StandaloneHyCatorTM:BFPReactorSystemforBiofoulingpreventionin CoolingTowerwater

CaseStudy1 Chemical treatment cost was high and the plant management was under pressure to reduce water usage and discharge. Cycle of concentration was also low. A hard scale often formed in the summer season.Thebacterialcountswere105cfu/ml.

HyCatorTM: BFP reactor system was installed in the cooling tower circuit. A detailed study was conducted on the cooling tower system over six month period to evaluate the performance of the devicefordisinfection,scaling,corrosion,cyclesofconcentrationandheattransferefficiency.

Performance exceeds customers expectations. Make up consumption has been reduced by 30% and blow down discharge reduced over 60%. Bacterial microbial counts become nil and cycles of concentration substantially was increased. The results also indicated that the HyCatorTM: BFP reactor systemtreatmentperformedwellcomparedtothechemicaltreatmentwithoutaddinganychemicals. Inthisparticularcasedosageofanticorrosionandscalepreventionchemicalswasalsonotrequired. Annual water saving exceed 3600 m3. The cost of HyCatorTM: BFP reactor system is economical in terms of operational costs with pay back period of less than 2 yrs; and it needs very limited maintenance.

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The main problem was high blow down water and bio fouling. The cooling tower was operated at low cycleofconcentration(3.0).

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AfterthesuccessfulinstallationofHyCatorTM:BFPreactorsystem,thebiocidesdosingreducedto10%

and other chemicals (dispersant, corrosion inhibitor and anti scalent) reduced to 40 % of the original.

The bacterial counts come down under the permissible limit. Blow down has been reduced 40 % and

Cycleofconcentrationisalsomarginallyincreased.Oldscalewasgraduallyremovedandnonewscale formed.

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CaseStudy2

HyCa Technologies Pvt Ltd

176, Udyog Bhavan, Sonawala Road, Goregaon (E), Mumbai 400 063 INDIA Ph: + (91) (22) 2566 8037 Web: www.hycator.com Email: mail@hycator.com

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 Casestudy3 Thevolumeofmakeupanddischargewaterwashighanditwasoperatedalowcycleofconcentration. Biofoulingwasalsohigh.

Bio fouling was fully controlled after the installation of HyCator: BFP reactor system. The scale and corrosion is also reduced over previous chemical treatment. Cycle of concentration also increase resultedinareductionof25%inmakeupwaterand50%inblowdownwater.

The customer saved huge money by installing the HyCator: BFP reactor system which resulted a payback period of less than 2 years. After the successful installation, the second HyCatorTM: BFP

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reactorsystemhasalsobeeninstalledinanothercoolingtoweratthesamesite.

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Representative image of standalone HyCator: BFP reactor system supplied to one of the reputed agrochemicalcompanyinIndia.ThesnapshotaboveshowsaHyCator:BFPreactorwithacentrifugal

pump and an electric motor. (Please note, each standalone HyCator: BFP reactor unit is custom

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

HyCa Technologies Pvt Ltd

176, Udyog Bhavan, Sonawala Road, Goregaon (E), Mumbai 400 063 INDIA Ph: + (91) (22) 2566 8037 Web: www.hycator.com Email: mail@hycator.com


Principle

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Expansion Phase

Maximum radius

Collapse Phase

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Collapseofthevoid (Cavity)onremoval ofenergysource

Breakinthecohesiveforcesin theliquid continuumformation ofvoids

Growthofvoids withcontinualsupply ofenergy

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SpecificEffects: Highmagnitudepressurepulse,100to5000atm Extremelyhightemperatures,1000to12000K Velocitiesinexcessof2to3timesthatofsound

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Bang!
Releaseof energy

Decreasing the pressure over the liquid to its vapor pressure generates vapor bubbles in liquid. This is also called as cavitation or cold boiling. When the pressure is brought back to normal

temperatureatthepointofcollapse.

Such intense conditions (9000 atm and 5000 K, intense turbulence) can bring about several physicalandchemicaltransformationsevenwhenthebulkconditionsareambient. HyCa technologies have mastered the art of producing, stimulating and collapsing such bubbles in the required manner and on the desired scale using its innovative product HyCatorTM Reactor System. HyCatorTM: BFP reactor systems are fine tuned for generating tailor made cavities suitable for particular applications like molecular breakdown. Due to such extremely high temperature, pressure intense turbulence; shockwaves are generated which are capable for

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destroyingthemicrobes.

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pressurethesevaporousbubblescollapsebackinwaterwithabangtogenerateintensepressureand

HyCa Technologies Pvt Ltd

176, Udyog Bhavan, Sonawala Road, Goregaon (E), Mumbai 400 063 INDIA Ph: + (91) (22) 2566 8037 Web: www.hycator.com Email: mail@hycator.com

RetrofittingHyCatorTM:BFPreactorsystemintoexistingcoolingtowersystem Figure 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 the HyCator: BFP reactor system and the treated cooling 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.

StandaloneHyCatorReactorDischargeLine

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Cooling tower

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Coolingtowersump

Strainer Suctionline

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Fig.:SchematicofcoolingtowercircuitandStandaloneHyCatorReactorSystemsInstallation

PotentialBenefits: HyCatorTM: BFP Reactor system prevents the bio fouling and reduces the blow down to a very low

value which in turn will reduce the make up water rate. Once the frequency of makeup water is reduced the addition of other chemicals will also reduce and other impurities due to addition of chemicalswillalsoreducesignificantly.

