Brominator Dispensing Device

General Information FeedChem Industrial Water Treatment bromine dissolution feeders (Brominator) have been designed exclusively for the safe and proper application of BromiCide® products distributed by FeedChem Industrial Water Treatment and its subregistrants. BromiCide is a unique bromine release oxidizing biocide used for the control of bacterial, algal and fungal populations in industrial water systems. The active ingredient in BromiCide is bromochlorodimethylhydantoin (BCDMH) which slowly releases biocidal bromine when dissolved in water. (CAUTION: The use of any chemical product other than BCDMH distributed by Bio-Lab, Inc. and its subregistrants in a FeedChem Industrial Water Treatment brominator dissolution feeder could cause a chemical reaction leading to excessive pressurization of the brominator tank, creating an explosion of the vessel, causing death, serious bodily injury, or property damage.)

This manual must be read in its entirety before the user commences assembly, installation or use of the FeedChem Industrial Water Treatment brominator dissolution feeder.

All FeedChem Industrial Water Treatment brominators are specialized bypass feeders constructed of fiberglass reinforced plastic (FRP) tanks and chemical resistant PVC piping. Supply water flows through “pressurized spray nozzles”, creating turbulence inside the brominator tank. BromiCide is dispensed into the industrial water system by dissolution and erosion of minute particles from the chemical bed. The amount of BromiCide dispensed can be easily increased or decreased by adjusting the supply water flow through the brominator.

Brominator Feed System

Brominator Sizing Considerations Proper sizing of a brominator feed system is critical to achieve successful control of bacterial, algal and fungal populations with BromiCide. The sizing of information presented in this document is only an approximation; each system is unique, and proper sizing may vary according to season, system demand, and feed frequency. For specific application and dosing information, consult your professional water treatment service company representative or FeedChem Industrial Water Treatment. Sizing a brominator is not complex, however certain factors may exist that could affect the size of the brominator. Consider the following before making a brominator selection:

1. Halogen Demand Some industrial systems have unusually high halogen demands. These systems usually require a higher feed rate and a larger brominator.

2. Water Temperature

It is important to know your water temperature. Hot supply water provides for a higher BromiCide dispensing rate. Cold water reduces the dispensing rate.

3. Flowmeter Range

After calculating the amount of BromiCide required for your system, select a brominator that will give you approximately twice the feed rate calculated. This will allow you to meet your specific dosage requirement while operating near the middle of the flowmeter range, which allows the freedom to increase or decrease the dispensing rate for seasonal variations or demand fluctuations.

4. Brominator Location

Allow at least 5 feet of clearance above the brominator for adequate ventilation and ease of refill. If height is a problem in your specific application, it is possible to achieve the feed rate of a large brominator by replacing it with two shorter units in parallel. The height of all BromiCide brominator feed systems is shown in the brominator system profile.

5. Refill Frequency

To maintain accurate BromiCide dispensing rate, refill the brominator when it reaches half the initial BromiCide bed level.

Brominator Sizing Calculation The key to calculating the amount of BromiCide required to treat a system is to determine the total amount of water that will need to be treated per day. With the following guidelines you will be able to approximate the amount of BromiCide needed per day. By dividing the daily amount of water need by the number of hours you wish to treat the system per day, you will obtain the approximate brominator dispensing rate in pounds of BromiCide per hour. For once-through water systems, simply convert the maximum annual daily flow(gal/min or MGD) to the total maximum volume of water that will be treated per day and proceed to step 4 below. 1. Estimate the system static volume.

Add 10% to accommodate for the volumes of the system piping configuration

A=System Volume + 10% 2. Determine the daily system make-up water supply volume.

This is the amount of make up to be treated in gallons per day.

B (gallons of make-up/day)=Make-Up (gpm) x 1440 (min/day)

3. Determine the total volume to be treated. Add the system static and make-up water volumes together to obtain the total volume of water to be treated per day.

