Key Scientific Principles of FRE-FLO™ Technology · Key Scientific Principles of FRE-FLO ... Analytical Laboratory Report of Nalco Corrosion Coupon Study..... 34 16. FRE-FLO™

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Key Scientific Principles of FRE-FLO™ Technology

Table of Contents 1. Introduction .......................................................................................................................................... 2 2. How FRE-FLO™ Works ........................................................................................................................... 4 3. Scientific Principles Underlying FRE-FLO™ Technology ........................................................................ 5 4. Overview of Technical Papers Clarifying FRE-FLO™ Processes ........................................................... 13 5. Principles of Catalytic Water Conditioners ......................................................................................... 14 6. Discussion of Babcock Laboratories Test Results ............................................................................... 17 7. Independent Lab Test Results of Changes in FRE-FLO™ Water .......................................................... 17 8. Nuclear Magnetic Resonance Spectrometry Test Results .................................................................. 20 9. Test Results of Water Surface Tension ............................................................................................... 22 10. Inside FRE-FLO™ Technology .............................................................................................................. 25 11. Key Errors in Chemical Company’s Description of FRE-FLO™ ............................................................. 26 12. A Fatally Flawed Copy of a FRE-FLO™ System..................................................................................... 28 13. Twelve Year Field Test Summary of Authentic FRE-FLO™ .................................................................. 31 14. Lab Report of Reduced Corrosion Using FRE-FLO™ ............................................................................ 33 15. Analytical Laboratory Report of Nalco Corrosion Coupon Study........................................................ 34 16. FRE-FLO™ Mechanisms for Environmental and Economic Management .......................................... 36 17. Concluding Comments ........................................................................................................................ 38


Key Scientific Principles of FRE-FLO™ Technology

1. Introduction

With specific information and scientific back-up, including independent lab tests and field test data, this paper answers three key questions you have raised regarding the FRE-FLO™ catalytic water conditioning technology:

1. What further specific information and details can we provide on the science underlying the FRE-FLO™ non-chemical scale control technology?

2. What is our response and analysis regarding the first link sent to us, containing a general overview of non-chemical technologies for scale control?

3. What is our analysis of a specific case history report, in the second link sent to us (which is also a subsection within the first link) of a “FRE-FLO™ installation?”

Although the links give a general overview of various “non-chemical devices (NCD)” that claim to control scale and corrosion, we note that the links were written by the founder of a company that sells scale control chemicals and that is a supplier of chemical water treatment programs. Therefore, they are unlikely to provide an unbiased review of our competing, non-chemical, green design approach to many of the same problems. Although the links are written with scientific terminology, they have numerous serious inaccuracies regarding the FRE-FLO™ non-chemical, catalytic scale control technology. Note that a substantial portion of this paper is newly presented (much of sections 1, 3 through 9, 11, 12, 14, 15, and 17), not generally available before to the public. As of this writing, only sections 2, 10, 13 and part of 16 are available.


Answer to Question #1 On Science Underlying FRE-FLO™

First, we present several sections providing technical information, analytical data, and scientific principles underlying FRE-FLO™ technology. To answer the many requests over the years for a concise, bottom line, expert overview of FRE-FLO™ principles, the FRE-FLO™ Chief Engineer presents “How FRE-FLO™ Works”. Then “Scientific Principles Underlying the FRE-FLO™ Water Conditioning Technology” discusses, in much greater detail, processes well known and well accepted in the scientific community, that are key foundations for the FRE-FLO™ results. Included within “Scientific Principles” is a “Journey Through a FRE-FLO™,” clarifying scientific processes involved. See also the analysis of principles of catalytic water conditioning that includes some of the specific chemistry involved. Independent lab test results supporting the FRE-FLO™ theory of catalytic water conditioning are presented, plus further independent lab test results utilizing Nuclear Magnetic Resonance Spectrometry showing changes occurring in FRE-FLO™ water. Also, see company test results, with analytical data, showing FRE-FLO™ produces reduced water surface tension, consistent with the FRE-FLO™ principles of operation. There is a brief exploration by a physicist, an agronomist, and the President of FRE-FLO™ describing what goes on inside a FRE-FLO™ unit.

Answer to Question #2 On Description of FRE-FLO™ Technology

We respond to the first link sent to us (that gives an overview by a chemical company of non-chemical descaling technologies) by correcting specific major errors and misrepresentations related to FRE-FLO™ technology.

Answer to Question #3 On Case History of a “FRE-FLO™”

Then issues raised in the second link sent to us for review are addressed. The “Case History Report” specifically on FRE-FLO™ has such serious inaccuracies about FRE-FLO™ that we have devoted a detailed analysis to correct them. Note that the “FRE-FLO™” installation in the case history was not an authentic FRE-FLO™ WaterLoop™ system, but rather a fatally flawed copy by a company that had omitted a key component before installation, instead using a much less appropriate component for that application. The product copied was a complex, integrated FRE-FLO™ system called WaterLoop™ for scale control for cooling towers. The President & CEO of FRE-FLO WATER SYSTEMS, INC. presents a report based on his first-hand knowledge of that specific installation. We include a twelve year field test summary showing excellent FRE-FLO™ results and cost-effectiveness with authentic FRE-FLO™ technology. Also see independent lab results and analytical data (from a corrosion coupon study by Nalco Chemical Company) showing outstanding results with the authentic FRE-FLO™ technology.

Concluding Comments

We present a brief overview of relevant FRE-FLO™ mechanisms for environmental and economic management, and concluding comments.


2. How FRE-FLO™ Works

Presented by John Heiny, FRE-FLO™ Chief Engineer

CATALYTIC WATER CONDITIONING TECHNOLOGY

FRE-FLO™ acts as a catalytic water conditioner that creates a soft calcium carbonate crystal. FRE-FLO™ is a non-magnetic, non-sacrificial unit that comes in varying size models. Most importantly, FRE-FLO™ controls scale and existing deposits and does not add anything to the water. Simply put, the FRE-FLO ™ works to control scale by the core of the FRE-FLO™ converting a portion of the calcium and carbonate ions that are dissolved in water into a “soft” calcium carbonate crystal, smaller than talcum powder.

LAMINAR VS. TURBULENT FLOW

The FRE-FLO™ non-magnetic unit creates a turbulent flow situation within its housing. The resultant turbulence allows the individual dissolved calcium and carbonate ions to contact the proprietary blend of metals of the FRE-FLO™ core. In the standard laminar flow situation, most of the calcium and carbonate ions would never contact the metallic core. This is why the FRE-FLO™ unit is sized based on flow. A corollary developed by FRE-FLO™ WATER SYSTEMS, INC. to illustrate this concept is that bigger is not better. In fact, if the FRE-FLO™ is oversized it will not work.

SOFT VS. HARD CRYSTAL

The typical hard water scale is composed of aragonite crystals. These crystals have the familiar sand paper feel of hard water deposits. The FRE-FLO™ is just changing the crystalline form of calcium carbonate. The new crystalline form is spherical (vaterite). As with any spherical shape, it is hard to build up any sort of deposit. A simple example of this would be to try and stack up some ball bearings. That is why FRE-FLO™ treated water does not build up bothersome deposits.

SAME ELEMENT – DIFFERENT CRYSTALLINE STRUCTURE

A well-known example of this duality of form is best illustrated with the element carbon. In one case, the element carbon creates the hardest substance on the planet called diamond. In the other case, with the same element carbon, a lubricant is formed called graphite. Same element, totally different structure and totally different physical properties, each are 100% carbon.


3. Scientific Principles Underlying FRE-FLO™ Technology

by D. M. Lakeman, Ph.D., C. David Lakeman, and John Heiny

FRE-FLO™ Model #125-075 CNU, with Copper Housing

Technology for Calcium Carbonate Scale Control

FRE-FLO™ specializes in providing solutions for a spectrum of scale problems caused by calcium carbonate, one of the most common minerals found on earth (comprising about 4% of the earth’s crust). Scientific principles are the foundation of the FRE-FLO™ water conditioning technology, allowing descaling results to occur in a safe, environmentally sustainable manner, utilizing catalytic, non-chemical design. Following are scientific principles underlying FRE-FLO™ technology. As scientific knowledge continues to grow, understanding will likely further develop of FRE-FLO™ processes involved and their interrelationships. Scientific Principles Underlying FRE-FLO™ Technology

FRE-FLO™ works effectively through a synergistic combination of several key factors, including (but not limited to) well-accepted scientific processes such as: lattice matching, epitaxial nucleation, mineral resorption, utilizing optimal water flow rate, and reduced water surface tension. A proprietary green design facilitates the descaling process. As this paper discusses, the FRE-FLO™ theory of operation is consistent with well-known scientific principles and processes that have frequently been observed in nature. The science behind FRE-FLO™ is fundamentally biomimicry, imitating what nature has already demonstrated is possible. It is well known that calcium carbonate in nature is able to have different crystalline structures and vastly different functions (while still remaining calcium carbonate.) The different calcium carbonate forms all have the same chemical formula (CaCO3), but exhibit distinctively different crystalline structures, appearance, and ways they interact with their environment. Forms of calcium carbonate are in marble, limestone, chalk, egg shells, and sea shells. With such flexibility, manufacturers use calcium carbonate in everything from cement to food supplements, even in toothpaste and as fillers in paper. Note that a variety of different crystalline forms of calcium carbonate occur, including: aragonite, calcite, vaterite, calcium carbonate monohydrate, and calcium carbonate hexahydrate. Since FRE-FLO™ works primarily with aragonite, calcite, and vaterite, those are the forms this overview will discuss. Aragonite and calcite are both hard, scaly forms of calcium carbonate.


