Introducing Nereus for Evaporative Condensers. Sustainable Water Solutions, Water Reuse, Reverse Osmosis, http://sustainablewatersolutions.com

1. Evaporative Cooling Condensers
Water Efficiency
and You

2. Executive Summary
Water Misalignment
• Current Water Practices are
unsustainable
• We face
– Epic Drought
– Pressure like never before on water
• Current WT industries method of
delivery sets incorrect incentives
– Maximize
• the sale of high margin “Specialty “
product
– Minimize
• “Service “ Time
– Almost Ignore
• Water and energy use
In the end, the current services delivery
method simply ignores the key issues and
costs customers more to operate chiller
system than should be the case
Resources Wasted
• Water
– Excessive Water
• Make up
• Bleed
– Excessive & Dangerous Chemical
• Antiscale
• Biocide
• Acids
– Excessive Utility Use
• Electrical Use
– Chiller inefficient Kw / Tn
• Process management
– Staff assigned no / low value activities
• Daily water testing
– Important information not communicated
• H/E
– Approach, Heat Flux, Etc
• Tower efficiency
• Atmospheric conditions
– Wet bulb, dew point, humidity
– Out of spec conditions not reported until
damage is done vs with in seconds

3. Getting Started
• No Cost to Client
– Water Samples provided to SWS LLC
• City & Tower
– System Information
• Cost
– Water, Sewer, Power, Descaling
– Tns total system design
– % Load On Line
» Fall, Winter, Spring, Summer
» Days in each season
• Output with in 2 weeks
– Savings available, Cap Ex, Op Ex
• Pilot is available
• Process guarantee
– $ savings will be delivered
– Water will be saved
– System will operate with less scale than is currently the case
– System will operate with less corrosion than is currently the case
– System will operate with less energy than is currently the case

4. Preface - Drought
Houston – We Have A Problem

5. Preface - Inefficiency

6. No Water
From Water Project
Preface – Surface Water
Reservoirs are Drying Up

7. Preface – Ground Water

8. Preface - Food Prices

9. Preface
People, Food, Energy – All Need H2O

10. Preface – Energy Cost Up

11. Executive Summary
Too Many Big Straws in The Milkshake

12. Help Do Your Part to Help Us Help You
Save 1,000,000,000 GPY

13. Evaporative Condensers
• Evaporative condensers reject energy from the hot, high pressure
compressor discharge refrigerant to the ambient air thereby causing a
change in state from vapor to liquid - Condenser
• Water from the basin is pumped to the top of the unit and sprayed down
over the outside of the coils as ambient outside air is drawn or blown
through the unit by fans.
• As the water pours over the coils and evaporates into the air stream
• the exterior heat exchanger surface tends to approach the outside
air wet bulb temperature
• energy is transferred from the high temperature
refrigerant to the relatively cooler water.
• Nearly saturated air leaves the top of the condenser at a
temperature lower than the saturated condensing
temperature (SCT), i.e., the saturation temperature
corresponding to the pressure inside the condenser.
• The refrigerant then drains from the condenser to the
system’s high-pressure receiver.
• The evaporative condenser is mainly a wet bulb sensitive
device

14. Distribution is Critical

15. System Capacity
• Provided by Manufacturer
– Nominal Volumetric Air Flow Rate
– Nominal ( Base )Heat Rejection Capacity
– Heat Rejection Adjustment Factor - HRAF
• Outside air wet bulb
• Ammonia Condensing temperature
Actual Capacity =
NHRC
HRAF
1600.0
1400.0
1200.0
1000.0
800.0
600.0
400.0
200.0
0.0
Evaporate Condenser Capacity in Tons
Holding
Pressure = 160 vs Wet Bulb Temp
50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80

16. Impact of Wet Bulb on Capacity
1600.0
1400.0
1200.0
1000.0
800.0
600.0
400.0
200.0
0.0
Evaporate Condenser Capacity in Tons
Holding
Pressure = 160 vs Wet Bulb Temp
50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80

17. Impact of Head Pressure on Spend
$ / Yr. Condenser Energy Consumption
vs Condenser Pressure
1000 Tns at $0.11 / KwHr
$682,903.32
$654,149.50
$740,410.97
$711,657.14
$790,730.16
$761,976.34
$848,237.81
$819,483.98
$884,180.09
R² = 0.9982
$1,050,000.00
$1,000,000.00
$950,000.00
$900,000.00
$850,000.00
$800,000.00
$750,000.00
$700,000.00
$650,000.00
150 155 160 165 170 175 180 185 190 195 200 205 210

18. Get the Water Chemistry Right
Proper Water Chemistry Allows Higher Cycles
Annual Water Use
14,000,000
12,000,000
10,000,000
8,000,000
6,000,000
4,000,000
2,000,000
-
500 Tn Chiller
2 4 6 8

19. Carbonate Based Scales
• 6/18 of common scales in cooling applications
are associated with Carbonate / BiCarbonate
– Calcite
– Aragonite
– Witherite
– Strontianite
– Calcium Oxalate
– Stederite
• Eliminate this with H+
In the past Today
danger
Condensafe II
0
CO3-2 + 2H+= CO2 + H20 0 0

