HyCator_CaseStudy_BFP

7/27/2019 HyCator_CaseStudy_BFP

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HyCa Technologies Pvt Ltd176, Udyog Bhavan, Sonawala Road, Goregaon (E), Mumbai 400 063 INDIAPh: +(91) (22) 2566 8037 Web: www.hycator.com Email: [email protected]

HyCaTe

chnol

ogies

StandaloneHyCatorTM:BFPReactorSystemforBiofoulingpreventioninCoolingTowerwaterCaseStudy1

Chemical treatment costwas high and the plantmanagementwas under pressure to reducewaterusageanddischarge.Cycleofconcentrationwasalso low.Ahardscaleoften formed in thesummerseason.Thebacterialcountswere105cfu/ml.

HyCatorTM: BFP reactor system was installed in the cooling tower circuit. A detailed study was

conductedon thecooling towersystemoversixmonthperiod toevaluate theperformanceof the

devicefordisinfection,scaling,corrosion,cyclesofconcentrationandheattransferefficiency.

Performanceexceedscustomersexpectations.Makeupconsumptionhasbeenreducedby30%and

blow down discharge reduced over 60%. Bacterial microbial counts become nil and cycles of

concentrationsubstantiallywas increased.Theresultsalso indicatedthattheHyCatorTM:BFPreactor

systemtreatmentperformedwellcomparedtothechemicaltreatmentwithoutaddinganychemicals.

Inthisparticularcasedosageofanticorrosionandscalepreventionchemicalswasalsonotrequired.

Annualwater saving exceed 3600m3. The costofHyCatorTM:BFP reactor system is economical in

termsof

operational

costs

with

pay

back

period

of

less

than

2yrs;

and

it

needs

very

limited

maintenance.

CaseStudy2

Themainproblemwashighblowdownwaterandbiofouling.Thecoolingtowerwasoperatedatlowcycleofconcentration(3.0).

After

the

successful

installation

of

HyCator

TM

:

BFP

reactor

system,

the

biocides

dosing

reduced

to

10

%

andotherchemicals(dispersant,corrosion inhibitorandantiscalent)reducedto40%oftheoriginal.

Thebacterialcountscomedownunderthepermissible limit.Blowdownhasbeenreduced40%and

Cycleofconcentrationisalsomarginallyincreased.Oldscalewasgraduallyremovedandnonewscale

formed.


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Casestudy3

Thevolumeofmakeupanddischargewaterwashighanditwasoperatedalowcycleofconcentration.Biofoulingwasalsohigh.Biofoulingwasfullycontrolledafterthe installationofHyCator:BFPreactorsystem.Thescaleand

corrosion is also reduced over previous chemical treatment. Cycle of concentration also increase

resultedinareductionof25%inmakeupwaterand50%inblowdownwater.

The customer saved hugemoneyby installing theHyCator: BFP reactor systemwhich resulted a

payback period of less than 2 years. After the successful installation, the second HyCatorTM: BFP

reactorsystem

has

also

been

installed

in

another

cooling

tower

at

the

same

site.

Representativeimage

of

standalone

HyCator:

BFP

reactor

system

supplied

to

one

of

the

reputed

agrochemicalcompanyinIndia.ThesnapshotaboveshowsaHyCator:BFPreactorwithacentrifugal

pump and an electricmotor. (Please note,each standaloneHyCator:BFP reactor unit is custom

made equipment based on particular flow rate, pressure and other various parameters at actual

coolingtowersite)


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Principle

Decreasing the pressure over the liquid to its vapor pressure generates vapor bubbles in

liquid.This isalsocalledascavitationorcoldboiling.When thepressure isbroughtback tonormal

pressurethesevaporousbubblescollapsebackinwaterwithabangtogenerateintensepressureand

temperature

at

the

point

of

collapse.

Such intenseconditions(9000atmand5000K, intenseturbulence)canbringaboutseveral

physicalandchemicaltransformationsevenwhenthebulkconditionsareambient.

HyCa technologies have mastered the art of producing, stimulating and collapsing such

bubbles in the requiredmanner and on the desired scale using its innovative product HyCatorTMReactorSystem.HyCatorTM:BFP reactorsystemsare fine tuned forgenerating tailormadecavitiessuitable for particular applications like molecular breakdown. Due to such extremely high

temperature, pressure intense turbulence; shockwaves are generated which are capable for

destroying

the

microbes.

