ClorTec Onsite Hypochlorite Generation Systems - Ohiowater.org

Consumables UsageFor each lb. equivalent of Cl 2 :• Salt (NaCl) 3 lbs (1.36 kg)• Softened Water 15 gal (56.8 L)• Electrical energy 2kWh6

OSHG ByproductsFor each pound of Cl 2 equivalent produced(15 gallons of 0.8% concentration Sodium Hypochlorite) :• 1/35 lb. of H 2 gas produced (7 ft 3 ).• Immediately diluted upon production with air blower100:1 to reduce H 2 to 25% of LFL.7

Salt• Typical salt is a solar dried saltwith no binders or additives.• NaCl: 96.3% minimum• Insolubles 0.1% max• Moisture 3.0% max• Calcium Sulfate 0.30% max• Magnesium Chloride 0.06% max• Calcium Chloride 0.10% max• Magnesium Sulfate 0.02% max• Pb 0.0007% max• Cu 0.0003% max• Fe 0.002% max• Fl 0.01% max8

WaterSoftened Water• Inlet Water Temperature: between 65˚F-80˚F[18˚C-27˚C].• Inlet Water Pressure: Minimum 20 psi [1.4 bar](minimum 40 psi [2.8 bar] for CT-600 andlarger), maximum 50 psi [3.5 bar].• Must be free of polymer additives, flocculants,coagulants and antiscalants.• pH 6.5 to 8.5• Hardness [Ca/Mg] < 10 ppm (at outlet of watersoftener)• Total organic content < 1 ppm• Iron

Advantages of the ClorTec Rectifier•Rated for 100 % continuous duty at 104 deg F•Thyristors designed for 200% load.•Heavy duty bus bars and connections•Transformer coils are vacuum impregnated•Sophisticated firing control strategy•Insulation is Class H (220 deg C)Transformer is.__•Protective sensors–Peak Overload Detector–Thyrister Over temp–Transformer Over temp–Fan Overload–Semiconductor Fuses•Constant Voltage & current +/- 1%10

Fig 2. Split Flow Chiller Process Flow Diagram0.8% NaOCl + H 21/2 Cell LengthCell Level SwitchCell Temp Switch1/2 Water1/2 WaterChiller orheater(Optional)1 Part 30% Brine Solution (Saturated)10-12 Parts Softened WaterSaltBrineWaterSoftenerBrine TankBrinePumpPATENTED11

12Water is sent through a twin tank softenerto reduce hardness

13New CT cells are housed in acrylic cells toallow for ease of operation

Cell TemperatureOptimum CellEfficiencyFig 1. Cell Temperature Rise UnderNormal Operating Conditions95F90F85F80F75F70F65FHalfConventional CellClorTec CT CellHalfCell Length14PATENT PENDING

151,500 PPD system in operation

16System at standby

17Soft start at 10 seconds

18At 45 seconds

19A single truck can deliver up to 25 Metrictons per single load

20Depending on the region we have frostprotection included

21200 gallon/2000 pound salt storage tank

22Recent Safety Innovations

Blowers are used to dilute hydrogen tobelow LFL levels•LFL (Lower Flammable Limit of H 2 ) is 4%•Introduce dilution air 100:1• H 2 concentration in diluted air is 25% of LFLTo AtmosphereExhaust VentPressureSwitchBlower DuctSolution LineFlowSwitchBlower DuctBlowerTo Dosing PumpHydrogenconcentration lessthan 1% by volumeHypochloriteGeneratorHypochloriteStorage Tank23

24Standard PLC packages integrate easilywith SCADA

25Graphical Displays are intuitive to operate

Heaters• All stainless steel tank ASMESection VIII stampedconstruction• UL, ASME & NSF approvals• Exterior is 304 SS• Molded rigid polyurethanefoam tank insulation• Advanced electronictemperature control withdigital display• Visual indication of faultconditions provides instantfeedback• Electronic leak detectionsystem26

Chillers• Compressor: Sealed HermeticCopeland Scroll• Safety Controls: High and LowPressure, Freeze Safety, Low FlowInternal O.L./Winding, Safety Fusesfor Pump and Compressor• Pump Type: Centrifugal StainlessSteel• Controller Type: Digital set pointcontroller with constant digital L.E.D.process water temperature readout• Evaporator Construction: StainlessSteel Copper Brazed Plate.• Reservoir: Insulated 304 StainlessSteel• Condenser Construction: CopperTube, Aluminum Fin27

What is the backup?What about redundancy?Hypo Dilution Panel• Low cost alternative to aredundant system.• Available in two sizes:– 12 to 900 lb/day– Up to 1200 to 2400 lb/day28