Vaterite is a soft, non-scaly form (unlike the harder aragonite and calcite that form scale deposits on surfaces in pipes, equipment and soil pores). From our current perspective, the bottom line of importance to FRE-FLO™ descaling is the smooth, soft non-scaly vaterite crystalline structure that forms within the FRE-FLO™ and that does not adhere to surfaces. Note that in nature, vaterite is typically a less stable crystalline structure than either the harder aragonite or calcite forms of calcium carbonate. However, there are some circumstances in nature in which vaterite can be stabilized, to prevent its transformation into calcite or aragonite. The proprietary FRE-FLO™ process allows the vaterite crystalline structure to stabilize (which considerably facilities the FRE-FLO™ track record of effective descaling in a variety of industrial, business, and irrigation applications). Lattice Matching and Epitaxial Nucleation Let us clarify how the operation of FRE-FLO™ relies upon observations of what can take place in nature, combined with well-accepted scientific principles such as lattice matching and nucleation (and specifically epitaxial nucleation). Essential to the functioning of FRE-FLO™ technology, inside the FRE-FLO™ unit we have created the rough surface of the proprietary core to have a lattice structure similar to what calcium carbonate can have in nature. The rough core has millions of extremely small spots upon which the vaterite form of calcium carbonate can grow, through epitaxial nucleation. FRE-FLO™ works with the fact that crystals are structures formed from a pattern of connected atoms or molecules, by the process termed nucleation. Nucleation is the initial stage in the formation of small particles which are capable of growing (in this case, allowing the formation of non-scaly vaterite calcium carbonate crystals). Nucleation is sometimes thought of as a natural change of a substance to a more condensed state, initiated at nucleation sites within a less condensed state. Inside the FRE-FLO™, nucleation is a natural process allowing new crystals to form on the nucleation sites provided on the lattice structure of the FRE-FLO™ core. In the assisted nucleation within the FRE-FLO™, calcium ions and carbonate ions in flowing water are provided a type of meeting place on the rough core. The core is rough for various scientific reasons, among them the experience that a rough surface tends to be much more attractive for the nucleation process than a smooth surface. Epitaxy refers to the growth of one crystal on top of another crystal. In epitaxial processes, the growth of one crystal on the surface of another crystal is influenced by the lattice structure of the substrate underneath. The process of epitaxy is certainly not unique to FRE-FLO™ technology. Epitaxial processes can be used, for example, in manufacturing semiconductors for use in integrated circuits. Thus, utilizing the well-documented scientific principles of lattice matching and epitaxial nucleation, FRE-FLO™ is allowing new growth (of soft, smooth vaterite calcium carbonate crystals) from the fundamentals of what already exists in the water flow. Nothing is added to the water. Nothing is deleted from the water. No chemicals are involved. No waste is involved. No problems are involved of dealing with toxic chemical residue and worker safety/risk management. The FRE-FLO™ catalytic core carries out its scientific processes many times and still retains its ongoing capacity to function (as it does not rely on metal corroding or dissolving in order to function).


It is clearly a renewable technology, as no depletion of resources is needed in its functioning. It prevents waste, as nothing new is produced (simply the formation of vaterite crystals from the already existing calcium ions and carbonate ions that are naturally in the water flow going into the FRE-FLO™). Journey Through a FRE-FLO™ We can follow the flow of water from the beginning of the FRE-FLO™ water conditioning process. As water enters the FRE-FLO™ unit, a drop occurs in water pressure and there is an optimal turbulent water flow. For these processes to occur, the FRE-FLO™ must be sized correctly. As the FRE-FLO™ literature repeatedly states, selecting the correct size of FRE-FLO™ model is essential and very easy, based solely on the range of water flow in gallons per minute (gpm) going into the FRE-FLO™ unit. Water entering a FRE-FLO™ normally has many dissolved calcium ions and carbonate ions that are not yet formed into any crystalline structure. Inside the FRE-FLO™, through processes such as the drop in water pressure and agitation of the water, the carbon dioxide (CO2) that is normally present in water goes from a dissolved state in water into a gas form (as extremely tiny bubbles). In the synergistic presence of these various processes in the FRE-FLO™ unit, the calcium ions and carbonate ions in the water become less stable. Within the FRE-FLO™, the unstable calcium and carbonate ions are now able to form, utilizing processes such as lattice matching and epitaxial nucleation, into a different crystalline structure (a softer, smoother, spherical vaterite form of calcium carbonate) that is stable and non-scaly. The hard calcium carbonate we typically find as scale build-up on pipes, equipment and in soil pores is often composed of aragonite crystals that are hard, rough and scaly, easily adhering to surfaces and continuing to build up over time if left untreated. Sometimes hard calcite crystals are involved. By contrast, the vaterite form of calcium carbonate (that is formed inside the FRE-FLO™) is relatively soft, smooth, non-scaly, spherical in shape (making it unlikely to be able to stick to surfaces), and very small in diameter (able to form a soft, white, powdery substance that is easily, naturally, non-chemically washed away in normal water flow). The extremely small vaterite crystals formed within the FRE-FLO™ are less than 0.0000006 of an inch (less than half a millionth of an inch) in diameter. Of crucial importance, the proprietary blend of metals of the FRE-FLO™ core functions as an alternative surface that allows the calcium and carbonate ions going into the FRE-FLO™ to form into vaterite, instead of forming into hard, scaly aragonite or calcite crystalline structures. Having such an alternative surface, with the appropriate lattice structure, is essential. Otherwise, the calcium and carbonate ions in flowing water would usually combine into hard aragonite or calcite scale deposits when they come into contact with most surfaces, such as equipment, pipes, machinery, or soil pores.

FRE-FLO™ Model #125-075 CWU, with Copper Housing,

Cut-Away View Showing FRE-FLO™ Core


Thus, FRE-FLO™ uses well-known scientific principles to stimulate the formation of vaterite. Inside FRE-FLO™ on the surface of the rough core in turbulent water, a sufficient percentage of the total calcium and carbonate ions going through the FRE-FLO™ are able to grow into vaterite crystals and then exit in the water flow in their non-scaly form. Now water can flow freely. The water exiting the unit is the FRE-FLO™ conditioned water. Note that the integrated processes of the FRE-FLO™ operation are very effective in a wide range of water conditions in which calcium carbonate is present: exceptionally high hardness, low hardness, low temperature (such as in ice machines), very high temperature (up to 297.980 F), ambient pressure, high pressure (up to 50.3 psig), high pH, low total dissolved solids (TDS), and even extremely high TDS (up to 42,000 TDS in an industrial application). Principles Underlying the Dual Preventive/Corrective Function of FRE-FLO™ FRE-FLO™ provides the advantages of dual preventive/corrective descaling action in a range of industrial, business, and irrigation applications.

FRE-FLO™ Preventive Function:

Processes for Initiating and Maintaining Scale Control

1.

Flowing water with calcium ions and carbonate ions enters a FRE-FLO™ unit

2.

They contact the surface of the FRE-FLO™ core (which has a lattice structure similar to calcium carbonate in nature)

3.

Calcium ions and carbonate ions are able to combine into calcium carbonate in vaterite form (soft, smooth, extremely tiny, non-scaly), utilizing processes such as lattice matching and epitaxial nucleation

4.

The hard aragonite and calcite forms of calcium carbonate do not grow on the FRE-FLO™ core’s lattice structure

5.

Non-scaly vaterite exits the FRE-FLO™ (naturally, non-chemically, safely being washed away in the normal exiting water flow)

6.

Thus, hard calcium carbonate scale is prevented from forming


FRE-FLO™ Corrective Function:

Processes for Solving Pre-Existing Scale Problems

1.

Flowing water normally has calcium ions and carbonate ions

2.

When the ions contact the surfaces of equipment and soil pores, they often combine into harder, scaly forms of calcium carbonate, such as calcite and aragonite

3.

The aragonite and calcite create hard deposits that build up over time, clogging up pipes, equipment, machinery, and soil pores

4.

After a FRE-FLO™ is installed, the aragonite and calcite scale now has contact with water that has gone through a FRE-FLO™ unit (the FRE-FLO™ conditioned water containing vaterite)

5.

The FRE-FLO™ treated water is able to dissolve and dislodge such pre-existing scale, utilizing processes such as mineral resorption and reduced water surface tension

6.