20. Carbonate Based Scales
• 4/18 of common scales in
cooling applications are
associated with Sulfate
– Anhydrite
– Gypsum
– Barite
– Celestite
• Eliminate this by not feeding
H2SO4
In the past Today
danger
Condensafe II
0
CO3-2 + 2H+= CO2 + H20 0 0

21. Condensafe II
• Synthetic
• Functional replacement for H2SO4
• On June 18, 2008
– Dr. Robert Scheuplein, Toxicologist and Veteran Director of the Office of
Toxicology Sciences at FDA’s Center for Food Safety and Applied Nutrition.
• Dr. Scheuplein has assessed that the active ingreadient in Condensafe II is “Generally Recognized as Safe
(GRAS) in accordance with FDA assessment guidelines.
• Condensafe product formulations
– carry a triple zero Hazardous Materials Information System Score
– An A rating with regards to required PPE
– Are 100% biodegradable in 30 days or less per EPA, Design for the Environment,
– OECD and Hach Reactor method guidelines and meet or exceed stringent Direct Release Guidelines for 10 day
bio-degradation.
– The entire family of SAFE products
• are non-regulated by the
– US D.O.T.,
– CANADIAN TDG, IMO and IATA.
• are classified as non-voc, non-corrosive, non-mutagenic, and non-toxic.
• show no potential for the generation of carbon dioxide under NIOSH 7903, OSHA & ACGIH testing protocols.

22. All Good Cooling Inhibitors Contain Common
Building Blocks
– BZT
• BZT is a corrosion inhibitor and/or yellow metal deactivator based on 1,2,3-
benzotrizole.
– BZT prevents corrosion of yellow metals such as copper, copper alloys, bronze, and other
metals.
– BZT inhibits the corrosion of steel, cast iron, cadmium and nickel alloys under certain
conditions.
– BZT reduces the corrosive influence of copper ions on various metals.
– HEDP
• HEDP is an organophosphoric acid corrosion / scale inhibitor.
– HEDP can chelate with Fe, Cu, and Zn ions to form stable chelating compounds.
– HEDP shows excellent scale and corrosion inhibition effects under temperature 250℃.
– HEDP has good chemical stability under high pH value, hard to be hydrolyzed, and hard to be
decomposed under ordinary light and heat conditions.
– HEDP acid/alkali and chlorine oxidation tolerance are better than that of other
organophosphoric acids (salt).
– HEDP can react with metal ions in water systems to form hexa-element chelating complex,
with calcium ion in particular.
– PBTC
• PBTC acts as a crystal modifying agent and threshold inhibitor for calcium and other
metal salts.
– PBTC is widely used in industry as a sequestering agent and calcium carbonate scale inhibitor.
– In systems that utilize oxidizing microbiocides, such as bromine, PBTC exhibits superior
stability under oxidizing conditions compared to other organophosphonate compounds.
– Silica Control Polymer
• ACUMER 5000 is a proprietary multifunctional polymer with a molecular weight of
5000 that provides outstanding silica and magnesium silicate scale inhibition.
– ACUMER 5000 prevents silica-based scale formation by dispersing colloidal silica and by
preventing magnesium silicate scale formation at heat transfer surfaces

23. Alternatives
• Do Nothing
• Dolphin and or Magnets
– Relies on Low Cycles
• Wastes Water
• Deposits
• Corrosion
• Softeners
– Improper water chemistry results in corrosion
• Other Water Treatment Companies
– Low degree of monitoring
– Disincentive to provide service

24. Traditional Water Treatment
• Monitored
– Conductivity
– pH
• Controlled
– pH
– Conductivity
– Antiscale pump on and off

25. Dolphin
• Controls nothing
• Tower is bled to keep
– Cycles Low
– Water Use High
• Essentially once through cooling

26. Softeners
Softeners are not recommended for galvanized towers
• Historically, maximum service life was obtained by maintaining the chemistry of
the circulating water at an essentially neutral state (pH of 6.5 to 9.0) and
allowing the natural formation of a protective, light crystalline film on the zinc
surface which retarded the formation of white rust.
• While there is still some disagreement on the actual cause of the recent increase
in reported cases of "white rust", various water treatment experts are concluding
that some of the newer, higher alkaline, treatment chemistries actually inhibit the
formation of protective films on the galvanized surface and thus allow the
development of white rust.
• There are also indications that soft water (less than 30 ppm total hardness),
when combined with these high pH conditions, can exacerbate the problem.

