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Innovative and Unique Delivery System for Solid Oxidizing Biocide Provides Safer, Easier & Faster Application Method for Microbiological Control of
Cooling Water
Terry P. Goeman Director of Manufacturing
David P. Guy, PE
Director of Engineering
King Technology, Inc.
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Introduction
Control of microbiological growths, corrosion, and scale are key components of any
cooling water treatment program. A wide range of chemicals and feed control methods
are available to the treatment operator. For small and medium sized re-circulating water
systems, BCDMH is frequently used for control of microbiological growths that can
contribute to corrosion and biofilm formation. Feed control methods for bromine include:
liquid feed systems with peristaltic pumps, tablet erosion feeders, and tablet floating
feeders. When choosing a feed system, the treatment operator often considers system
size, desired output level, and level of control. Another important consideration is safety
and material handling.
Safe handling of any water treatment chemical is always a necessary precaution
and when using an oxidizing biocide such as BCDMH it is absolutely critical. Best practice
includes minimizing dust formation and avoiding direct contact with the skin. BCDMH can
irritate or burn both the skin and eyes. It also can just make a mess of a facility and ruin
clothing unless protected with PPE such as a Tyvek ® style suit. Per OSHA - “Controlling a
hazard at its source is the best way to protect employees. Depending on the hazard or workplace
conditions, OSHA recommends the use of engineering or work practice controls to manage or
eliminate hazards to the greatest extent possible. For example, building a barrier between the hazard
and the employees is an engineering control; changing the way in which employees perform their
work is a work practice control.
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When engineering, work practice and administrative controls are not feasible or do not provide
sufficient protection, employers must provide personal protective equipment (PPE) to their
employees and ensure its use. Personal protective equipment, commonly referred to as "PPE", is
equipment worn to minimize exposure to a variety of hazards. Examples of PPE include such items
as gloves, foot and eye protection, protective hearing devices (earplugs, muffs) hard hats,
respirators and full body suits.”1
An innovative solution to provide a safer, easier, and faster method of handling
BCDMH incorporates the use of prepackaged biocide cartridges rather than bulk buckets
of BCDMH tablets. Systems using prepackaged biocides & feed systems, such as the one
manufactured by King Technology significantly changes the way in which employees
perform their work substantially reducing their exposure to both the handling and the odor
associated with bulk BCDMH. When compared to the use of bulk brominators, these
systems could be considered a work practice control as defined by OSHA.
For over twenty years, prepackaged biocide cartridges developed by King
Technology, Inc. have been successfully used in the recreational water market delivering
tens of millions pounds of EPA registered sanitizers in over 1million feed systems. The
purpose of our test was to determine if this same concept could be applied to industrial
cooling water systems. Key variables affecting feeder output performance include: feeder
dial setting, flow rate, backpressure, and temperature. Lab testing of the King Technology
chemical feed system showed a wide range of output could be achieved with the dial
1 https://www.osha.gov/Publications/osha3151.html
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setting alone. Time to dispense a pre-packaged five pound cartridge of granular BCDMH
could be varied between hours and 25 days as shown in the graph below [Figure 1].
A wide range of adjustability is critical to the industrial water market as a wider variety of
water body size, flow rates, and pressure could be expected when compared to the
recreational water market. One important thing to note during lab testing was at flow rates
less than 10 gpm and dial settings less than 3, the BCDMH in the cartridge was
susceptible to sticking together and bridging.
Figure 1: Time to Dispense vs Dial Setting (at 80F)
Bridged
0
5
10
15
20
25
30
0 2 4 6 8 10 12
Time to Dispense 4.5 Lbs BCDMH (Days)
Dial Setting
Time to Dispense vs Dial Setting (at 80F)
10 gpm
30gpm
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Bromo-Chloro-Dimethylhydantoin
Active Ingredient: 1-Bromo-3-Chloro-5, 5-Dimethylhydantoin…………… 96% Other Ingredients: ........................................................... 4% Total: .......................................................................... 100%
Unlike typical industrial water treatment tableted bromine chemistries, the King Technology, Inc. prepackaged biocide cartridge utilizes granular material. The higher surface area provides greater output ranges including the ability to slug dose if necessary.
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Field Test Results
Field test site number 1 consisted of a cooling water treatment system in an
injection molding facility servicing 24 injection molding machines. A bulk erosion feeder
was the previous water treatment method [Figure 2, 3]. The existing bulk erosion feeder
was located on a bypass leg of the main circulation line.
Figure 2: Bulk brominator Figure 3: Brominator refill
The bulk erosion feeder was replaced by an erosion feeder using prepackaged
biocide cartridges [Figure 4, 5]. Each cartridge consisted of 5 pounds of granular BCDMH
vs the one inch tablets used in the bulk feeder. The pressure and temperature were very
similar to what is experienced in recreational swimming pools; however, the flow rate was
significantly less at 8 GPM [Figure 6, 7]
Figure 4: Test feed system Figure 5: Pre-packaged cartridge
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Test conditions: Field Test 1 Injection Molding Plant
Dial Setting 5
Flow Rate (gpm) 8
Pressure (psi) 6
Temperature (F) 85
Volume of Water Treated (gallons) 3,000
Sanitizer BCDMH
Desired Output Level (ppm) 0.5-1.0
Figure 6
Typical Recreational Water Conditions
Dial Setting 3-6
Flow Rate (gpm) 30-80
Pressure (psi) 4-12
Temperature (F) 70-85
Volume of Water Treated (gallons) 10,000 - 25,000
Sanitizer Trichloro-S-Triazinetrione
Desired Output Level (ppm) 2-4
Figure 7
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Test Results
Field Test Site #1 Injection Molding Facility
Incoming water levels 7.23 pH 590 TH (CaCO3)
Using the system as a component of a complete water treatment system allowed halogen levels to be reduced 50% while maintaining desirable bacteria levels [Figure 8, 9].
