UTILIZING ONLINE TOC MONITORING TO CONTROL INDUSTRIAL WATER QUALITY

IMPORTANCE OF MONITORING INDUSTRIAL WATER QUALITY

Industrial Water Types include:

• Processing

• Cooling

• Heating

• Cleaning

• Condensate

• Surface/Storm

• Grey water

• Wastewater

• Water for recycling

Online Total Organic Carbon (TOC) monitoring can play a part in managing all types…

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CHALLENGES OF INDUSTRIAL WATER MANAGEMENT

Industries, plants and processes are complex and variable

• Real-time

• Quick & easy to disseminate

• Accurate

• Reliable

Information drives operational

decisions

If you can’t Measure or Trust, you can’t Control!

• Lost product (pollutant) being drained out of the plant

• Damage to valuable equipment

• Wasted energy

• Wasted water

• Biological overload WWTP

• WORST CASE Scenario => Unexpected production Down Time!

Inaccurate or delayed information

can lead to:

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ABILITY TO MEASURE >>> CHANGES BEHAVIOR

Speed Camera

Driver behavior changes almost instantly.

What are the Goals?

What is the value of

Accurate & Reliable Measurement to the Process/Plant?

The core measurement technology must be capable of

achieving the Goals and of having commercial value.

Increased

Efficiencies

Process Control

Energy & Water

Consumption/

Reduction

Information

Dissemination

Incident ID &

Tracking

WWTP Capacity

& Performance

Lost Product

Detection &

Reduction

Regulatory

Compliance

Management Information Waste Reduction

SUSTAINABILITY! Lower Maintenance Tighter Budgets

WHAT RELIABLE ON-LINE ANALYSIS CAN BRING TO YOU!

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SOLUTION TO INDUSTRIAL CUSTOMERS

MEASUREMENT CHALLENGES

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* Information supplied by Instrumentation Testing Association, 2011 ** Information supplied by BioTector, 2013

ONLINE TOC MONITORING AS A SOLUTION

“TOC analysis, as an alternative to BOD5, COD and TOD is a more cost effective, accurate and timely test with less interferences and also has the

capability to be used for process control and real-time monitoring.” Instrumentation Testing Association 2011

Total Organic Carbon (TOC): A measure of the carbon content of dissolved and undissolved organic matter present in a sample.

Standard Method: TOC measurement is an infra-red measurement of CO2

gas generated by oxidation

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WHY IS TOC MONITORING NOT USED MORE WIDELY?

Conventional TOC Technology: UV Persulfate

Disadvantages

• Weak Oxidation

• Requires filtering

• Salts 0.05% inhibit oxidation

• Turbid/dirty samples block the UV

• Scaling of UV light

• Material gets trapped in reactor

• Requires frequent re-calibration

• High Maintenance

• Not able to measure VOC’s

Conventional TOC Technology: Thermal Oxidation

Disadvantages

• Sample volume <10 micro litters

• Delicate Sampling System

• Relies on filtering

• Salts and other material coat inside

of Furnace

• Requires frequent reactor cleaning

• High Maintenance

• Requires frequent re-calibration

TYPICAL ONLINE TOC ISSUES

Frequent Maintenance & Service – High cost of ownership

Low Reliability – Lack of trust analyzer will be running when an incident occurs

Signal Drift – Lack of confidence in the results provided

Filtering – Removes what should be measured

Breakthrough TOC Technology: Two Stage Advanced Oxidation (TSAO)

Advantages

• Powerful oxidation

• Unaffected by salts up to 30%

• Can handle samples with oils,

fats, greases, particulates etc.

• No sample filtration or delicate

sampling systems

• Self-cleaning reactor

• Self-cleaning sample line

• Low maintenance (6 month

service)

• High reliability (99.86% uptime)

Measures in Safe & Hazardous Areas

Measures up to 6 process streams

TOC Total Organic Carbon TN Total Nitrogen TP Total Phosphorous COD Chemical Oxygen Demand BOD Biological Oxygen Demand TC Total Carbon TIC Total Inorganic Carbon VOC Volatile Organic Compounds

Patented Technology

NOT JUST FOR ENVIRONMENTAL COMPLIANCE…

HOW DO CLIENTS GET THESE RESULTS FROM ONLINE TOC MONITORING?