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HyCa Technologies Pvt Ltd

176, Udyog Bhavan, Sonawala Road, Goregaon (E), Mumbai 400 063 INDIA Ph: + (91) (22) 2566 8037 Web: www.hycator.com Email: mail@hycator.com

HyCator Reactor

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Timer arrangement torunpump forpre decidedtime making systemFIT& FORGET

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Ingeneralfornormalfeedwaterqualitythepotentialbenefitsare: 1. 2. 3. 4. 5. Helpsinthepreventionofbiofouling,corrosionproblemsandscaleformation. EnvironmentallySafeNochemicalsaddedorunwantedresidualscreatedbytheprocess. Noneedofbiocideschemicals. Reduce40%consumptionofdispersantsandcorrosioninhibitors.

Reducedblowdownofwaterduetooperationathighercyclesofconcentration.

6. Reduce4080%consumptionofblowdownwater. StandaloneHyCatorTM:BFPreactorsystembuyingprocedure 1. 2. 3.

OnclientsrequestHyCawouldsendadetailedquestionnaire.

Onreceiptoffilledupquestionnaire,HyCawillgiveaquoteforfullscaleequipment. HyCatorTM:BFPReactorsarecustomdesignedandfabricated.

FrequentlyAskedQuestions(FAQs)

Index Equipment 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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HyCa Technologies Pvt Ltd

176, Udyog Bhavan, Sonawala Road, Goregaon (E), Mumbai 400 063 INDIA Ph: + (91) (22) 2566 8037 Web: www.hycator.com Email: mail@hycator.com

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Once receipt of Purchase order (PO) for full scale, HyCator: BFP is fabricated and delivered. All

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 Equipment WhatisthespacerequirementforHyCatorTMBFPreactorsystem? StandaloneHyCatorTMBFPreactorsystemrequiresverylessfootprint.Typicallyitisthespace required for installation of pump set. The HyCator: BFP reactor to be installed at the pump dischargeside. WhatwillbetheweightofHyCatorTM:BFPreactorsystem?

Based on the pipe size the typical weight of HyCator will be ~100 kg to 400 kg. However the actual weight and size of HyCatorTM: BFP reactor system may vary depending upon pipe size, pumpsize,sumpvolume,capacityofcoolingtowerandblowdownfrequency. IfneededhowcanweseparatetheHyCator:BFPfromthemainline?

AbypassvalveisprovidedinHyCator:BFPreactorsystemanditcanbecompletelybypassed

WhatwillbedeliveryperiodofHyCatorTM:BFPreactorsystem? ThedeliveryperiodoftheHyCatorwillbe68weeksafterthereceiptofbothtechnicallyand

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DoesthestandaloneHyCatorTM:BFPreactorsystemrequireanyexternalenergysupply? An external energy source is required to an electric motor which will run the standalone HyCator:BFPreactorsystem.

Whatadditionalhardwareormanpowerisrequiredforinstallation? No additional hardware is required. For installation client needs to arrange only fitter, welder & an electrician. Tuning of the HyCatorTM Reactor System is very well documented in the

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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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installationguideprovidedwithHyCatorTMReactorSystem. Isthistechnologycosteffective? Yesitis,becauseitsavespower,waterandchemicals.Theprocessgenerallyis~2040%less costlythanconventionalchemicaltreatment. Whataboutthepaybackperiod? Formostofourclientstilldatethepaybackperiodwasinrangeof12yrs.

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HyCa Technologies Pvt Ltd

176, Udyog Bhavan, Sonawala Road, Goregaon (E), Mumbai 400 063 INDIA Ph: + (91) (22) 2566 8037 Web: www.hycator.com Email: mail@hycator.com

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commerciallycompletedpurchaseorder.

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fromtheexistingcoolingwatercircuitwheneverrequired.

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IsInstallationofstandaloneHyCatorTM:BFPreactorsystemdifficult? Installation of standalone HyCatorTM: BFP reactor system is very easy and needs only fitting it in bolted flanges at the required location. The weight of the HyCator ranges from 100 kg to

WhatwillbetheoperationalcostofstandaloneHyCator:BFPreactorsystem?

The exact operational cost of HyCator: BFP reactor system can be estimated only after receivingcoolingtowerdetailsasperourstandardquestionnaire.

The performance can be monitored by analyzing (pH, CFU, TDS, total hardness and total alkalinity)ofthecoolingtowerwater. Environmental&Safetyissues

IsHyCator:BFPreactorsystemenvironmentallysafe?

Yesitis,becauseitreducesthetotalconsumptionofchemicalsusedforgivencapacityof coolingtower.

Whatarethesafetyissuestobeadoptedduringitscourseofoperationandhandling? Standalone HyCatorTM: BFP reactor system demands no critical safety measures; however someofthegeneralsafetymeasuresareasfollows: The weight of standalone HyCatorTM: BFP reactor system will be ~100 kg to 400 kg. So use appropriate chain pulley blocks or other lifting equipment is recommended duringitsinstallation. 2. Give the proper support to equipment and the adjoining piping. HyCatorTM: BFP reactorsystemcanbeinstalledinanyorientation,eitherverticalorhorizontal. WhileinoperationstandaloneHyCatorTM:BFPreactorsystemdoesNOTgenerateany

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3. 4.

pressure or temperature higher than the inlet water pressure and temperature.

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

operatingmanualsuppliedwithequipment.

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HyCa Technologies Pvt Ltd

176, Udyog Bhavan, Sonawala Road, Goregaon (E), Mumbai 400 063 INDIA Ph: + (91) (22) 2566 8037 Web: www.hycator.com Email: mail@hycator.com

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Whatisproceduretomonitor/evaluateperformanceofHyCatorTMReactorSystem?

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400kgdependingonthepipesize.