Acid Cleaning Cart• Safe and efficient cleaning ofelectrolytic cells in-situ• Integrated pumping systemand reservoir• 30 gal reservoir• Easy dilution and disposal ofmuriatic acid• 14 gpm model12-300 lb/day systems• 40 gpm version450-1500 lb/day systems29

Summary• ClorTec has developed a safe, reliable, robust, andcost effective system with safety designs that allow forthe dilution and dispersal of the hydrogen byproduct• We have established an internationally qualified andexperienced Engineering Department to support theSales and Marketing of our products• Over 3500 units in operations• Please contact us if we can support your efforts30

Questions?31 31

On-Site Hypochlorite Generators• Wide Range of Systems Offered:• MCT 12-36 lbs/day• CT 75-300 lbs/day• CT 450-1500 lbs/day and Larger32

33RMS Water Storage TankManagement System

RMS System Configurations34 34

RMS Features• Continuous circulation of water• Automatic injection and mixing of chemicaldisinfectant• Real time sampling• Sample solution returned to water storage system• Flexible capacity ranges (10 MG)• Easy installation, no down time required• Small footprint35 35

RMS Benefits• Eliminates thermal and residual stratification• Promotes improved water quality• Consistent and accurate water quality monitoring• No waste effluent generated in the sampling process• Maintains residual level• Compliance with regulatory data recording• Flexible system, applicable to varying flow rates• Low operating and maintenance costs• Low energy requirements36 36

RMS System Components• Submersible Pump and Eductor Assembly• Analyzers– Free Chlorine Residual Analyzer– Total Chlorine Residual Analyzer– Ammonia Residual Analyzer• PLC controls (if needed)• Recorder• Associated Valves and Tank Level Controls37 37

RMS Rover- Enhanced EngineeredDesignOldNew38 38

(+) (-)(-)(+)Recirculating Eduction & Residual RMS Process Control DrawingCLORTECPLC CONTROLLEROPERATORINTERFACETERMINALCLORTECFREE & TOTALANALYZERMIXERAMMONIASTORAGETANK0.8%HYPOCHLORITESTORAGE TANKRECIRCULATINGPUMPDOSINGPUMPCLORTECON-SITE SODIUMHYPOCHLORITEGENERATORDOSINGPUMPSTORAGE TANK39 39

RMS Rover Installation• Simple process• No plumbing changes required• No dewatering required• Fits into a 24” access way• Can be disassembled into threepieces, each weighing under 25 lb40 40

RMS Rover Installation Continued• Air in the tanks enable the RMS Rover to float along the surface• Then air is released from the tanks and the RMS Rover travels to the bottom• Installation is then complete41 41

RMS Rover Mixing• The RMS Rover begins to mix the water• Multiple units can be used to mix larger water storage systems42 42

RMS Rover Sampling• Optional real-time samplingavailable• A sample is pulled and sent to thecontrol building• Sample is measured in chlorineresidual analyzer• If set point residual detected,disinfection not required• If low residual detected,disinfection injection required43 43

RMS Rover Disinfection Options• Disinfection can be provided bysodium hypochlorite, chlorineor chloramines• A low set point signal from thechlorine residual analyzer to thecontroller will dose adisinfectant into the waterstorage system44 44

RMS Rover Disinfection Injection-Chlorine or Chlorine Equivalent• A low set point signal from thechlorine residual analyzer to thecontroller will dose a chlorine orsodium hypochlorite, a chlorineequivalent, into the waterstorage system45 45

RMS Rover Disinfection Injection-Chloramines• A low set point signal fromthe chlorine residualanalyzer to the controllerwill then dose chlorine andammonia to provide achloramines disinfectantinto the water storagesystem46 46

RMS Rover System Removal• Stop mixing• Inflate air into the tanks• The air will cause the RMSRover to float to thesurface47 47

48RMS Ancillary Equipment

RMS Chemical Storage Option• LiquidChem Chiller can be used for ammonium hydroxide(aqua ammonia) or sodium hypochlorite– Integrated dosing skid available– On-Board Fume scrubber available– Standard sizes: 200 gal-1500 gal∙Larger custom sizes available49 49

LiquidChem Chiller Features• Dual-contained insulated tank• Vent-to-atmosphere ventilation system• Maintains liquid chemical at low temperature• Consistent suction head• Air cooled condenser• No pressurized storage of liquid chemical required (aquaammonia only)• No check valves or vacuum relief valves required• No Off-gassing, stable with consistent strength• Portable skid-mounted unit50 50