SpecificEffects: Highmagnitudepressurepulse,100to5000atm

Extremelyhightemperatures,1000to12000K Velocitiesinexcessof2to3timesthatofsound

Growth of voidswithcontinualsupply

of energyReleaseof energy

Collapseofthe void(Cavity)on removalof energysourceBreakin the cohesiveforcesin

the liquid continuumformation

of voids

Nuclei Expansion MaximumPhase radius

CollapsePhase

Bang!


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RetrofittingHyCatorTM:BFPreactorsystemintoexistingcoolingtowersystemFigure below shows schematic of a typical cooling tower circuit and an installation of standalone

HyCator:BFPreactorsystemforpreventingbiofouling.HyCator:BFPisastandaloneunitwhichwill

take its feed from cooling tower sump,pass it through theHyCator:BFP reactor system and the

treatedcooling

water

will

be

either

discharged

to

the

line

going

for

process

or

back

to

cooling

tower

sump as a closed circulation. The HyCator: BFP reactor system is available in a package having

centrifugalpumpwhichwilltakecareofrequiredflowrateandpressureneededforHyCatorTM:BFPto

workwithitsfullefficiency.

Fig.:SchematicofcoolingtowercircuitandStandaloneHyCatorReactorSystemsInstallation

PotentialBenefits:HyCatorTM:BFPReactorsystemprevents thebio foulingand reduces theblowdown toavery low

valuewhich in turnwill reduce themake upwater rate.Once the frequency ofmakeupwater is

reduced the addition of other chemicalswill also reduce and other impurities due to addition of

chemicalswillalsoreducesignificantly.

HyCatorReactor

Coolingtowersump

Suctionline

StandaloneHyCatorReactorDischargeLine

TimerarrangementtorunpumpforpredecidedtimemakingsystemFIT&FORGET

Coolingtower

Strainer


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Ingeneralfornormalfeedwaterqualitythepotentialbenefitsare:1. Helpsinthepreventionofbiofouling,corrosionproblemsandscaleformation.

2. EnvironmentallySafeNochemicalsaddedorunwantedresidualscreatedbytheprocess.

3. Noneedofbiocideschemicals.

4. Reduce40

%

consumption

of

dispersants

and

corrosion

inhibitors.

5. Reducedblowdownofwaterduetooperationathighercyclesofconcentration.

6. Reduce40 80%consumptionofblowdownwater.

StandaloneHyCatorTM:BFPreactorsystembuyingprocedure1. OnclientsrequestHyCawouldsendadetailedquestionnaire.

2. Onreceiptoffilledupquestionnaire,HyCawillgiveaquoteforfullscaleequipment.

3. Oncereceipt

of

Purchase

order

(PO)

for

full

scale,

HyCator:

BFP

is

fabricated

and

delivered.

All

HyCatorTM:BFPReactorsarecustomdesignedandfabricated.

FrequentlyAskedQuestions(FAQs)IndexEquipment

WhatisthespacerequirementforstandaloneHyCatorTM:BFPreactorsystem?

WhatwillbetheweightofstandaloneHyCatorTM:BFPreactorsystem?

IfneededhowcanweseparatetheHyCator:BFPreactorsystemfromthemainline?

WhatwillbedeliveryperiodofstandaloneHyCatorTM:BFPreactorsystem?Saving DoesHyCatorTM:BFPreactorsystemrequireanyexternalenergysupply?

Whatadditionalhardwareormanpowerisrequiredforinstallation?

Isthistechnologycosteffective?

Whataboutthepaybackperiod?Operation&Installation DoesstandaloneHyCatorTM:BFPreactorsystemrequirescontinuousmonitoring?

IsInstallationofHyCatorTMBFPreactorsystemdifficult?

WhatwillbetheoperationalcostofHyCatorTM:BFPreactorsystem?

Whatisproceduretomonitor/evaluateperformanceofHyCator:BFPReactorSystem?Environmental&Safetyissues IsHyCator:BFPreactorsystemenvironmentallysafe?

Whatarethesafetyissuestobeadoptedduringitscourseofoperationandhandling?


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Equipment WhatisthespacerequirementforHyCatorTMBFPreactorsystem?

StandaloneHyCatorTMBFPreactorsystemrequiresverylessfootprint.Typicallyitisthespace

requiredfor

installation

of

pump

set.