27. We Use Water More Effectively

29. Nereus On Line Chemistry
• Conductivity
– Controls cycles of concentration
• pH
– Controls alkalinity / LSI / Scale
• ORP
– Controls biocide feed
– Biological control
• Antiscalant
– Controls scale
• Ca
• Si
• Fe

30. Nereus On Line Meters
• Make Up
– Water Use and cost
• Bleed
– Sewer discharge and cost
• Recirculation
– Supply to Heat Exchangers
• Temperature
– Air Dry
– Air Wet bulb
– Heat exchanger supply water
– Heat exchanger return water
– Refrigerant condensing temperature
• Chemical inventory levels
• Chemical feed rate

31. Nereus Auxilary
• Corrosion coupons
– System metallurgy
• Biological Testing
– Total Aerobic Count
– Sulfate Reducing Bacteria
– Mold
– Fungus

32. Nereus Calculations
• Tower
– Efficiency and efficiency vs design
– Approach and approach vs design
– Delta T and delta T vs design
• Water
– $ / Day, Month, Yr
– $ vs budget Day / Month / Yr
– Yr over Yr
• Sewer
– $ / Day, Month, Yr
– $ vs budget Day / Month / Yr
– Yr over Yr
• Chemical
– % Tank level
– $ / Day, Month, Yr
– $ vs budget Day / Month / Yr
– Yr over Yr

33. Nereus Calculations
• Refrigeration tns on line
• Refrigeration as a % of design max
• Cost / Tn of refrigeration for
– Water actual / actual vs budget / Yr vs Yr
– Sewer actual / actual vs budget / Yr vs Yr
– Chemical actual / actual vs budget / Yr vs Yr
– Power actual / actual vs budget / Yr vs Yr
• Refrigeration Efficiency
– Kw / Tn refrigeration actual / actual vs budget / Yr vs Yr

34. Nereus vs Old School

35. We Use Water More Effectively

36. Getting Started
• No Cost to Client
– Water Samples provided to SWS LLC
• City & Tower
– System Information
• Cost
– Water, Sewer, Power, Descaling
– Tns total system design
– % Load On Line
» Fall, Winter, Spring, Summer
» Days in each season
• Output with in 2 weeks
– Savings available, Cap Ex, Op Ex
• Process guarantee
– $ savings will be delivered
– System will operate with less scale than is currently the case
– System will operate with less corrosion than is currently the case
– System will operate with less energy than is currently the case

37. Appendix
• Chiller / Condenser Facts
• Measuring
• Definitions
• Chillers
• Fouling
• Chiller Efficiency
• Improving Chiller Efficiency
• Typical Water Treatment Problems
• Pitting

38. • Inability to remove
heat effectively
– Higher head
pressure

39. Fouling
• 240 ton chiller
– Greg Bush Regional Services Lead for Americas
• SAP GFM Data Center Services
• Regional Energy Manager for Americas
– In the case of SAP at $0.15 kWH
– $5,600.00 a year in wasted electricity per degree approach
fowling. This is a meter verified number.
• Chiller in study has efficiency of .65 Kw per ton annualized.
EPA statement said a 1000 ton chiller at
$0.11 per kWH is $10,000.00 a year of
wasted energy per degree fouling

40. Typical Problems Encountered
• Tower Basin
– Calcium deposits
– Corrosion Tubercle
• Tubercle removed
• Under Deposit Corrosion
• Corrosion Perforation
– Under Deposit Corrosion

41. Pitting
• All forms of corrosion, with the exception of some types of high-temperature
corrosion, occur through the action of the electrochemical
cell.
• The elements that are common to all corrosion cells are:
– An anode where oxidation and metal loss occur,
– A cathode where reduction and protective effects occur,
– Metallic and electrolytic ( system water ) paths between the anode and
cathode through which electronic and ionic current flows,
– A potential difference that drives the cell.
• The driving potential may be the result of differences between the characteristics of
dissimilar metals, surface conditions, and the environment, including chemical
concentrations.

42. Pitting
• Pitting corrosion is a localized form of corrosion by which cavities or
"holes" are produced in the material.
• Pitting is considered to be more dangerous than uniform corrosion
damage because it is more difficult to detect, predict and design against.
• Corrosion products often cover the pits.
– A small, narrow pit with minimal overall metal loss can lead to the failure of an entire
engineering system.
– Pitting corrosion, which, for example, is almost a common denominator of all types of
localized corrosion attack, may assume different shapes.
• Pitting is initiated by:
– Localized chemical or mechanical damage to the protective oxide film; water chemistry
factors which can cause breakdown of a passive film are acidity, low dissolved oxygen
concentrations (which tend to render a protective oxide film less stable) and high
concentrations of chloride (as in seawater)
– Localized damage to, or poor application of, a protective coating
– The presence of non-uniformities in the metal structure of the component, e.g. nonmetallic
inclusions.
• Theoretically, a local cell that leads to the initiation of a pit can be caused
by
– an abnormal anodic site ( under a deposit ) surrounded by normal surface which acts as a
cathode,
– or by the presence of an abnormal cathodic site surrounded by a normal surface in which a
pit will have disappeared due to corrosion.

43. Theory
• Water Chemistry
– Lack of proper water treatment chemistry allows deposits to occur
– Ca, Mg, Fe
– Deposits cause corrosion
– Corrosion products cause more deposits / corrosion with out proper treatment

44. Observations
• Corrosion
• Corrosion Products
• Corrosion products covered with
scale
• Scale is chips off and anode is
formed
• Small anode
• Combined with large cathode
• Pitting is expected