LiquidChem Chiller Benefits• Promotes safe and stable solution of liquid chemical• Easy-to-install and operate ventilation system• Ensures stable solution of liquid chemical• Reliable chemical feed of liquid chemical• Eliminates injection pump vapor lock cavitation• Simple-to-install• Low maintenance• Design accommodates mobility• Reduced energy consumption a result of 3” thick urethane insulation• Helps maintain consistent product dosing levels• Increased product storage life• Reduces volatilization of ammonium hydroxide– Stores ammonia at 55˚F• Reduces DBP formation (hypochlorite only)51 51

Liquid ChemChiller• 3” thick urethane insulation• Low Maintenance• Air Cooled Condenser• Integrated dosing skidavailable• On-Board Fume scrubber (forammonium hydroxide)available• Standard sizes:– 200 gal– 300 gal– 500 gal– 1000 gal– 1500 gal• Larger Custom sizes available55

56RMS

Reservoir Management System (RMS)• Can be used for:• Mixing• Mixing & Real time monitoringof water level• Chlorination• Blending Chloraminatedwater with Chlorinated water• Chloramination• Reducing free ammonialevels in chloraminated waterby boosting chlorine.57

584000 gallon/40,000 pound FRP tank withpneumatic fill system

Typical Water Softener Configurations• Kinetico Water Softeners– Recharge based upon actualusage not time.– Dual tank design allowscontinuous softened flow rate– No electrical components.Actuates by flow driven gears– Compact design– Adjustable recharge cycle byeasily replaced gears– Expected resin life 10 years59

Water Softeners(For Generators greater than 1500 lb/day)• Several Configurations:• Kinetico and others.• Recommend use of a HachSP510 Hardness Analyzer (10mg/L trip point60

61The softened water is fed to a brine tankwhere brine is generated and stored

6280 gallon/800 pound HDLPE brine tank

63Saturated brine is fed & mixed with softenedwater in a 1:12 ratio

Brine is injected into the system using severalmethods depending upon system sizeDual Head Brine Pump usedon MCT 12-36 lb/daySingle Head Brine Pumpused on CT 75-300 lb/day64

65CT 450 and larger systems use either aneductor or brine pump to deliver the brine

66Split Flow design provides higher efficiency &reduced chlorate production

67Clear cell casing provides indication of cellcondition

68Clear body allows for visual inspection ofthe cell and process

69Plate design allows for self cleaning

70CT-200

ClorTec Today• Over 3500 installationsworldwide.• A Product Group of SevernTrent Water Purification, Inc.(STWP)Torrance CA.• STWP is a division of SevernTrent PLC– £2.015 Billion ($3.68 BillionUSD) Annual Revenue– Listed on London StockExchange– 15,000 employees worldwideTorrance Facility71

72CT-1,200 with twin tank softener

Introduction to ClorTecHistory• 1989 Founded in Northern California asChemical Services Company with a focus onleasing equipment ot the aquatics industry.• 1990 Tested first chlorine generator on a wellsite in Pajaro Valley Unified CA• 1995 Began marketing Sanilec products.• 1998 Introduced ClorTec Onsite Generation• 1999 Joined Severn Trent ServicesFirst Sanilec InstallationFirst ClorTecFirst “B Series” ClorTec73

74AC power converted to DC current

75Rectifiers ranging from 65 to 3000 Amps DCare supplied based on capacity

76Larger units exhaust hot air from the room allowing thesystems to operate without raising the room. Optionalwater cooled units available. All Rectifiers are UL andCSA certified

MCT Series Power Supply• Designed to run “cool” underextreme thermal conditions• Low temperature rise- 37°/32° Crise with a 45° C ambient.• 180° C class H insulation system• Increased reliability• Fully controlled full-wave bridgerectifier for lower RMS currentscreatesminimum heat• Extremely high PIV (peak inversevoltage) rating (1600V) on SCR’s• Fans and heat sink for addedcooling/air circulation• Solid State Relay• Proven Reliable Firing board77

78Hypo tanks and feed systems come in manysizes and shapes depending on capacity

79HDPE and FRP tanks available

80HDLPE tanks are used for 2 – 300 lb/day

81Multiple tanks are used for largerapplications

82Safety ladder and cage is provided

83Hydrogen Dilution Air & Vent System

84H2 sensors, air flow sensor and PDswitches are also used

Recommended Venting• Vent Stack within 6 ft of generator• Vent duct no longer than 50 ft (20 ft for MCT)• Maximum hypo pumping head of 15 ft height tostorage tank0.80% HYPOCHLORITESTORAGE TANK85

ClorTec Safety1. Active Ventilation / DilutionSystem designed to prevent buildup of hydrogen2. Maintain hydrogen concentrationat less than 25% of the 4% LEL or,1% by volume3. Seven tier safety interlocks on thegeneration plant4. Multiple redundant protectivedevices on electrolytic celloverpressurization5. Maintain a simple cost effectiveproduct86

