BacComber Power Plant Success Stories

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INDEX

Sr. No. Topic Page No.

1 Outline of Two Power Plants 2
2 Indian Cane & Power Ltd. 2
3 Shri Prabhulingeshwar Sugars & Chemicals 3
4 Design by Ecospec India 5
5 Installation Overview 6

1
Outline of Two Power Plants of Sugar Industry in Karnataka, India

Date of
Company MW CT m3/hr Remarks
Installation
28 5,500 April 2010
Indian Cane & Power Ltd.
55 10,500 Sept. 2015 Repeat order
ShriPrabhulingeshwar
25 6,000 Nov. 2015 E2 used in makeup
Sugars & Chemicals Ltd.

Indian Cane & Power Ltd

Introduction

Initially, when Ecospec approached the Company with BacComber, they found the concept
promising, their General Manager – N Ravish had used our system previously at another
sugar company and was highly impressed with our Technology.

However they analyzed the possible risks and the potential that BacComber had for their
Plant. After 3 months of Technical discussions, they felt that the very job of Engineers is
to continuously improve upon existing practices and Technologies and strive for making
operations as safe and Environment-friendly as possible. Their Group is renowned for
implementing new and innovative technologies successfully. With this positive approach
they decided to go for BacComber on their 5,500m3/ hr flow rate Cooling Tower. The
system was installed and commissioned on April 2010.

They decided to monitor bi-hourly for first few days. They completely stopped all chemical
additions to the Cooling Tower water including almost 300 kg of daily Sulphuric acid
dosing. Initially the water parameters were maintained at existing levels. But after one
month, their confidence in BacComber grew and they decided to increase the limits. After
3 months, they opened the condensers as part of their routine maintenance schedule and
found them to be absolutely clean and free from hard scale.

It has been now 7 years since BacComber has been in operation. We have received repeat
order from them for additional 10,500 m3/hour cooling tower. You can also check on their
website where they have mentioned about ULF Microprocessor Controlled
Treatment. http://www.icpluttur.com/power.html
H

Major Benefits
1B

BacComber has removed almost 90 % of Calcium Hardness daily. The TDS & Total
Hardness has not gone up proportionate to the COC. Thus Bleed-off required is
considerably reduced

2
 Calcium Hardness Trend
490

440

390

340
Make up
Range

290
Circulation
240
Expected
190

140

90

40

 As TDS and Hardness did not increase in proportion to COC, Bleed-off was
considerably reduced. This resulted in Water saving.
 The condenser tubes are much better protected since the TDS and Hardness are
actually removed from the water.

Shri Prabhulingeshwar Sugars & Chemicals Ltd.

Introduction

Shri Prabhulingeshwar Sugars & Chemicals Ltd. (SPSCL) is a well-known name in sugar
industry. The people at SPSCL are always ready to adopt new technologies. When we
approach them with our BacComber system, they showed great interested in the
technology.

In traditional chemical treatment people are treating cooling tower water with chemicals.
So mostly people find it hard to believe that water can be treated without a drop of chemical
and all routine maintenance, handling of hazardous chemicals will come to end.

They were using Nalco 3D Tracer for cooling tower water treatment. Since BacComber
system is nature friendly and saves a lot of water, the Director SPSCL, Mr. Jagadeesh S
Gudagunti, and General Manager Mr. Kotresh, took the decision to go with the new
technology. He decided to replace Nalco 3D tracer with our system.

3
SPSCL was facing water scarcity, they was using E2 condensate along with raw water as
cooling tower make up. The E2 water has high COD and BOD level, we had informed the
customer to continue with some amount of chlorination along with BacComber because he
has no control over the E2 condensate.

They keep on watching the changes in circulating water three times a day. During first
three months they came to know surprising results from water analysis. Day by day, water
in cooling tower was becoming more and more clear. Calcium hardness in circulating water
is not increasing with COC, but it is less than the expected hardness. Same thing is
happening with silica. It is also not increasing with COC.

Major Benefits

 They have increased their COC from 3 to almost 7. Earlier they were measuring
COC on the basis of TDS and now they are measuring on the basis of Chlorides.

COC Trend

15.0

13.0

11.0
Range

9.0
COC
7.0

5.0

3.0

1.0

 Condenser Tubes are free of Hard Deposits.

Now all the SPCL people are well satisfied with the system and are proposing everybody
about this system.

4
Design by Ecospec India

Water Parameters
Limits (Max) in Water
Parameter
Make Up CT
TDS (ppm) 500 2,500
pH 7.2 8.75
Total Hardness (ppm) 400 1,000
Chloride (ppm) 200 800
Silica (ppm) 20 100
P. Alkalinity (ppm) Nil 50
BOD (ppm) <20 50 *
COD (ppm) <50 80 *
M. Alkalinity (ppm) 200 *
P. Alkalinity (ppm) 10 *
Turbidity (NTU) 10 10
TSS (ppm) 10 10
Phosphate (ppm) Nil Nil
Please refer File attached: Guide for Proper C.T Water Treatment
* No Chemicals are added by BacComber Treatment to increase or decrease these parameters.
 BacComber Treatment is only for dissolved solids
 Control of parameters mentioned is by Bleeding and addition of make up water.
 Standard practice is to use the lowest limit as the bleeding limit. For example, if Chloride
reaches the limit before the pH then bleeding is based Chloride.
 Quite often bleeding is to be done to maintain the maximum limit of pH and other parameters
would follow the limits set.
 It is important that the make up and CT water parameters are controlled by user to get
optimum results.
 The water in the cooling tower should be maintained at Minimum 1,000 ppm TDS.
BacComber Treatment does not cover the following:
 Parameters of make-up water.
 Pre-treatment or control of make-up water (before it goes into cooling tower) parameters
such as pH, BOD, COD, Phosphate.
 Removal or control of suspended particles, mud, clay, sludge , foreign particles such as
wood, metal, stones, rust, chlorides, silica and phosphates.
 Removal of contaminants such as oil and process leakages.
 Deposits on the fins of cooling tower.
 Algae on the splash areas, in hot wells on top of cooling tower.
 If STP water is used as make up water, it should be free of nutrients for bacteria and
suspended particles.
 If there is any equipment with small gaps such as plate heat exchanger kindly notes that these
are basically designed to operate with low TDS water and because of the small gap between
the plates suspended particles could clog it. They would need cleaning if it happens.
 If muddy substances come out of the pipelines etc, these are due to old deposits since
BacComber does not add any chemicals. In such cases extra blow down and frequent
cleaning may be required till the water becomes clear.

5
Installation Overview

Cooling Tower & BacComber Control Room

General Arrangement of BacComber System

6
General Arrangement of Inductor Coil placement

Actual Placement of Inductor Coil Assembly

7
General Arrangement of ULF Emitter placement

Actual placement of ULF Emitters

8
 General Arrangement of Control Room

Actual placement of Enclosures inside Control Room