ELECTROchem water systems

299 Industrial Park Drive,
Nazareth, PA USA 18064
Phone: 800 949-3445
Fax: 610 746-3567
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Systems manufactured by ELECTROchem Water Systems have been installed in facilities worldwide with year-in, year-out reliability and 100% client satisfaction

Industrial Water Treatment Through Electrostatic Separation

Historically, chemicals have been used for water treatment to inhibit scale, colonization of bacteria, and corrosion. In this balancing act, however, polymers that solve one problem worsen another. Lower pH needed to inhibit scale encourages biological growth and corrosion.

Chemical dispersants serve as nutrients for growth, and must be offset with biocides. Water use and discharge also increase with each additional chemical additive and both scale and biological fouling decrease energy efficiency significantly.

effects of particle bonding at varying conductivity
A Superior Alternative to Chemical Additives
as manufactured by ELECTROchem Water Systems

Electrostatic technology is the application of physics to accomplish water treatment. All water-borne particles have an existing electrostatic charge, which is generally too weak to prevent them from bonding with one another and attaching to surfaces to form scale and biofilm.

Electrostatic rods are mounted directly into the water stream and fed with a high-voltage, low current static charge. As water flows through the static field, the surface charge of the particles is strengthened, causing them to repel one another as well as pipe surfaces, and remain in suspension. Particles do not bond and accumulate mass that would cause them to drop out of solution.

electrostatic rods

Figure 1: Electrostatic Rod Application

Rods are mounted invasively and maintain a strong static field in flowing water as it approaches heat transfer. Typical rod lengths are 24" to 30"

Note: Sidestream reaction chambers house rods when pip size is less than 3" inside chamber.

 typical installation

Figure 2: Preventing Bonding, Scaling, Colonization

Particles passing though the static field become surface charged and repel one another, thus preventing colonization. All particles (bacteria, inert materials) remain separate and in suspension.

 typical installation

Figure 3: Breakup of Existing Scale and Fouling

Electrostatically charged particles encounter matter through turbulence and break up existing biofilm, scale and fouling.

 typical installation

BIOLOGICAL CONTROL
Traditional chemical treatments provide nutrients that accelerate the growth of microbes in an open system such as a cooling tower. Bacteria grow to produce a biofilm that may host different types of organisms as well as scale, rust particles and silt. As the film thickens, an anaerobic zone is created which can be invaded by sulfur reducing bacteria (SRB) - a main cause of corrosion in cooling towers.

cooling tower before
Chemically treated tower
with particle clumping, turbidity

cooling tower after
Adjacent tower electrostatically
treated water remains clear

Costs of Fouling and Scale
It is estimated that cooling systems industry-wide average 20% loss of heat transfer due to fouling. This chart correlates fouling and energy waste.

Figures from Ashrae® 2000 Handbook, HVAC Systems & Equipment, Chapter 35, "Maintenance and Operation, Effect of Fouling on Chiller Performance"

Chiller/Cooling Tower
Fouling Factor Versus Electrical Energy Waste

Fouling
Factor

Fouling
Thickness

Increase
in Energy

0.00025

1/320"

3.1%

0.00050

1/160"

6.2%

0.00100

1/80"

12.4%

0.00200

1/40"

24.8%

Chiller Operating Cost Comparison
Annual operating data from a ELECTROchem installation is plotted to show the 'before (red) and after (blue)' effects of electrostatic treatment versus chemical additive treatment. Note that even with a slightly warmer season, the energy-per-ton expenditure was significantly less the following year after installation.

 cost comparison

Savings Benefits

Electrostatic systems provide an attractive return on investment of one to two years based on savings in the following areas:

  • Chemical Costs
  • Water / Disposal Costs
  • Energy Costs
  • Maintenance Costs

Environmental Benefits

  • ISO 14001 Compliance / Toxic Ruse Reduction / Odor Elimination
  • OSHA/DOL Hazard Communication Compliance
  • Eliminated Handling and Storage of Hazardous Material

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 cost savings

Applications

  • Cooling Towers / Chillers / Heat Exchangers
  • Process Cooling / Jacket Cooling
  • Steam Boilers / Humidifiers
  • Reverse Osmosis
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clean and greenELECTROchem Water Systems is a subsidiary of Chemfree Water Systems Inc., and is certified by the Cleaner and Greener Environment Program for its positive emission reduction actions. Visit the Cleaner and Greener Web Site for information on reducing energy use and emissions.