The ClorTec DesignSeven tier safety interlocks on generation plant•Rupture Disk sensing•Inlet Pressure switch check•PRV flow switch check•Blower current sensing•Air Flow sensing•dP sensing•Plant H2 sensingSolution LineExhaust VentTo AtmospherePressureSwitchFlowSwitchBlower DuctBlower DuctBlowerTo Dosing PumpHypochloriteGeneratorHypochloriteStorage TankNOTE: In order for the unit to run all safety devices must be enabled, in the event ofa component failure or H 2 detection the system will shut down and alarm. Thesoftware will not allow the system to run if the sequence does not cascade in thedesignated order. Thereby identifying switch failure or an attempt to manually enablea primary safety device.87

Revamped ClorTec Test Facility• 900 sq. foot Final Test Facility• Capable of full systems up to 1500 lb/day• Includes testing of all ancillary components (Blowers, pumps, etc.)• All systems shipped are fully tested and adjusted before reachinginstallation site.88

Electrolytic Cell Layers of ProtectionElectrolyticCellPrevious 2layersFlow meterLevel SensorPressureSwitchPressureRelief ValveRupture DiskIntrinsicallySafe BarrierPositiveLocationPositioner onOutlet Valve89

90Dosing Systems- A range of optionsavailable to meet all requirements

Recommend skid mounted dosing pumps•Ease of Installation•Compact Design•Chemically resistant construction•Low maintenance91

92Dosing pump components can be suppliedloose

Dosing Control Philosophy• Recent change to dosing control philosophy• Modular control system dedicated to dosing system• Allows On-site generator to be taken off-line formaintenance and service.93

Dosing Controller Options• MANUAL CONTROL• Stroke length adjustment onthe pump allows for a 10:1turn down ratio with manualcontrols.• VFDVariable Frequency Drive inNEMA 4X enclosure can beoperated with the manualfrequency adjustment or witha 4-20 mA signal from theplant's SCADA system, ordedicated dosing controller94

Dosing Controller Options (cont’d)• 1451 - MICROPROCESSORBASED CONTROLLER• Designed to use two inputsfor flow pacing or compoundloopdosing control.– plant flow meter– chlorine analyzer• Outputs a 4/20 mA signal tothe VFD• For duty/standby pumps, onecontroller can be used withthe addition of an analogsignal splitter.95

Dosing Controller Options (cont’d)MICROCHEM 2CHLORINE ANALYZER & CONTROLLER• standard PID algorithm with sensorinput• PID feed forward controller utilizing thesignal from the sensor and a plant flowmeter96

Dosing Controller Options (cont’d)• PLC - METERING PUMPCONTROL• Best choice for managing multipledosing systems.• Output 4-20 mA signals to eachpump's VFD for flow paced orcompound loop dosing.97

Verderflex Hose Pumps•Economic•Reliable Units withlittle maintenance•If velocities arekept low, hosesneed to bechanged onlyevery 6 months.•Capable ofpressures up to230 psi and flowrates up to 390gpm98

Hydra-Cell Pumps•Wobble Plate DesignProvides Low PulseOutput•Economic PurchasePrice•Reliable Units/LowMaintenance•Teflon head modelcapable of pressuresup to 250 psi•Flow rates up to 37gpm99

100Standard Control Panels

101If an alarm is registered the possible causeand correction (s) are displayed on screen

102Set points are operator selected through thedisplay by using password

103Heaters & Chillers A range of optionsavailable to meet all requirements

Costs of OSHGChlorine Gas per Pound12% Bulk Sodium Hypochlorite Cost per GallonSalt Cost per PoundkWh CostFully Burdened Labour Cost Per Hour$$$$$0.500.650.150.0525.00Yr 1Yr 2Yr 3Yr 4Yr 5Yr 6Yr 7Yr 8Yr 9Yr 10Yr 11Yr 12Yr 13Yr 14Yr 15$0 $100,000$200,000$300,000$400,000$500,000$600,000$700,000$800,000ClorTec OSHGChlorine Gas12% Sodium HypochloriteCompetitor OSHG104

105RMS

RMS Instrumentation• Microchem 2 is used for free& total chlorine• ChemScan ChloraminationAnalyzer used for Free andTotal Ammonia, TrueMonochloramine & TotalChlorine106

107500 gallon/5000 pound brine tank

ClorTec Product Offering• On-Site Sodium HypochloriteGenerators• Chemical storage / LiquidChemical Chillers• Tank Management Systems108

109Redundant 72 ton Brine makers

110Vents are used to purge hydrogen prior tohypochlorite flowing to the storage tanks