Thus, pre-existing hard calcium carbonate scale is safely removed in an environ-mentally sustainable manner

Review of Preventive Function The FRE-FLO™ preventive action is accomplished through scientific principles (as we have discussed), resulting in initiating and maintaining scale control so that new scale deposits do not form. As we have seen in our journey with water through a FRE-FLO™, the FRE-FLO™ prevents formation of new hard calcium carbonate deposits by providing an environment where calcium and carbonate ions can naturally grow into a different vaterite structure, with substantially different functions. Thus, very simply stated, we say that within the FRE-FLO™, calcium carbonate remains the same mineral (only in a different form). The millions of tiny calcium carbonate crystalline “seeds” planted on the millions of spots on the FRE-FLO™ rough core produce non-scaly vaterite. The extremely small vaterite crystals are typically easily washed away in the water flow. Exploration of Corrective Function FRE-FLO™ also provides underlying processes for the removal of pre-existing scale. When a FRE-FLO™ is first installed, there is often a pre-existing accumulation of hard, crusty calcium carbonate scale on the equipment or in the soil pores. With some well-accepted scientific processes that we will explore (such


as reduced water surface tension and mineral resorption), FRE-FLO™ is able to dissolve and successfully dislodge the hard calcium carbonate deposits, so the scale can be carried away in the normal water flow. Note that sometimes FRE-FLO™ is installed on equipment with an exceptionally excessive amount of large, hard pre-existing scale (such as when there has been no descaling water treatment of any kind for long periods of time before the FRE-FLO™ installation). Then after a FRE-FLO™ is installed, large amounts of scale can appear in the water flow from the pipes and machinery. This is normal and demonstrates the effectiveness of the FRE-FLO™. Under those circumstances, the large amount of scale suddenly being dislodged is a very desirable outcome. In circumstances in which the equipment has a blow down function, then the loosened, dislodged scaly material will go down the drain. If there is no blow down on the equipment, then the loosened scale will need to be cleaned out. In water cooling towers, the pre-existing scale tends to break off and settle to low flow areas of the cooling system (which can be flushed out with a hose or otherwise manually removed). In irrigation applications, the deposits flow to below the root zone. Water Surface Tension Reduced water surface tension, a well-known scientific process, is one of the factors contributing to FRE-FLO’s™ corrective function. Low, reduced water surface tension allows water to spread out (to permeate and more easily, effectively, completely, and quickly get to more areas). For example, it is well accepted that disinfectant liquids have a low surface tension, which allows them to spread out on cell walls of bacteria in order to more fully break up the functioning of the bacteria. Water surface tension refers to a natural phenomenon that is a property of liquid arising from the relationships of molecules and molecular forces at and near the surface of the water (allowing the surface of the water to resist an external force). The integrated FRE-FLO™ system produces reduced water surface tension. The reduced water surface tension makes it much more possible for water exiting the FRE-FLO™ to penetrate and get underneath hard scale and to successfully lift the existing hard scale from the equipment and soil pore surfaces. Reduced water surface tension is valuable in both the preventive and corrective aspects of FRE-FLO™ technology and especially in the corrective solutions for existing hard scale. Scientists know water surface tension is partly dependent on temperature, with hot water generally having lower surface tension than cold water. FRE-FLO™ works well in a wide range of temperatures, as demonstrated by successful installations on equipment from ice machines to steam boilers. Since the practical, everyday effects of reduced water surface tension are well known, lowered water surface tension is valued in a range of applications. FRE-FLO™ has the substantial advantage of achieving reduced water surface tension naturally (nothing added to the water, and with much more cost-effectiveness than having an on-going expenditure for chemicals). The attached report by H. Chang, Ph.D. (on the principles and chemistry of catalytic water conditioning) further discusses the process of reduction of water surface tension. Also, the attached company test results and analytical data show FRE-FLO™ produces reduced water surface tension, consistent with the theoretical principles proposed by Dr. Chang’s analysis.


Mineral Resorption Another key principle utilized by FRE-FLO™ in dissolving and removing existing hard scale is mineral resorption. With the process of resorption, there is dissolution, a breaking down, and assimilating something that was previously differentiated (with processes of restructuring what already exists). For example, in nature, we repeatedly see with bone resorption that osteoclasts (a type of cell) can go into mineralized bone to release minerals (such as releasing calcium). Under the circumstances of suitable stimuli, we observe that resorption naturally occurs. There are also examples of resorptive processes in nature that geologists see when there is partial or complete dissolution of a mineral due to various factors. The proprietary, innovative FRE-FLO™ system imitates what nature can do, safely, with green design.

The reduced water surface tension of FRE-FLO™ conditioned water, better allowing water to spread out, to penetrate, to more fully break up and dissolve hard calcium carbonate scale, also facilitates processes of hard calcium carbonate mineral resorption. Nuclear Magnetic Resonance Spectrometry to Measure Changes in FRE-FLO™ Water Water micro-clustering may be another factor in the corrective FRE-FLO™ function of solving existing scale problems. Water clustering refers to a hydrogen bonded assembly of molecules of water. The concept of micro-clustering refers to water molecules changing from being in large clusters (with a larger number of molecules in each cluster) to having less molecules per cluster. Micro-clustering is a controversial concept among some water experts. We have included the concept, as we continue to be interested in the phase of scientific endeavor in which hypotheses are considered. FRE-FLO™ technology functions with outstanding results whether or not micro-clustering exists to an appreciable degree, or for a long enough time frame upon each occurrence to influence descaling processes. The perspective of FRE-FLO™, with attached supporting analytical data from an independent lab utilizing Nuclear Magnetic Resonance Spectrometry, is that reduced micro-clustering of water molecules does occur in FRE-FLO™ treated water. We hypothesize that water micro-clustering facilitates the FRE-FLO™ removal of existing hard scale by providing hydrating properties and higher permeability. At this point, the precise impact and benefits of micro-clustering are open to further study. Importantly, what the attached independent lab data demonstrates is that water does undergo changes going through a FRE-FLO™, measurable by Nuclear Magnetic Resonance Spectrometry. The FRE-FLO™ Technology Difference Let us put the FRE-FLO™ technology in perspective, in relation to several other technologies that seek to provide descaling functions with other underlying principles. . What FRE-FLO™ is not:

FRE-FLO™ is not a filter (as it does not remove anything, instead it does crystallize calcium ions and carbonate ions into a different calcium carbonate structure).

FRE-FLO™ is not a magnet (FRE-FLO™ is not designed to use magnetic fields, nor is it a temporary fix lasting only a few hours).

FRE-FLO™ is not a water softener (water softeners remove beneficial calcium and magnesium, replacing these elements with an increase in water sodium or potassium chloride levels, which can be harmful to people, plants, roots, soil, and sewers).


FRE-FLO™ is not a chemical (instead it provides a non-chemical, safe, catalytic descaling solution).

FRE-FLO™ uses no electrical hook-ups, has no wires and no grounding, requires no batteries, does not require you to use any electrical current whatsoever (an attractive safety feature).

FRE-FLO™ is not a sacrificial anode (instead the FRE-FLO™ catalytic design is actually a strong non-sacrificial core that does not rely on metal dissolving or corroding in order to function).

FRE-FLO™ Model # 800-400 SS, with Stainless Steel Housing, Cut-Away View Showing FRE-FLO™ Catalytic Core

The foundation of biomimicry in FRE-FLO™ technology, with innovative green design, combined with several underlying principles that are well-known in the scientific community, provides a distinctive, safe, non-chemical “FRE-FLO™ Scale Control Solution.”


4. Overview of Technical Papers Clarifying FRE-FLO™ Processes

Additional Technical Papers Following are papers further describing principles underlying FRE-FLO™ technology. Sections with analytical data give supporting scientific evidence.

The paper by H. Chang, Ph.D., on scientific principles and theory underlying catalytic water conditioning, includes some of the chemistry involved. His analysis clarifies processes of epitaxial nucleation and lattice matching occurring in the catalytic water conditioning technology, contributing to the formation of extremely tiny calcium carbonate crystals. His analysis came about when a prior owner of FRE-FLO™ technology wanted a more comprehensive understanding of principles contributing to the descaling technology. Dr. Chang was selected, as he had an extensive background working with calcium carbonate (in the paper industry where calcium carbonate is used as a filler). Since the Dr. Chang report, we have found that the calcium and carbonate ions within the FRE-FLO™ form a type of calcium carbonate crystal called vaterite (not calcite as mentioned in the Chang paper).

The independent lab report by Babcock Laboratories has results consistent with Dr. Chang’s findings that processes inside the FRE-FLO™ catalytic unit allow very tiny calcium carbonate crystals to form and then flow freely in water. Included in this section is a discussion of the Babcock Laboratories test results by Jim Stewart, Ph.D. (in physics, from Yale University) A summary page of analytical test data from Babcock Laboratories is included in this section.

See also the 2008 analytical lab report of Acorn NMR Laboratories testing, with Nuclear Magnetic Resonance Spectrometry, of water before and after FRE-FLO™ treatment. A summary and analytical data show water changes suggesting that water exiting through a FRE-FLO™ has smaller water micro-clusters compared to the water entering a FRE-FLO™.