TV (total volume to be treated per day in gallons per day)=A + B

4. Determine the BromiCide Dosage Requirement in pounds of product.

Using the following equation, determine the BromiCide dosage requirement in pounds of product per day:

DR (Dosage Requirements-lbs/day)= TV (total volume in gal/day) x 0.000036 (lbs/gal)

Note: 0.000036 (lbs/gal) = 3 pounds BromiCide per 100,000 gallons of total

volume plus a 20% allowance for peak capacity periods. Experience has shown that range may vary for specific applications from 1-4 pounds BromiCide per 100,000 gallons of total volume. Depending on system conditions, wastewater treatment facilities could require up to 12 pounds of BromiCide per 100,000 gallons of total volume.

5. Determine the Dosage Rate in pounds per hour.

Divide the dosage requirement calculated in step 4 by the amount of hours per day you will be feeding chemical to obtain a dosage rate in pounds per hour. Dosage Rate(Pounds per hour)=DR ÷ Hr/day (Hours per Day)

6. Brominator Selection To select the proper brominator model, simply compare the dosage requirement you have calculated with the maximum brominator dispensing rates shown on the next page. Use the column that corresponds to the appropriate supply water temperature of your specific system. It is recommended that you select a model giving you approximately twice the feed rate calculated. This will allow you to meet varying dosage requirements while operating near the middle of the flowmeter range. More than one brominator may be appropriate. To decide between two models, calculate your refill frequency as shown in the equation on the next page and select the unit that meets your specific requirements.

Note: The maximum dispensing rate information has been derived under

average conditions. Actual rates may be affected by system demand, condition of supply water, or specific treatment objectives. Therefore, while this information is believed to be accurate, actual conditions may vary from the rates shown above. No warranty, expressed or implied, is extended to the accuracy of this information.

7. Maintain the system.

To maintain accurate BromiCide dispensing rate performance, refill the brominator when it reaches half the initial capacity level.

Refill Frequency (hours) = ½ Brominator Capacity (lbs) ÷ Dosage Requirement (lbs/hr)

Brominator Dimensions

Brominator Assembly Exercise care during the assembly of the brominator dissolution feeder. It is important to tighten all connections to prevent leaks. Do not tighten excessively, as components will crack or break.

1. Apply Teflon® tape to all male threaded connections before assembly. Start at the outer edge and tightly wrap clockwise toward the inner base. If leaks are detected during the pressure testing process, disassemble the affected pipe connection, remove the Teflon tape, and reseal using Teflon paste.

Safety Note: Use only Teflon tape or Teflon paste to seal all

threaded connections. Other types of pipe sealant may contain chemicals that will react with BromiCide leading to excessive pressurization of the brominator tank. System pressures in excess of the recommended maximum operating pressure may create an explosion of the vessel causing death, serious bodily injury or property damage.

2. Assemble the internal parts according to the diagram and parts list enclosed with the brominator feed system. Do not cross-thread or over-tighten.

3. Construct the bottom assembly. On the SC-10-05 brominator, the bottom assembly simply threads into the tank. On the SC-10-10 model, insert the spray nozzles into the GL hub and position it securely into the 4-inch bottom closure. Thread the entire assembly into the bottom of the tank.

Spray Arm Subassemblies and Hub Assemblies (Figure1)

Follow the instruction given below to install the bottom assembly and spray nozzles in all brominator tanks larger than the SC-10.

A. Place the tank on its side. B. Screw the 4-inch bottom closure with O-ring into the bottom opening on the tank. Use Teflon tape or Teflon thread sealant on the bottom closure threads. Do not cross-thread or over-tighten. C. Assemble the six spray arm subassemblies (Figure 1) D. Thread two spray arm subassemblies into adjacent holes on the canted hub. Note: The thread holes in the canted hub are drilled at an angle. This allows the canted hub with spray arms to be installed inside the bottom of the tank with adequate clearance. Position the nozzles to point up when installed. E. Insert the canted hub with two spray arms attached through the top of the tank. Lightly attach a ½ inch threaded pipe extension that is long enough to reach the bottom of the blind hole in the center of the canted

hub. This extension is used to install the canted hub and is to be removed when the installation is complete. F. Thread the remaining four spray arm subassemblies into the canted hub. This step is completed inside the top of the tank. Position all six spray arms to point up when installed. G. Using the extension, lower the assembled canted hub to the bottom of the tank and push it into the bottom closure. H. From outside the tank, insert the male end of the 2-inch elbow with O-ring through the bottom closure and engage the female threads of the canted hub. I. The inlet piping of the external connect kit will be connected to a 2-inch pipe nipple extending from the 2-inch elbow with O-ring. orientation of the elbow is determined by the position of the external piping. Tighten the connection between the elbow and the canted hub. Do not cross-thread or over-tighten. J. Using a hole saw, drill a 3 ½ -inch diameter hole through the tank base to allow the 2-inch pipe nipple to pass through the tank base. Align the 2-inch elbow with O-ring with the hole inside the tank base.