The

HyCator:

BFP

reactor

to

be

installed

at

the

pump

dischargeside.

WhatwillbetheweightofHyCatorTM:BFPreactorsystem?BasedonthepipesizethetypicalweightofHyCatorwillbe~100kgto400kg.Howeverthe

actualweightandsizeofHyCatorTM:BFPreactorsystemmayvarydependinguponpipesize,

pumpsize,sumpvolume,capacityofcoolingtowerandblowdownfrequency.

IfneededhowcanweseparatetheHyCator:BFPfromthemainline?AbypassvalveisprovidedinHyCator:BFPreactorsystemanditcanbecompletelybypassed

fromthe

existing

cooling

water

circuit

whenever

required.

WhatwillbedeliveryperiodofHyCatorTM:BFPreactorsystem?ThedeliveryperiodoftheHyCatorwillbe68weeksafterthereceiptofbothtechnicallyand

commerciallycompletedpurchaseorder.

Saving DoesthestandaloneHyCatorTM:BFPreactorsystemrequireanyexternalenergysupply?

An external energy source is required to an electricmotorwhichwill run the standalone

HyCator:BFP

reactor

system.

Whatadditionalhardwareormanpowerisrequiredforinstallation?Noadditionalhardwareisrequired.Forinstallationclientneedstoarrangeonlyfitter,welder

& an electrician. Tuning of theHyCatorTMReactor System is verywell documented in the

installationguideprovidedwithHyCatorTMReactorSystem.

Isthistechnologycosteffective?Yesitis,becauseitsavespower,waterandchemicals.Theprocessgenerallyis~2040%less

costlythanconventionalchemicaltreatment.

Whataboutthepaybackperiod?Formostofourclientstilldatethepaybackperiodwasinrangeof12yrs.

Operation&Installation DoesstandaloneHyCatorTM:BFPreactorsystemrequirescontinuousmonitoring?

Standalone HyCatorTM: BFP reactor system does not require continuous monitoring. It

operates on Fit and forget principle.HyCator requires zero operational supervision and

maintenance,freeingthepersonnelforotherproductivework.


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HyCa Technologies Pvt Ltd176, Udyog Bhavan, Sonawala Road, Goregaon (E), Mumbai 400 063 INDIAPh: +(91) (22) 2566 8037 Web: wwwhycator com Email: mail@hycator com

HyCaTe

chnol

ogies

IsInstallationofstandaloneHyCatorTM:BFPreactorsystemdifficult?InstallationofstandaloneHyCatorTM:BFPreactorsystemisveryeasyandneedsonlyfittingit

inboltedflangesattherequired location.TheweightoftheHyCatorrangesfrom100kgto

400

kg

depending

on

the

pipe

size.

WhatwillbetheoperationalcostofstandaloneHyCator: BFPreactorsystem?The exact operational cost of HyCator: BFP reactor system can be estimated only after

receivingcoolingtowerdetailsasperourstandardquestionnaire.

Whatisproceduretomonitor/evaluateperformanceofHyCatorTMReactorSystem?The performance can bemonitored by analyzing (pH, CFU, TDS, total hardness and total

alkalinity)ofthecoolingtowerwater.

Environmental&Safetyissues IsHyCator:BFPreactorsystemenvironmentallysafe?

Yesitis,becauseitreducesthetotalconsumptionofchemicalsusedforgivencapacityof

coolingtower.

Whatarethesafetyissuestobeadoptedduringitscourseofoperationandhandling?StandaloneHyCatorTM: BFP reactor system demands no critical safetymeasures; however

someofthegeneralsafetymeasuresareasfollows:

1. TheweightofstandaloneHyCatorTM:BFPreactorsystemwillbe~100kgto400kg.

Souseappropriate chainpulleyblocksorother liftingequipment is recommended

duringitsinstallation.

2. Give the proper support to equipment and the adjoining piping. HyCatorTM: BFP

reactorsystemcanbeinstalledinanyorientation,eitherverticalorhorizontal.

3. WhileinoperationstandaloneHyCatorTM:BFPreactorsystemdoesNOTgenerateanypressure or temperature higher than the inlet water pressure and temperature.

Normalpressuresafetyprecautionneedstobetakenasperyourpolicy.

4. Install and operate the equipment as per the instructions given in installation &

operatingmanualsuppliedwithequipment.

Documents

HyCator_CaseStudy_BFP