The analytical data and 2011 and 2008 company tests on water surface tension show reduced water surface tension in FRE-FLO™ treated water compared to non-treated water. These results are consistent with the principles proposed in Dr. Chang’s analysis and with the FRE-FLO™ principles of operation.

The brief exploration, “Inside FRE-FLO™ Technology” by C. David Lakeman, Jim Stewart, Ph.D., and Allan James, Ph.D., includes a diagram showing processes inside the FRE-FLO™ unit.


5. Principles of Catalytic Water Conditioners

Prepared by Hou-min Chang, Ph.D. in 1990

Introduction

The hardness of untreated water is caused by dissolved materials, calcium bicarbonate being

one of the most important. In water the bicarbonate, anions are in equilibrium with carbonate

anions and carbonic acid, with the latter being formed by the dissolved carbon dioxide gas in

water.

2 HCO3–

bicarbonate

anion

CO3– –

carbonate

anion

+ H2CO3

carbonic

acid

The solubility of calcium carbonate in water is very low, about 13 ppm at 77ºF (and zero

atmospheres of pressure), whereas calcium bicarbonate is much more soluble in water. Thus,

the solubility of calcium in water depends greatly on the dissolved carbon dioxide in water,

which in turn is dependent on the partial pressure of carbon dioxide in the atmosphere. At 77ºF

and a normal carbon dioxide partial pressure of 0.0003 - 0.0004 atmospheres, the solubility of

calcium as calcium carbonate in water is approximately 70 ppm. The actual calcium carbonate

content of water taken from lakes or underground aquifers may be higher, depending on the

amount of carbon dioxide dissolved in the water. In normal uses, under saturated and even

saturated waters are not concentrated enough in calcium and carbonate ions to cause scaling.

However, carbon dioxide may be lost from water if the water is heated or if the water pressure

drops significantly in its transport system. The bicarbonate anions are converted to carbonate

anions and the water becomes supersaturated with calcium carbonate. This causes calcium

carbonate to precipitate and become a scale problem in various end uses.

Ca (HCO3)2 Ca++

+ 2 HCO3–

calcium

bicarbonate

calcium

(cation)

bicarbonate

(anion)

2 HCO3– CO3

– – + CO2 + H2O

Ca++

+ CO3– –

CaCO3

calcium carbonate


Principles of Operation

Prevention of Scaling. The core of the catalytic water conditioner consists of a special

perforated metal bar composed of a mixture of various heavy metals including copper, zinc and

nickel. When water flows through the perforated metal bar, the pressure drops drastically,

causing the dissolved carbon dioxide to escape, which results in the water being supersaturated

with calcium carbonate as illustrated above. The surface of the metal bar has millions of tiny

spots with a lattice structure similar to that of calcium carbonate. These tiny spots provide a site

for the calcite crystal to form (a process known as epitaxial nucleation). Because the surface of

the bar is non-uniform and these small areas are interrupted by imperfect lattice structures, the

calcite crystals can only grow to subcolloidal sizes that are not visible by the light microscope.

These tiny crystals are eventually dislodged into the water due to the shearing force of the flow

and remain suspended in water. Millions of these tiny crystals (seeds) are formed to provide a

sufficient surface area for calcium carbonate to grow on and thereby prevent it from forming as

scale. Although millions of crystals are formed, this still involves less than 0.1% of the total

calcium carbonate. This prenucleation theory was proposed by G. T. Western1 and reviewed

recently by R. G. Barile2. While Western provided the theoretical background and experimental

evidence in support of the calcite prenucleation theory, the review by Barile is especially helpful

for understanding the mechanism of the catalytic water conditioner.

Reduction of Water Surface Tension. Water passing through the catalytic conditioner can

be changed so as to reduce its surface tension. An explanation of this phenomenon is also a bit

difficult.

It is important first to recognize that water is highly organized. All water (H2O) molecules

are bonded on all sides by hydrogen bonding, except those at the water surface layer.

Consequently, the energy at the surface layer is higher than the energy at the interior. The

difference between the energy at the surface and the interior is called surface tension. Obviously,

if the interior energy is changed, this will affect the surface tension. For example, if salt (sodium

chloride or NaCl) is added to water, the salt ionizes to form sodium cations (Na+) and chloride

anions (Cl–). These ions are stabilized by the surrounding water molecules in a process called

solvation. As a result of solvation, the water molecules become even more highly organized and

thereby decrease the interior energy, which in turn increases, the surface tension. This is because

the difference between the energy at the surface and the interior has increased. Evidence is

provided by the fact that when salt is added to water it takes more energy to make it boil.

In water, the calcium cation (Ca++

) and the bicarbonate anion (HCO3–) also are involved in

the solvation process. When they are present in large numbers, this causes an increase in water

surface tension similar to that which is caused when salt is added. However, when the water is

passed through the catalytic conditioner, some ions combine to form calcium carbonate (CaCO3)

as explained above. This decreases significantly the number of charged ions, which in turn

decreases the water surface tension, causing the creation of "wetter" water.

1 Western, George T. 1980. Study of the Physical Principles Operational in the Stabilizer Water Conditioner.

Prepared for Fluid Mechanics, Inc. (Lafayette, Indiana). 2 Barile, Ronald G. 1988. The Fluid Mechanic Stabilizer: Literature review and current research. Prepared for Fluid

Mechanics, Inc. (Lafayette, Indiana).


Descaling. A considerable body of evidence is now available to illustrate that catalytic

conditioned water can cause descaling. An explanation of such descaling is also related to

surfaces and energy. In understanding this phenomenon, it is important to recognize that there is

a state of equilibrium between the calcium (Ca++

) and carbonate (CO3–) ions and the calcium

carbonate (CaCO3) crystals or seeds in the water and that formed on pipes, heating elements, etc.

as scale.

Scale

CaCO3

Ca++

calcium

cation

+ CO3– –

carbonate

anion

Crystals (seeds) in Water

CaCO3

When the calcium carbonate seeds are formed by action of the catalytic conditioner, this

creates an enormous internal surface and the equilibrium forces shift away from the scale to the

seeds and thus cause the descaling action. Because the calcium carbonate attached to the seeds

moves out with the flow of water, the equilibrium shift or imbalance continues and thus descaling

with the conditioned water continues.

Summary

The prenucleation of calcium carbonate is a physical change that is difficult to measure

quantitatively. The hardness, or more precisely the calcium content of water, does not change,

because nothing has been added to or taken out of the water. The conductivity and surface

tension of water should decrease but may be too small to detect by simple instrumentation. The

pH should increase as a result of the loss of carbon dioxide but again the change may amount to

no more than 0.1 pH unit. Thus, well-documented results of field applications of the catalytic

water conditioner may be the best and the only way at present to convince prospective customers.

Applications

On the basis of prenucleation as the mechanism of operation, it is recommended that the

catalytic water conditioner be used in systems where supersaturation. of calcium carbonate is

likely to occur. Heat exchangers, hot water tanks, cooling towers, automatic coffee makers, ice

machines, dishwashers and washing machines are some examples of where the catalytic water

conditioner would be beneficial when the water hardness is high. Properly conditioned water

also has a variety of uses in agriculture that are associated with water movement in soil and

descaling of various structures including roots. Important benefits can be achieved in the

conservation of water, and the use of nutrients and other chemicals. For all uses, the water

pressure at the inlet of the conditioner should be sufficiently high so as to cause a cavitation

condition for the dissolved carbon dioxide inside the conditioner and to help dislodge the calcite

crystals formed.


6. Discussion of Babcock Laboratories Test Results

by Jim Stewart, Ph.D.

Babcock Laboratories (see following report and analytical data) analyzed tap water compared with that same tap water flowing through a FRE-FLO™ catalytic water conditioner, on a single pass and on multiple passes. The turbidity was measured with ultraviolet spectrophotometer. As you can see in the accompanying chart and table, the FRE-FLO™ causes a statistically significant increase in turbidity, almost doubling that of the tap water. This is the result of the formation of the calcium carbonate microcrystals predicted by the Chang report (see preceding section which discusses how the catalytic water conditioner works). There are also measurable decreases observed in the concentrations of calcium carbonate and bicarbonate, since these are the principal constituents of the microcrystals that have been formed. Even though the decreases observed in the calcium concentration are not statistically significant, they are in the expected direction, as some calcium is removed from solution by the formation of the calcium carbonate microcrystals. Although low turbidity is typically considered desirable among water quality authorities, note that the turbidity of the FRE-FLO™ treated water (ranging from a low of 0.60 to a high of 1.20) is safely below the World Health Organization prescription of a maximum water turbidity of 5.0 Nephelometric Turbidity Units (NTU). It is important to note that the increase in turbidity within FRE-FLO™ consists of the newly formed calcium carbonate crystals, the material of which already existed naturally in the water. No significant changes are observed in the measured values of conductance, pH or TDS in this test, since these are caused by other ions in solution in this test. Thus, the Babcock Laboratories cover letter is correct. The results are indeed consistent with the changes predicted by the Chang report.