EMERGING VIEWPOINT OF THE $$$ IN WASTEWATER

Product lost duringprocessing

Wastewater requiringtreatment

WWTP Budget fortreatment

Energy used duringprocessing

Water suitable forrecycling

Ratios will differ according to industry and process type.

Production & WWTP functions need to work together to optimise overall plant operations Online TOC monitoring enables shared process insights, accountability and increased efficiencies

RELIABLE PERFORMANCE IN DIFFICULT APPLICATIONS

SOME WATER QUALITY APPLICATIONS

• Condensate Return Water

• Cooling Water

• Boiler Condensate

CONDENSATE RETURN WATER

Why measure it?

• Boiler protection

• Water reuse optimisation

• Energy optimisation

• Chemical/additive cost reduction

• Make-up water cost reduction

• WWTP treatment cost reduction

Process breakthrough in a heat

exchanger will contaminate

condensate return water and will damage

the boiler

Steam

Boiler Feed & Anti-Corrosion

Additives

To drain diversion @ >5ppm approx

Condensate return water is valuable because of the cost of treatment

Condensate Return

Process In

Process Out Process Out

Process In Process In

Process Out TOC

Condensate Return Application

CONDENSATE RETURN WATER – APPLICATION NOTE #1 Chemical Plant, Texas, USA

• Steam is purchased from Cogen

• Returned condensate water goes back

• Penalties for TOC exceedance

Problem

• Had UV Persulfate TOC analyzers

• Weekly calibration c. $52,000 per year

• High downtime

• No confidence in accuracy of measurements

Solution

• Hach BioTector installation

• 6-monthly calibration and maintenance only required

• Penalties and calibration costs eradicated immediately

BOILER CONDENSATE APPLICATION

• Most boilers will be damaged if the organic levels exceed 5 – 10 mgC/l in the return condensate water. • For refinery and chemical applications a leak in a heat exchanger may result in flammable or explosive Compounds entering the condensate return water.

Why use TOC? • TOC is an absolute measurement of the organic content As opposed to conductivity which is an indicator of change only • Purgeable and non-purgeable compounds included in the TOC

measurement

TYPICAL BOILER CONDENSATE APPLICATION

Why measure it?

• Cost savings from water reuse

– Cooling water is one of the largest water uses in the US!

• Energy optimisation

• Environmental compliance

COOLING WATER

TOC CONTROL & MONITORING OF CARBON BED ADSORBER - 3 STREAM BIOTECTOR

Process waste water Operation

(A) Monitor and Control the

Organic Load feeding into the Carbon Bed Adsorber

(B) Monitor the performance of the bed which

is online and Switch beds as Required.

Benefits

(A) Protection of Carbon Bed

Absorber from Excessive Loads

(B) Maximise Use of each bed

before Regeneration.

BioTector

Stream1: Range 0-1000

Stream2: Range 0-90

Stream3: Range 0-90

TOC & VOC Option

MULTI-PROCESS CHEMICAL PRODUCTION PLANT (TOC, TC, VOC, TIC MONITORING)

Process 1

Process 2

Process 3

Process 4

Process 5

Process 6

Discharge

Wastewater Treatment Plant

TOC

TOC

TOC

TOC

TOC

TOC

TOC

TOC

Low Maintenance: 6 monthly routine service only required. No calibration in between services

High Reliability: 99.86% MCERTS Certified Uptime

Robust Equipment for Clean & Dirty water analysis: Can handle salts, fats, oils, greases, particulates etc.

No Pre-Filtering Requirements: Fully representative sample

Simple Operations: Easy to operate and service. Comes with intelligent diagnostics.

Remote web access for results and operations

Hach BioTector Patented Technology

THE RACE TO SAVE THE ENVIRONMENT STARTS WITH YOUR 1ST STEP…

ARE WE READY!

The world’s water, energy and food systems are tightly linked.

Water is needed to extract energy and generate power, Energy is needed to treat and transport water; and both water and energy are needed to grow Food.

In the coming decades these vital resources will come under greater pressure.

Working across industries and sectors will help address their complex relationship, known as the energy-water-food nexus.

THANK YOU