4. Position the top diffuser in a downward position. PVC glue is provided for all socket connections. On SC-10-05 and SC-10-10 models, the molded screen simply threads into the outlet nipple after it is installed into the side of the tank. 5. Assemble the external parts according to the diagram and parts list enclosed with the brominator feed system. Do not cross-thread or over-tighten. Brominator Installation Install the brominator feed system in an area that allows for easy access and protection from vehicle traffic. Permit at least 5 feet of clearance above the tank for filling and servicing. The tank has a self-supporting base. However, it is recommended to strap the tank to a vertical support for additional stability. 1. Figure 2 displays three routes for the discharge piping. Select the route that directs the brominated water to the area of greatest anticipated need, or select a split route to direct the discharge to multiple areas. Whenever possible, discharge the effluent to atmospheric pressure in the tower sump.

Example of a Typical Brominator Feed System Installation (Figure 2)

Special Note: Use backflow prevention where necessary and Consult your

water treatment service professional. 2. Use corrosion-resistant piping, such as schedule 80 PVC, for all piping from the outlet union to the point of injection. Conventional plant piping may be attached to the inlet union. 3. When piping the brominator feed system discharge to the suction side of a pump, allow sufficient distance for dilution and mixing. The concentrated effluent is generally corrosive to iron, stainless steel and brass. 4. To achieve maximum BromiCide dosage rates, supply the inlet pressure necessary to overcome the following pressure drops through the brominator tank.

5. Pressure test the system before operation. Open the outlet valve completely and slowly open the inletvalve to allow the normal operating pressure to be established, without including water hammer. Check and correct leaks before full pressure is applied and before BCDMH is added.

Safety Note: Do not contaminate BromiCide with foreign substances (rust,

dirt, etc.), organics (including Alcohols, aldehydes and ketones ), reducing agents, oxidizing agents, corrosion inhibitors, scale inhibitors, dispersants or any other chemicals. Contamination may cause a chemical reaction leading to excessivepressurization of the brominator tank. System pressure in excess of the recommended maximum operating pressure may create an explosion of the vessel causing death, serious bodily injury or property damage.

6. Make-up water should be used as a supply line whenever possible. In some cases, backflow prevention may be required between the Brominator and the make-up water supply line. Utilizing a make-up water source can prevent BromiCide from coming in contact with other water treatment chemicals. When the quality of the water source is poor, a filter before the inlet is recommended to minimize the chance of BromiCide becoming contaminated with particulate material. Note: Hot water will dissolve BromiCide more rapidly. However, higher

water temperatures will serve to reduce the recommended maximum operating pressure of the unit.

Brominator Operation To maintain an accurate and consistent dispensing rate, only fill the brominator tank to the level of the outlet diffuser and refill the system when the BromiCide level reaches one-half the original fill height. 1. Warnring

BromiCide is corrosive in solution and may be fatal if swallowed. Inhalation of dust may cause irritation to the nose and throat. Always use the appropriate respiratory, eye, and skin protection when filling or servicing the brominator feed system with BromiCide. Review a material safety data sheet (MSDS) for specific safe handling instructions.

2. Remove the tank top closure

Close the inlet valve first and then the outlet valve. Open the drain valve slowly to release any water pressure and then close it to avoid draining the tank. Carefully unscrew and remove the top closure. A hook wrench is provided for 4-inch lids, and a tri-pin wrench is provided for 6-inch lids.

3. Refill the tank with BromoCide

Make certain that the tank is approximately half full of water. Remove the O-ring from the top collar so it does not fall into the tank while

refilling. Add the appropriate amount of product to bring the chemical bed level to, but not above, the level of the outlet diffuser. BromiCide packaging is designed to minimize any exposure to the solid product during the filling process.

4. Replace the tank top closure

Clean the threads on the top collar and closure, inspect and replace all O-rings.