7. Independent Lab Test Results of Changes in FRE-FLO™ Water

by E.S. Babcock & Sons



8. Nuclear Magnetic Resonance Spectrometry Test Results

by D. M. Lakeman, Ph.D., C. David Lakeman, John Heiny, and Bill Galli, C.C.A. (Certified Crop Advisor with Crop Production Services, Inc.)

This section presents test results from an independent laboratory, Acorn NMR Laboratories, demonstrating water changes with FRE-FLO™ water conditioning, measured by Nuclear Magnetic Resonance Spectrometry. Water micro-clustering refers to the concept that water molecules can change from being in large clusters (with a larger number of molecules in each cluster) to having less molecules per cluster, and to the hypothesis that the change to micro-clustering provides better hydrating properties and higher, improved permeability of the water. We have been asked what affect FRE-FLO™ technology may have on converting water to micro-clustered water. Acorn NMR Laboratories in Livermore, CA (a lab that has scientific protocols in place to evaluate water micro-clustering) was chosen to do testing in 2008 of FRE-FLO™ water, exploring whether or not FRE-FLO™ treated water changes in a manner indicating water micro-clustering. Water samples of before and after FRE-FLO™ water treatment were shipped and sent to the lab where they were tested within a few days. For testing, the lab used Nuclear Magnetic Resonance Spectrometry, utilizing the Oxygen Isotope 17 method.

A control sample of untreated irrigation water was collected from the water source at Quail H Ranch (sweet potato growers) in the central valley of CA. Right after the first water sample, then 1,000 feet away, a FRE-FLO™ test sample was collected from the end of an irrigation drip line having FRE-FLO™ treated water in it (with one pass through a FRE-FLO™ Model # 1000-800 SS). The laboratory compared the two water samples.

A sample of untreated tap water from a private residence in Santa Monica, CA was compared with FRE-FLO™ treated water from the same tap water source (on the same day, immediately afterward) that had only one pass through FRE-FLO™ Model # R075-025 PVC.

A sample of untreated tap water from a private residence in Long Beach, CA was compared with a sample from the same tap water source (on the same day, immediately afterward) with FRE-FLO™ treated water that had two passes through FRE-FLO™ systems (a FRE-FLO™ Whole Home System Model # H100-075 and a FRE-FLO™ Model # R075-025 PVC and also --- since inquiries about micro-clustering had been made by an ionizing corporation ---once through ionizing equipment designed for home use).

Following is a summary of research results from the independent lab showing the water sample results. The lab informed us that the smaller the number in the test results, the smaller the cluster, and the stronger was the indication of a change in the water (that could be interpreted as micro-clustering). The analytical laboratory data in the summary below refers to Hz (the hertz in this test measuring the characteristic NMR resonance of oxygen in water) and specifically to the width at half-height of the peak observed in each test of the spectrum of oxygen atoms in the water. This type of measurement has been interpreted by some other laboratories and by some scientists as being a measurement of water cluster size.


Hz Result Water Sample

% Difference

84 Untreated irrigation water from central valley in CA

8.33% 77

FRE-FLO™ treated irrigation water from same source

65.8 Untreated tap water from residence in Santa Monica, CA

9.3% 59.7

FRE-FLO™ treated water from same source with one pass

60.9 Untreated tap water from residence in Long Beach, CA

23.3% 46.9

FRE-FLO™ treated water from same source with multiple passes

The analytical test data show considerable reduction in the size of water micro-clusters in the FRE-FLO™ treated water. The independent laboratory results show that irrigation water going through a FRE-FLO™ unit (with only one pass through the unit) changes 8.33% in a direction indicating smaller water micro-clusters. The lab data indicate that tap water going through a FRE-FLO™ unit (with only one pass through a FRE-FLO™) changes 9.3% in a direction indicating smaller water micro-clusters. Lab results also indicate that tap water going through two passes of a FRE-FLO™ and through an ionizer, changes 23.3% in a direction indicating smaller water micro-clusters. Thus, the independent lab testing shows that water treated with FRE-FLO™ technology does demonstrate considerable water changes measurable by Nuclear Magnetic Resonance Spectrometry.


9. Test Results of Water Surface Tension

by C. David Lakeman

This section presents test results of reduced water surface tension produced by the FRE-FLO™ technology. It is well-known in the scientific community and among manufacturers that reducing water surface tension has the benefit of allowing water to spread out, to permeate and more effectively get to more areas. Following are three FRE-FLO™ tests done in 2011 and 2008 of untreated and FRE-FLO™ treated water, testing for any changes in water surface tension produced by FRE-FLO™ technology (and specifically for a reduction in water surface tension). Since experience over several decades has shown that FRE-FLO™ works exceptionally well in water having high total dissolved solids (TDS), we also hypothesized that water with higher TDS (that has a high level of calcium and carbonate ions) would exhibit a greater reduction in water surface tension (after going through a FRE-FLO™) than water with lower TDS. This is consistent with the fact that most high TDS water has a large amount of calcium and carbonate ions in the water, with which the FRE-FLO™ can react (since FRE-FLO™ is designed to specifically work with calcium carbonate).

When Dr. Chang (see “Principles of Catalytic Water Conditioning”) predicted that it was difficult to measure the difference in water surface tension, we accepted the challenge. We gathered samples from each location listed below:

A control sample of untreated irrigation water in Mexico in 2008 was collected. Then a FRE-FLO™ treated test sample was immediately collected from the same water source (having gone through one pass of FRE-FLO™ Model # 125-075 PVC). The TDS was a very high 2,300.

A sample of untreated tap water from a private residence in Santa Monica, CA was collected in 2011. Immediately afterward, a sample of FRE-FLO™ treated water from the same source was collected. The FRE-FLO™ treated water had only one pass through FRE-FLO™ Model # R075-025 PVC. The TDS was in a more moderate range at 480.

In 2011 another sample of untreated tap water was collected from a private residence in Santa Monica, CA. Immediately afterward, a sample of FRE-FLO™ treated water from the same source was collected, after only one pass through FRE-FLO™ Model # R075-025 PVC. The TDS was even lower at 255.

All of the test measurements were done with the water samples at room temperature (73.50F). The TDS and temperature was recorded using a Myron L AR1 Conductivity Meter. A glass slide was wiped with distilled water to clean the slide. Then using a Micropipette (using a 100 micro liters tip) a sample of water was drawn from each sample bottle, the outside of the micro tip dried (to eliminate the water drops still on the outside of the disposal tip), and the water sample was placed on the glass slide. Using a macro lens built into the camera, a tripod held the camera to a fixed focal length, a picture was taken, the camera was moved to the next water drop, moving the slide as little as possible, and another picture was taken. The camera was then connected to a computer and the pictures were downloaded. Each picture taken was then printed in 8” x 10” format. Then using a digital caliper, each water drop (of


exactly 100 micro liters each) was measured in millimeters (mm) four ways to get an average of the diameter size of each sample water drop. This averaged number was then divided by the increase in the diameter of the water drop (which is a measurement of the reduced water surface tension that allows the water drop to expand out over a wider surface area). The wider the area of the water drop, the more reduced is the water surface tension. The numbers are presented in the chart. The results demonstrate that FRE-FLO™ produces reduced water surface tension:

The following results for each test show the percent (%) difference in water surface tension between untreated water and FRE-FLO™ treated water from the same source. Since each drop of water was exactly 100 micro liters, if no change was produced by the FRE-FLO™ technology in water surface tension, then the diameter of the FRE-FLO™ treated water sample would have been the same diameter as the untreated water. However, results show measurable changes produced in the FRE-FLO™ treated water. The wider diameter of the FRE-FLO™ treated water (compared to the untreated water) in each test, shows the FRE-FLO™ treated water has spread more fully, over a wider area, as is expected when there is reduced water surface tension.


The following data further clarifies the results:

Mm Diameter TDS Water Sample

% Difference

7.8

2,300

Untreated irrigation water from Mexico

21.8 % 9.5

From same source, FRE-FLO™ treated irrigation water with one pass

66.73

480

Untreated tap water from residence in Santa Monica, CA

6.7 %

71.23 FRE-FLO™ treated water from same source with one pass

58.75

255

Untreated tap water from residence in Santa Monica, CA

3.4 %

60.95 FRE-FLO™ treated water from same source with one pass

In conclusion, in addition to the results showing considerably reduced water surface tension produced by the FRE-FLO™ , the test results also show (as expected) that the greater the TDS in the water, the greater the reduction in water surface tension.

FRE-FLO™ technology demonstrates functioning that produces a reduction in water surface tension, which provides numerous properties of effective hydration and improved permeability. The test results of reduced water surface tension produced by FRE-FLO™ are consistent with the FRE-FLO™ principles of operation, and with Dr. Chang’s analysis of principles of the FRE-FLO™ catalytic water conditioning.


