fouledChiller condenser

From Betz Water handbook

WINTECS

Corrosion problem

Inside of Condenser tube

Pitting corrosion Pin hole

Copper Corrosion

WINTECS

Algae growth and Biofouling

Cooling tower pond

Upper basin

Bio-fouled sludge in pond

From Betz Water handbook

Algae growth

WINTECS

Legionella

Legionella

Biofilm

• Rivers, lakes, sediment, sludge, scale, soils, organically-rich environments

• Growth between 68 - 113 F– dormant @ lower temperatures and does not

survive above 140 F

• Aerobic, parasitic, protozoonotic

Legionella is a major cooling water treatment control issue.Biofilm provides an environment for its rapidgrowth, then releases it into bulk water.

Legionella Ecology

WINTECS

! Initial population

! 2 Days later

! 4 Days later– A protective biofilm is formed– Film thickness can be 100

microns

Biofilm Grows Exponentially On Surfaces

- Only two hours contact

WINTECS

Substrate

Organic Conditioning

Film

Bacterial Cells

Bio

film

Extracellular Polymeric Substance

(EPS)

Biofilm section observation

WINTECS

MSU Center for Biofilm Engineering

Biofilm Forming Process - Stage 1

WINTECS



WINTECS

" Most biocides were designed to kill planktonic (free floating) cells

" Trends in water treatment inhibit biocide performance

BULK LIQUID

• Most (99%) microorganisms are on surfaces and in aggregates• Biofilm and cell aggregates are root causes of most problems

Biofilm The fact of life


SUBSTRATUM

WINTECS

Cooling tower

Chiller

Makeup water

Corrosion/Scale Inhibitor

Conductivity sensor

BiocideAlgaecide

T

Redox (ORP)ControllerConductivity Controller

Interlock

Bleed solenoid valve

Chemical Treatment

Bleed

WINTECS

Problem on conventional cooling water treatment

! Corrosion of cooling water mild steel pipe can be protected by corrosion inhibitor dosing, but condenser tube (copper tube) canundergo serious pitting corrosion caused by Microbiologically Influenced Corrosion (MIC) with improper microbiologic treatment due to poor biocide selection or incorrect operation of dosing timer.

! Legionella bacteria halogen (Chlorine or Bromine, etc.) treatment at higher dosage rates cooling water treatment, can sometimes accelerate corrosion problems. Ultrasound application would be expected to minimize the corrosion risk and simultaneously reduce consumption of halogen dosing.

! Higher water reuse and recycle trends predominant in the microelectronic industry, prefer alternative treatment like ultrasound, ozone and UV more so than chemical treatment.

WINTECS

Ultrasonic LG XL

Cooling Tower for LG-XL Evaluation Inside of Tower Pit bottom

Ultrasonic beam seems to be not reachedto the end of pit, but cooling water is circulatedall the time.

Holding water : 18m3Circulating water : 900 t/hr

July 06,2006

WINTECS R-1 Control Cooling Tower (No LG Treated)

- Tower pit looks very dirty because of standby in winter time.

- Oxidizing Biocide has been fed by timer several times in a day.

- Organic Bromine Biocide test started from July 21st.

Black sludge is covered the bottom of the pit.

July 24th, 2006

WINTECS

R-1 Chiller (No LG Treated)

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Conductivity Redox Conc. Of Corrosion Inhibitor

Stabilized Bromine treatment

Control test started

DBNPA test started

Oxiding Biocide has been dosed every day, but Redox was low all the time.

Conductivity is very stable.

WINTECSR-2 Cooling Tower LG XL Treated

Dip slide bacteria test : 1,000-10,000 FCU/ml

July 24th, 2006

Sampled July 14th

Bacteria count seems to be lower even without Biocide dosing

WINTECS

1 weeks later 3 weeks later

Started

July 6, 2006

July 24, 2006July 14,2006

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3 weeks later

Started

1 week later

A lot of foaming observed

July 06,2006

July 14,2006

July 24,2006

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R-2 Chiller (LG XL Ultrasonic Treated)

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LG XL Test Started

Set point of Conductivity was low andthe load was still lower in June, Redoxtends increasing because of fresh watermade up.

Redox is increasing time to time

WINTECS

July 31st, 2006 R-2 LG XL Ultrasonic Treated

WINTECS

Bacteria Counts measurement

Sampled July 14th

R-2

Sampled July 28th

R-1

Bacterial count is lower than two weeks ago.

R-2

With Chemical Treatment

LG Sonic treated LG Sonic treated

WINTECS

R-2 Water Quality trend

R-2 Chiller (LG XL Ultrasonic Treated)

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LG XL Test Started

Set point of Conductivity was low andthe load was still lower in June, Redoxtends increasing because of fresh watermade up.