5. Return System to Service Open the inlet valve to allow any head space in the tank to be displaced with water. Close the inlet valve and replace the top closure on the tank. Do not cross-thread or over-tighten.

Safety Note: Do not leave partially submerged BromiCide inside the tank or permit the BromiCide to become wet without being completely covered with water. After adding BromiCide to the brominator tank, but before replacing the top closure, visually confirm that the tank is filled with enough water to completely cover the BromiCide.Failure to completely cover the BromiCide with water may cause product decomposition leading to excessive pressurization of the brominator tank. System pressure in excess of the recommended maximum operation pressure may create an explosion of the vessel causing death, serious bodily injury or property damage. 6. Adjust Flow Rate Open the outlet valve completely and slowly open the inlet valve to allow normal operating pressure to be established, without inducing water hammer. Re-adjust the flow meter level by throttling the inlet valve and not the outlet valve. This will aid in the elimination of pressure fluctuations inside the tank. Never open or close any ball valve too quickly when operating the brominator feed system. 7. Idle Service When the brominator feed system is not in use, as with shock feeding, do not completely isolate the tank by shutting both ball valves. Close the inlet valve, but leave the outlet valve open to relieve pressure inside the tank. Since each industrial water system is different, control ranges will vary from system to system. Factors such as seasonal Temperature variations and demand fluctuation may alter control. Consult your professional water treatment service company for specific application recommendations. Before handling BromiCide, all persons must be thoroughly aware of its hazardous properties and have reviewed a material safety data sheet (MSDS). An MSDS may be obtained from your professional water treatment service company

Temperature Rating When installed and operated according to instructions, all brominator feed systems are rated to a recommended maximum operation pressure of 100 psi at a temperature of 100º F. Systems may be operated at temperatures greater than 100º F but at reduced recommended maximum operating pressures. Systems operated at very high temperatures will have little or no pressure rating. Therefore, it is recommended that brominator dissolution feeders never be operated at temperatures exceeding 130º F. Safety Note: Improper assembly, installation and operation may cause

excessive pressurization of the brominator tank. System pressure in excess of the recommended maximum operating temperature or pressure may create an explosion of the vessel causing death, serious bodily injury or property damage.

Pressure Rating External pressure relief valves and inlet pressure regulator valves are recommended for all applications, but especially where system pressure could fluctuate in excess of the recommended maximum operating pressure. The brominator dissolution feeder should not be used for any application in which the system pressure is unknown. Limited Warranty FeedChem hereby warrants, subject to the conditions set forth below, that should our brominator or any component part included with the brominator prove defective by reason of improper workmanship or material from the original date of purchase and up to one year thereafter: FeedChem will replace the defective part(s) upon receipt of those same part(s) from the purchaser. FeedChem will not pay for any labor costs incurred in the removal or replacement of those parts.

Conditions 1. Notification: The purchaser must notify Feed Chem Industrial Water Treatment, within 30 days after discovery of part failure and state which part of parts were defective or broken.

2. Use of Unauthorized Chemicals: These FeedChem Industrial Water Treatment brominators have been designed exclusively for the safe and proper application of BromiCide products distributed by FeedChem Industrial Water Treatment and its subregistrants. The placing of any chemical other than BromiCide products distributed by FeedChem Industrial Water Treatment and its subregistrants within a FeedChem Industrial Water Treatment brominator will void this warranty. 3. Installation and Operation: of the warranted equipment must be in accordance with this manual. Should the warranted equipment prove defective in workmanship or material, the consumer’s sole remedy shall be such replacement of parts as is hereinabove expressly provided; under no circumstances shall FeedChem .be liable for any loss or damage direct or consequential arising from the use of the warranted equipment. Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. This warranty gives you specific legal rights and you may also have other rights which vary from state to state. The information in this document is based on data currently available to FeedChem. and is thought to be correct. Since FeedChem has no control over the use of this information by others, FeedChem does not guarantee the same results described herein will be obtained, and makes no warranty of merchantability or fitness for a particular purpose or any express or implied warranty. This information is intended for use by technically trained personnel at their discretion and risk.

BromiCide® is a registered trademark of Great Lakes Chemical Corporation Teflon® is a registered trademark of E.I. DuPont De Nemours & Co., Inc.