10. Inside FRE-FLO™ Technology

by C. David Lakeman, Jim Stewart, Ph.D., and Allan James, Ph.D.

Upon entering a FRE-FLO™, water experiences a pressure drop and turbulent flow. This causes dissolved carbon dioxide (C02) to become a gas in the water (much like bubbles in carbonated water).

The pressure drop alters the characteristics of the water, producing a "saturated" condition with respect to calcium carbonate. This means the water in the FRE-FLO™ is ready to precipitate or grow non-scaling micro-crystals of “soft” calcium carbonate. Hard calcium carbonate is commonly called "scale”.

As the saturated water travels over the core in the FRE-FLO™ housing, the core promotes the epitaxial nucleation or growth of scale crystals. However, the force of the water passing through the FRE-FLO™ continually keeps the core free of scale. The now “soft” crystals are then carried out of the unit suspended in water.

The descaling benefit comes as the FRE-FLO™ treated water passes through applications such as cooling towers, ice and coffee machines, humidifiers, misting systems, evaporative coolers, or any system that uses water. At locations where calcium and carbonate ions in water would ordinarily grow into hard scale on equipment surfaces, they now grow on the non-scaly, soft crystals grown on the FRE-FLO™ core (because the crystals that were generated within the FRE-FLO™ function as alternative growth surfaces). This process can also attract and eliminate scale that was present in the equipment before the FRE-FLO™ was installed.

In essence, FRE-FLO™ takes existing total dissolved solids (TDS) and, through the processes of epitaxial nucleation and lattice matching, converts a portion of the TDS to suspended solids. That portion of the TDS that is converted to suspended solids protects the equipment from the growth of scale. The crystals stay suspended within the system and are discharged when the water exits the system.

The equipment stays clean and the scale goes down the drain. FRE-FLO™ works with nature to prevent scale from growing on your equipment.


11. Key Errors in Chemical Company’s Description of FRE-FLO™ Following are eleven basic observations regarding the many inaccuracies of a chemical company’s description of “non-chemical devices (NCD)” sent to us for review and analysis. We will focus on the errors related to FRE-FLO™ technology.

1. Instead of presenting our product name accurately, there are repeated incorrect spellings of FRE-FLO™ (as “Fre Flow” and in other places as “Fre Flo tm”).

2. It appears that due diligence did not occur when the author makes a highly inaccurate

description of FRE-FLO™ as claiming to restructure the “minerals calcium and magnesium”. This is a serious misrepresentation of what FRE-FLO™ does and does not do. Any individual knowledgeable about FRE-FLO™ knows that FRE-FLO™ makes no claims for descaling any magnesium or any other type of mineral deposits, except for calcium carbonate. We are not aware of any such claims since FRE-FLO™ was invented in 1972. To date, we specialize in providing safe, non-chemical, energy efficient, cost-effective solutions for deposits in pipes, equipment, and soil pores related to calcium carbonate. It is easy to test for the presence of calcium carbonate. We refer consumers to other technologies in the rare instances in which scale problems are not caused by calcium carbonate, such as when the scale problem is due to a high level of silica over 200 parts per million (ppm).

3. The author lumps catalytic, electromagnetic, magnetic, electrostatic, and mechanical water

treatment devices all into one non-chemical category, which is like categorizing all chemical companies (including his) as being the same. Although there are some distinctions made between NCD subcategories, the generalizations contribute to the very inaccurate portrayal of FRE-FLO™, omitting the scientific principles behind how FRE-FLO™ works, the FRE-FLO™ track record in multiple applications, the FRE-FLO™ history of installation successes, and its key feature of a reliable high level of effectiveness. In the “Case History Report” specifically on the FRE-FLO™ catalytic water technology, major misrepresentations are made, and no mention is offered of various examples of field test summaries showing effective FRE-FLO™ calcium carbonate scale control in a range of applications such as industry, business, agriculture, and turf.

4. In generally lumping FRE-FLO™ together with other NCD theories of operation, the author

misrepresents the mechanisms by which FRE-FLO™ technology functions. He discusses the theory, proposed by some, that an NCD works to control scale by having any existing calcite form of calcium carbonate in the system re-crystallize to aragonite. That is not what FRE-FLO™ does. Plus, such a mechanism would likely not produce descaling, as calcite and aragonite are both hard forms of calcium carbonate. FRE-FLO™ has no preference for working with scale caused by either hard aragonite or calcite forms of calcium carbonate. FRE-FLO™ works well with any form of calcium carbonate. How FRE-FLO™ does function is discussed in greater detail in “Scientific Principles Underlying the FRE-FLO™ Water Conditioning Technology”. Basically, the integrated FRE-FLO™ technology imitates what nature already has demonstrated is possible, with observations well known in the scientific community that calcium carbonate is able to have a variety of different forms and different crystalline structures. As the calcium ions and carbonate ions that normally flow in water go into the FRE-FLO™ unit and reach the proprietary FRE-FLO™ core, they are able (relying on such well-accepted scientific principles as lattice


matching and epitaxial nucleation) to combine into a smooth, tiny, spherical shaped vaterite crystalline structure (a non-scaly form of calcium carbonate) that easily washes away in normal water flow.

5. The author hypothesizes that a non-chemical technology may work because no treatment was needed in the first place or that some other mechanism, other than the NCD, accounts for the descaling results after an NCD installation. Many times customers buy FRE-FLO™ because no other technology (chemical or otherwise) has previously worked for the severity of their problem. A variety of FRE-FLO™ field test summaries and PowerPoint presentations describe the high level of effectiveness and history of installation success found with the FRE-FLO™ technology for calcium carbonate scale control in agriculture, turf, business, and industry.

6. The author’s discussion of the Langelier Saturation Index as an NCD theory has no relevance to the FRE-FLO™ mechanisms that produce descaling. Even the (now deceased) inventor of FRE-FLO™ technology, who was a licensed professional engineer (P.E.), with whom the current President of FRE-FLO WATER SYSTEMS, INC. spent considerable time, thought the Langelier Saturation Index was a theory of no relevance to the FRE-FLO™ functioning.

7. The author’s presentation of a general NCD theory of operation as reporting to “crush and kill” micro organisms does not apply to FRE-FLO™. FRE-FLO™ recommends other systems to control micro organisms of any kind. That is not our specialty. FRE-FLO™ is not a filter and, when used by itself, does not claim to filter out any organisms or act as a biocide.

8. The author describes theories of operation used by magnet companies. FRE-FLO™ is not a magnet.

9. Several hypotheses are proposed in the link for why large numbers of non-chemical scale control units are sold each year. One reason proposed is “chemophobia” and the concern with harm that chemicals can do to people and the environment. Our perspective at FRE-FLO™ is that currently more consumers, more corporations, and even more governmental agencies are interested in non-chemical, environmentally sustainable products that work, that are energy efficient, cost efficient, without the problems of chemical storage and chemical waste disposal. Our experience of the main reason why FRE-FLO™ green design sells is that it actually works, even in situations where chemicals have previously been tried and have not worked.

10. Another hypothesis proposed in the link for the current large market for non-chemical scale control is lack of scientific knowledge. By contrast, at FRE-FLO WATER SYSTEMS, INC., we value both public and proprietary scientific knowledge. We are fortunate to have regular input from associates and colleagues with a high level of scientific knowledge (such as Ph.D.s in physics and in agronomy and in hydrology, as well as colleagues having extensive experience and/or degrees related to wastewater management and planning, mechanical engineering, aerospace engineering, manufacturing, certified crop advising, biology, desalination engineering and design, reverse osmosis engineering and design (FRE-FLO™ is part of a patented reverse osmosis (RO) design to prevent scaling of RO membranes, eliminating the need for chemical hard water treatment), plus decades of knowledgeable experience (since 1982) in FRE-FLO™ technology. We value our scientific knowledge base, and make it available to the public, but with the obviously important limitation essential to any innovative corporation that there are some


proprietary aspects of our technology that we do not reveal. Both chemical and non-chemical companies have proprietary aspects of their work.

11. Yet another hypothesis in the link for the large customer base interested in buying non-chemical scale control technology is the substantial cost reduction over time compared to chemicals. This is an interesting reason, and accurate for the sale of FRE-FLO™ units. Since 1972, the outstanding return on investment (ROI) for FRE-FLO™ units continues to be from 3 months to 2.8 years, depending on the specific application. FRE-FLO™ provides the advantages of positive economic value.

12. A Fatally Flawed Copy of a FRE-FLO™ System

by C. David Lakeman

This section presents our response to serious inaccuracies in the case history by a chemical company of a “FRE-FLO™ installation.” Note that the following, by C. David Lakeman contains his first-hand knowledge of this specific case study. At the time of the installation of this cooling tower system at Motorola in Phoenix, AZ, he was working with FRE-FLO™ technology for the then-owner of FRE-FLO™ technology, Arral Industries, Inc.