Figure 8: Dip slide pre field test Figure 9: Dip slide during field test
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
Bromine as Free Chlorine (ppm)
Bromine Concentration vs Time
TARGET CONCENTRATION: 0.5‐1.0
Empty
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Field Test Site 1 Participant Comments
Julio V., Maintenance Technician
“It is much easier to change the BCDMH. I don’t have to re fill the feeder, I just
replace the pac.”
“It saves me time for other maintenance work because it only takes about 1/4th of
the time to change compared to the bulk brominators.”
“It is much safer to use. I do not have to wear any personal protective equipment,
not even gloves or a face shield because I never come in contact with the BCDMH. When
using bulk brominators our safety department requires us to wear full PPE. Dust is
everywhere.”
“The consistency of the BCDMH feed rate is excellent, I know what to expect with
this feeder.”
Tom G, Water Treatment Supplier
“The consistency in feeding a low but effective halogen level minimizes equipment
damage risks.”
“The safety aspect of the system is huge. Not having to suit up when changing or
refilling the feeder improves worker safety. The exposure rates are drastically reduced with
the innovative packaging.”
“The system supports our position of offering sustainable water management.”
“I am very pleased with the results for this high stress application. 24 injection
molding machines running 24/7 with average water temp of 85F puts a lot of demands on
your treatment system. The total ATP of 269 is almost 50% better than similar sized
systems not running the Oxi-King system.”
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Field test site number 2 was a cooling tower application at a 17 story urban
apartment building [Figure 10]. A floating feeder was the previous water treatment
method. The floating feeder was filled with bulk one inch BCDMH tablets and was located
in the cooling tower basin [Figure 11]. .
Figure 10: Site 2 CT Figure 11: Site 2 previous treatment method The floating feeder was replaced by an erosion feeder using prepackaged biocide
cartridges located on a bypass line [Figure 12, 13]. Each cartridge consisted of 5 pounds of granular BCDMH vs the one inch tablets used in the bulk feeder. The pressure and temperature were very similar to what is experienced in recreational water; however, the flow rate was significantly less [Figure 14, 15].
Figure 12: System install Figure 13: System install
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Test conditions: Field Test 2 Residential Apartment CT
Dial Setting 10
Flow Rate (gpm) 3.5
Pressure (psi) 10
Temperature (F) 75
Volume of Water Treated (gallons)
Sanitizer BCDMH
Desired Output Level (ppm) 0.5-1.0
Figure 14
Typical Swimming Pool Conditions
Dial Setting 3-6
Flow Rate (gpm) 30-80
Pressure (psi) 4-12
Temperature (F) 70-85
Volume of Water Treated (gallons) 10,000-25,000
Sanitizer Trichloro-S-Triazinetrione
Desired Output Level (ppm) 2-4
Figure 15
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Test Results
Field Test Site #2 Residential Apartment CT
Under the extremely low flow conditions of 3.5 gpm of this field test, consistent output was not able to be achieved. After 7 – 10 days of use the BCDMH cartridge was found to have “bridged” and was no longer dissolving [Figure 16, 17] which confirms the importance of having proper minimum flow rates.
Figure 16: BCDMH bridging in pac Figure 17: BCDMH bridging in pac
Field Test Site 2 Participant Comments
Brian M., Facilities Manager
“This is much better than lugging buckets upstairs to equipment room.”
“I love the fact that we don’t have to wear a mask and worry about getting bromine dust all
over me and the equipment room.”
“With the previous treatment method I never knew how much was being filled into the
floater or how often. Now I can just take a quick count of remaining pacs.”
“The initial plumbing of the system was easy & replacing bromine pacs is simple. They
can only be installed one way so I don’t have to worry about someone not doing it
correctly.”
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Tom G., Water Treatment Supplier
“This application is a residential 17 story high rise where residents have complained of
maintenance workers smelling like chemicals when riding elevators. The pre-packaged
canister eliminates this.”
“Knowing it is not new technology, just new to the industrial water market gave me
confidence in using for field tests / trials.”
Summary
Both lab testing and real world field testing confirm that the King Technology, Inc.
Oxi-King™ treatment system provides a safer, simpler and faster microbiological treatment
method for small to medium sized industrial cooling water systems than traditional bulk
brominators.
The prepackaged biocide cartridges eliminate a significant portion of the hazardous
handling and storage issues associated with alternative treatment methods providing a
higher level of safety to both operators and facilities. The design of the feed system
provides a broad range of easily adjustable output while eliminating additional accessories
such as cap wrenches and filling funnels resulting in time savings for the operator.
When installed in the proper operating conditions, the system achieved a targeted
halogen level reduction of .5 – 1 ppm while maintaining acceptable treatment conditions.