Redox tends increasing

WINTECS

Legionella Count Measurement

Legionella bacteria was determined as following;

(Sampled July 31)R-1 DBNPA treatment 300 CFU/100mLR-2 LG treatment 110 CFU/100mL

(Sampled Aug 03)R-1 DBNPA treatment 150 CFU/100mLR-2 LG treatment 50 CFU/100mL

(Sampled Aug 08)R-1 DBNPA treatment 120 CFU/100mLR-2 LG treatment 80 CFU/100mL

R-2 result shows that Ultrasonic is able to control Bacteria, eveneffective for Legionella by controlling biofilm formation.

Limitation : <100CFU/100mL

WINTECS

August 15, 2006

July 31

Aug 15July 24

A week after stopped LG XL treatment

New Algae has been grown

Aug 15 Aug 15

3 weeks later with LG treatment

4 weeks later with LG XL treatment

WINTECS

520

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Corrosion Inhibitor

ORP

Conductivity

DBNPA Treatment(Jul 21- Aug 8)

No Biocide treated DBNPA startedagain

R- 1 Tower

ORP trend on R-1 Decreased after DBNPA treatment

WINTECS

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Corrosion Inhibotor

LG Ultra Sonic Treatment(Jul 5 - Aug 8)

ORP

Conductiity R- 2 Tower

Wothout LG and Biocide

ORP on R-2 Showed Little Change After LG XL Treatment

WINTECS

Another Trial: Small Cooling Tower

-Operation Condition : Operated from June to October Recycled water (RO treated water, having Conductivity of 6-8ms/m) is supplied under the concentration cycle of 3-4, in set point 20ms/m Conductivity controller.

- Location : C-1 Cooling tower has the location having most sunlight in 3 Cooling towers on this building..

- Capacity : 120 USRT Chilling Unit having 1.5 m3 holding water in the system

- Chemical Treatment:

Stabilized Bromine as Biocide (Stopped during this evaluation)

Phosphonate, Polyacrylate, Corrosion Inhibitor maintained 100ppm level in cooling water.

WINTECS2-2C C-1 (started test in August 7)

Drain stream of Cooling tower bleed

- Algae grows in pit and on the wall.

- Bleed water stream shows very heavy algae growth.

XL

WINTECS2-2C C-1 (September 9)

- Much of the algae removed.- Drain stream algae was also reduced.

XL

WINTECS2-2C C-1 (September 12)

August 07

XL

WINTECS 2-2C C-2 Cooling tower (September 12)With chemical treatment

WINTECS

Bacterial Count Test (August 29)

C-1 Cooling Tower

(with LG Ultrasonic)C-2 Cooling Tower

(with Chemical Treatment)

WINTECS

Discussion for Large Cooling Tower SystemBasin material is FRP with framed steel structureLG Tank or XL

8m

5m

2m

５０－８０ｍ toHeat exchangersAnd return to Cooling towers Pump

80m3

Header

Total holding water : 400m3Circulating water amount : 8,000 tons/h

WINTECS

Steel Frame

Cooling tower

Return Header

Example of Big Cooling Tower

WINTECS

Inside of Cooling tower pond

Makeup water

Overflow Eliminator

Pond

WINTECS

CT-3 CT-2 CT-1

Cooling tower pond wall

Cooling water

CT-3 CT-2 CT-１Contamination level ofCooling water and tower pond wall

Co-gen cooling tower

WINTECS

Bacteria Fungi

Bacteria

FungiE-Coli

Cooling water Cooling waterTower wall Tower wall

Palintest(UK)

Bio-check(Japanese)

１００CFU

<１００CFU

１０,０00CFU

１０,０00CFU

１,０00CFU

Cooling water Cooling waterTower wall Tower wall

Staphylococcus

WINTECS

Possibility & Expectation

! LG Sound Ultrasonic products control bacteria population in cooling tower systems by severely inhibiting biofilm formation providing a large market potential in cooling water treatment applications.

! It is well known that Legionella propagate by reproduction within larger bacterium hosts as a parasitic organism. Biofilm reduction in these systems by ultrasonic treatment lowers the probability of Legionella finding a suitable host, thus reducing their numbers.

! Air conditioning small cooling towers (100-1000 USRT) are easily treated by ultrasonic treatment. Larger more complex towers will require multiple units for coverage.

! Ultrasound treatment impact on reduced biofilm growth can significantly reduce overall chemical treatment costs.

ultrasound for cooling water application · treatment due to poor biocide selection or incorrect...

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