Background of a WaterLoop™ Installation Two six inch, stainless steel, FRE-FLO™ catalytic water conditioning units (product 1000-600SS) manufactured by Arral Industries, Inc. (then the owner of the FRE-FLO™ catalytic technology) were purchased from Arral by L&H Airco, a company that was based in Rockland, CA. The objective of the purchase was to provide scale control treatment for a cooling tower system at Motorola in Phoenix, AZ.

The scientific context of this sale and installation in 1995 is important. For many years, FRE-FLO™ had been building an effective cooling tower system for scale control called Water Loop™. I was very aware of the technology behind the system, as I had spent a lot of time with Frank Schutz, the originator/inventor of the FRE-FLO™ water conditioners and the WaterLoop™. From Frank Schutz (who is now deceased), I had learned many details about how FRE-FLO™ and the WaterLoop™ function to produce safe, non-chemical, effective results. Note that when Arral became owner of the FRE-FLO™ technology, they changed the name of WaterLoop™ to WaterLoop 2000™. At the time of the above mentioned purchase by L&H Airco from Arral, I was doing work with FRE-FLO™ technology for Arral. Thus, in the course of my responsibilities, I offered to help L&H Airco with their work for Motorola in Phoenix, AZ. Fatally Flawed Copy of a FRE-FLO™ System

Most unfortunately, L&H Airco decided to change the standard FRE-FLO™ design of the Water Loop 2000™ that had been working well for many years and that was essential for the system to function properly as an integrated whole. First and foremost, when they rejected knowledgeable advice and chose a sand filter in place of a centrifugal separator, I knew the design was clearly not going to work (because it differed too fundamentally from what was needed for good results). The centrifugal separator included in a genuine WaterLoop™ will take out any particles in the water that are heavier


than the water, and when it reaches its maximum capacity, the centrifugal separator will not clog up as a sand filter will. Therefore, with the centrifugal separator, the flow of incoming water is not restricted through the FRE-FLO™ (allowing the FRE-FLO™ to keep working at its design flow rate). A sand filter, while very effective for some select purposes, had never been used by the inventor of the FRE-FLO™ in a cooling tower system, because of the likely problem of the system clogging up when large amounts of debris are collected inside the sand filter unit. A centrifugal separator, once it reaches capacity, will stop removing debris and let water circulate back into the open loop cooling tower system. In cooling tower systems with an excessive amount of initial scale deposit build-up that might overload the system (as was the case at Motorola in Phoenix, AZ), the centrifugal separator can make the difference between success or failure.

L&H Airco called their inauthentic, inferior product a WaterLoop 2000™, when it clearly was not a Water Loop 2000™ system and did not include the fundamentals required by FRE-FLO™ technology for successful functioning. They tampered considerably with the design and changed it. Their doomed, copied design was no longer a genuine FRE-FLO™ product. To make their system even less likely to function, they then installed it on a Motorola cooling tower system that had been running for several months without any water treatment whatsoever during the construction of the Motorola building. This meant that the cooling tower system already had a lot of scale before the FRE-FLO™ was installed. When the L&H Aircold system was installed, the FRE-FLO™ component within the system did its normal job of stimulating the breaking loose of the hard scale build-up from hundreds of feet of process cooling water pipe. This loose scale had to go somewhere. The scale went to the sand filters and “Y” strainers. This equipment soon became overwhelmed with the volume of scale being removed from the system. With this blockage now in the sand filters (instead of the recommended centrifugal separator), there was subsequently a substantial reduced flow through the FRE-FLO™. Now there was not enough water flow through the FRE-FLO™ for proper functioning, and the reverse effect of the desired descaling result started taking place.

Note that a specific incoming water flow range rate is essential to each size FRE-FLO™ unit (as the FRE-FLO™ literature states). When the proper size is chosen, and there is maintenance of typically annual cleaning, then the FRE-FLO™ consistently works. If the improper size is chosen (either too big or too small), then it will not work. Selecting the proper FRE-FLO™ size model is very easy, as the selection is based simply and only on the range of water flow rate in gallons per minute (gpm) going into the FRE-FLO™ unit. After Arral Industries purchased the FRE-FLO™ technology, a couple of million dollars were spent by Arral (based on my recommendations to them) to scientifically document flow rates and verify the housing design. After a year of Arral’s work, they re-released the FRE-FLO™ product to the market. There were a few changes made to enhance the performance of the product and we enjoy them today with a superior product to market.

First Hand Knowledge of Installation

My information regarding Motorola is first hand. I was at the meeting in Phoenix, AZ with Motorola and L&H Airco when Motorola said that the cooling tower system sold to them by L&H Airco was not working. In that meeting, I did communicate to Motorola that the cooling tower system they had was not a WaterLoop 2000™ by Arral Industries, as an essential aspect of the system had been changed. Neither L&H Airco nor Motorola appeared to have an interest in that vital bit of information. My experience has been through the years that when individuals do not understand how the integrated aspects of a FRE-FLO™ system work together, nor the science behind the system, they sometimes mistakenly feel certain they can substitute one part with another and still expect it to work.


One of the Motorola maintenance men did say in the meeting that after the L&H Airco system was installed and prior to the L&H Airco system having a reversal of working when the sand filter clogged, the “Y” strainers would need to be dumped every shift and they were loaded with what he called“white sand.” The white powdery sand (the “soft” powdery calcium carbonate scale) would pour out of the strainer and easily wash down the drain line. Factually, that was a constructive outcome since the system was purging itself of unwanted scale build-up. It is important to note that the “severe white rust problem” (described in the chemical supplier link) was the white calcium carbonate crystals successfully becoming “soft,” small, powdery crystals, coming off of the pipes (however, way too quickly because the L&H Airco system was a flawed copy of the WaterLoop™).

If a non-chemical, genuine WaterLoop2000™ system had been utilized (with the adjustment of having a centrifugal separator instead of an inappropriate sand filter), the system would have effectively accomplished its job. A proper expectation of the client in such situations is also important (with vitally important education by the seller to the client), of having to dump “Y” strainers and purge the centrifugal separator of the scale build-up that is successfully being removed from the open loop cooling tower system. After all, there was approximately six months of build-up in this cooling tower system that had to be removed suddenly from several hundred feet of process piping (22” diameter and smaller) when the L&H Airco system was installed. This project would have been labeled a major success with small, but vital adjustments on the part of seller and client before they came to an impasse with each other.

Note that the analytical data in the case study in the link supports my conclusion that the L&H Airco system (a fatally flawed copy of the genuine WaterLoop2000™ system) was not working properly.

Additional Relevant Technical Papers

Following, see a twelve year field test summary showing the outstanding results and cost effectiveness that are achieved with the authentic WaterLoop™ technology.

Also see the following NALCO Analytical Laboratory Report (with test data) showing excellent (0.5) results from a corrosion coupon study (the authentic FRE-FLO™ WaterLoop™ technology attached to a cooling tower is projected to extend the metal life in the processing piping in excess of 65 years).


13. Twelve Year Field Test Summary of Authentic FRE-FLO™

by Jim Stewart, Ph.D.

Results of FRE-FLO™ project at:

TOLMAN & WIKER INSURANCE – VENTURA, CA

Executive Summary Installation of a FRE-FLO™/Water Loop™ system in February 1990 (report filed in 2002) on a fluid cooler of an office building in Ventura, California, just a few hundred yards from the ocean, resulted in the extended life of the tower, and saved $3,288 per year, considering both capital and maintenance costs. FRE-FLO™ also has less down time for maintenance and requires no dangerous chemicals. FRE-FLO™ paid for itself in less than 2 years.

Detailed Report In 1987 Tolman & Wiker Insurance Company purchased an office building and updated all the HVAC systems, including installation of a new 150-ton evaporative cooler located on the top of the building. This building is located in Ventura, California, only 500 yards from the ocean. Co-owner Dennis Corte reports that only 5 months after installation, in September 1987, the brand new cooling tower shut down because of scale from the hard water. Therefore, the company implemented chemical treatment procedures, at a cost of over $300 per month. However, the chemical treatment was not working well and required frequent acid baths to remove scale. One of the co-owners was very concerned about the environmental impact of flushing these powerful acids and other chemicals down the drain where they could eventually end up in the ocean. In addition, there is the damage the acid does to the tower itself. Note that the water going into the cooling tower was extremely hard. The make-up water was 1,100 TDS from the city of Ventura, CA and the tower was run at 3 cycles of concentration, resulting in 3,300 TDS.

Trouble Free Operation: In February 1990, Tolman & Wilker installed a Water Loop™ at a

cost of $5,200. Although it was working satisfactorily, the company decided to upgrade to an updated version of Water Loop™ with more features in 1995 at a cost of $8,000. This model has been operating without any problems for the past seven years. There have been no shutdowns of the cooling tower from any malfunction of the Water Loop™ for twelve years. Mr. Corte estimates that maintenance on the Water Loop™ has been less than $500 per year for the semiannual checkup and cleaning.

Operation Alert Feature: The Water Loop™ unit provides an alarm system if there is any

malfunction, such as a valve stuck open or closed. It activates an alarm light in the computer room in the building. Tolman & Wiker Insurance chose the data processing room as the room most likely to have people present at all hours. Before the installation of Water Loop™ with the alarm feature, the blow down line stuck open for an extended period, losing five gallon per minute (over 200,000 gallons a month). The malfunction was not discovered until the water bill showed an increase of nearly $2,000. After the installation of Water Loop™ with the alarm feature, the same malfunction occurred, but it was discovered immediately and was stopped within a couple of hours. The alarm feature can also greatly reduce the chance of any damage


to the tower if a valve is stuck shut preventing the blow down of the high total dissolved solids (TDS). Extended Life: Mr. Corte reported that a tower such as this is supposed to last 15-20 years (more likely 15 years this close to the ocean). It is currently 15 1/2 years in age and a recent inspection estimated that it would last at least another 2-3 years.

Comparison of Costs between FRE-FLO™ and Chemicals

Costs of chemical treatment: Mr. Corte reported they started out at over $300/month in 1987, and recently checked to verify current costs and was told it would be about $450/month. Mr. Corte has estimated the average over the 12 years of 1990-2002 would be about $390/month.

TABLE 1: Comparison of Costs from 1990-2002

Water Loop™ Chemicals

Capital Costs $13,200 $2,500

Maintenance Costs $6,000 $56,160

Total Costs $19,200 $58,660

Net cost savings over 12 years of using Water Loop™, compared to chemical treatment: $39,460 or $3,288/year. Water Loop™ paid for itself in less than 2 years, from reduced operating and maintenance costs. When the total cost of operating the tower is considered, i.e. better heat transfer, which translates into lower energy costs and less corrosion from chemicals, the ROI is even faster.

Advantages of Water Loop™/FRE-FLO™ Systems

1. Cost savings of thousands of dollars per year. 2. Greater reliability of cooling system, with fewer breakdowns and loss of service. 3. Keeps equipment constantly clean and therefore always operating at design

specifications. 4. Extended life of cooling tower. 5. Alarm system to warn of malfunction in the Water Loop™ is standard equipment. 6. The absence of dangerous chemicals benefits workers and the environment. 7. Increases the quality of discharge water by eliminating the scale inhibiting chemicals

and reducing the concentration of biological chemicals needed.


14. Lab Report of Reduced Corrosion Using FRE-FLO™

Introduction to Nalco Chemical Company Lab Report by Jim Stewart, Ph.D.

The following two pages present the results of a corrosion study by NALCO Chemical Company

conducted at the Emanuel Medical Center in Turlock, California. The test reported extremely low

corrosion of a steel coupon in a small cooling tower using a Water Loop™ treatment system, which

utilizes a FRE-FLO™ water conditioner for scale control. The test was done as a blind test. The client

agreed to having a blind test done, provided the test results, whatever they turned out to be, were released

for public information.

Over an 89-day period, the mild steel coupon showed a corrosion rate of only 0.5 mils per year, which,

as the letter from NALCO states, “is considered excellent and projects metal life in excess of 65

years.”

Note that this test was done with no chemical corrosion inhibitor being used in the cooling tower, only the

FRE-FLO™ Water Loop™ treatment system.


15. Analytical Laboratory Report of Nalco Corrosion Coupon Study

by Nalco Chemical Company



16. FRE-FLO™ Mechanisms for Environmental and Economic Management

by D. M. Lakeman, Ph.D. and C. David Lakeman

Environmental and Economic Problem As the usual cause of “hard” water scale deposits, calcium carbonate (sometimes called “lime scale”) poses multi-million dollar hassles for business, industry, agriculture and turf. The corporate bottom line and the environment are both harmed when deposits clog up water flow in pipes and machinery, as well as in soil, crop roots, and turf roots. It is well known that calcium carbonate scale build-up can bring equipment to a slow down or even a standstill when deposits stop water flow in pipes. In agriculture and on golf courses, calcium carbonate can clog up soil porosity, and contribute to dense soil compaction, diminishing the ability of water, air and nutrients to reach root zones. Effective Environmental and Economic Management The FRE-FLO™ non-chemical descaling unclogs pipes, filters, and machinery, permitting business and industrial productivity to resume, and equipment to work to design specifications. Energy efficiency and productivity are improved. In irrigation applications, FRE-FLO™ treated water allows soil pores to open and reduces soil compaction. This is part of how FRE-FLO™ significantly improves soil quality so that nutrients can reach roots, resulting in much healthier, higher quality turf and crops, generating an increase in profits, while using less water. Energy-Saving Mechanisms The energy savings from utilizing FRE-FLO™ occur when there is a decrease in energy consumption related to descaling in heating or cooling applications. The build-up of scale deposits results in the need for more fuel to heat water to any given temperature and therefore costs more money to operate. When there is scale build-up, the transfer of heat is less efficient in equipment such as heat exchangers, cooling towers, evaporative coolers, steamers, hot water heaters, coffee makers, dishwashers, and other water using machinery. Scale clearly diminishes energy efficiency and wastes money. For example, research shows that scale build-up results in considerable additional fuel cost:

Scale Build-Up Thickness Unnecessary Extra Energy Consumption (Inches) (Percentage) 1/32” 8.5% 1/16” 12.4% 1/8” 25.0% 1/4" 40.0% 1/2" 70.0%


The economic value of solving scale and related energy consumption problems is considerable. Thus, for example, a $20,000 energy bill with a 1/8” scale build-up costs $25,000 because of the 25% additional energy consumption.

Maintenance-Saving Mechanisms

There are clear mechanisms for maintenance-savings with FRE-FLO™ technology when there is less cleaning of equipment, lessened periods of staff time for repairs, longer life of equipment with descaling, and better risk management without the need to deal with potentially dangerous chemicals and chemical storage, chemical transportation in and out of your facility, and chemical waste management.

Application Domain

FRE-FLO™ descaling provides environmental and economic advantages wherever (locally or internationally) calcium carbonate in flowing water is causing scale deposit damage. As approximately 4% of the earth’s crust is calcium carbonate, applications for FRE-FLO™ technology are extensive. Many of the FRE-FLO™ applications utilize the 14 standard FRE-FLO™ model sizes, that come in 3 housing materials (stainless steel, copper, or PVC). The standard models are designed and manufactured to last for decades, typically requiring only annual maintenance.. Applications in which FRE-FLO™ already has a track record for industry and business include: heat exchangers, hot water heaters, water storage tanks, steam boiler equipment, evaporative coolers, valves, fume scrubbers, misters, and cooling towers. FRE-FLO™ also now has an annually replaceable line of highly cost-effective units for: ice machines, water cooled condensers, tankless water heaters, coffee makers, water drinking fountains, and other water using equipment. Field test summaries for business and industry applications are available.

FRE-FLO™ Model # R150-100, with PVC Housing, From the New Model Line of Annually Replaceable Units


FRE-FLO™ already has a track record of applications for irrigation in agriculture and turf environments. Considerable water conservation results occur. Field test summaries and a history of installation success show typically 16% to 29% less water is needed in various types of irrigation applications where hard calcium carbonate water and poor soil percolation exist. In such settings, there is also typically from 16% to 29% less power and energy needed for irrigation pump use. By itself, FRE-FLO™ calcium carbonate descaling technology does not control other types of scale or contaminants. FRE-FLO™ specializes in providing solutions for a spectrum of calcium carbonate scale problems for business, industry, agriculture and turf. When integrated with other systems, however, FRE-FLO™ contributes to solving additional significant 21st century water concerns (such as taking contaminated water to being potable water appropriate for irrigation and drinking purposes).

17. Concluding Comments We respect due diligence and trust this presentation has answered your questions about the science supporting FRE-FLO™ technology, as well as our analysis of the two links sent to us. As we have shown, processes utilized in the FRE-FLO™ operation are based upon a foundation of principles well accepted in the scientific community. Utilizing scientific principles also used by many scientists and manufacturers, yet combining those processes in an innovative, proprietary manner, FRE-FLO™ facilitates what nature already demonstrates is possible. The result: FRE-FLO™ catalytic, non-chemical technology producing a cost-efficient solution with a high level of effectiveness, safety, and ease of use for scale control. In conclusion, in this paper we have presented a foundation of well-known scientific processes underlying the integrated, synergistic FRE-FLO™ water conditioning system. We value the essential need for scientific verification by independent third parties, such as testing done by independent labs and field tests done by third parties. Additionally, and to us of considerable value, are the case studies, FRE-FLO™ field tests, and testimonials from those with direct, in-the-field experience using FRE-FLO™ technology. The users have purchased, and some have made additional FRE-FLO™ purchases to expand the FRE-FLO™ benefits in their industrial, business, and irrigation endeavors. To us, that is the highest compliment and verification that FRE-FLO™ works. Again, we believe both types of verification are absolutely necessary and welcome. We welcome your comments and any questions. We look forward to a long and mutually satisfying relationship.

Documents

Key Scientific Principles of FRE-FLO™ Technology · Key Scientific Principles of FRE-FLO ... Analytical Laboratory Report of Nalco Corrosion Coupon Study..... 34 16. FRE-FLO™