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COOLING TOWERS

Non-Toxic Cleaning Solutions

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    SANITATION OF EVAPORATIVE TOWERS

    ALRBIO creates, promotes, and organizes technologies and products to improve the environment. ALRBIO technology is designed to protect the well-being and health of people and bring better performance and longevity to industrial applications.

    The innovative protocol for the prevention and hygiene of industrial cooling systems proposed reduces the use of chemical products and the resulting environmental risks, improving the safety and efficiency of evaporative towers. The microbiological methodology adopted is based on the application of a probiotic solution in industrial process waters.

    Live microorganisms:

    •   Avoid the proliferation of pathogens,
    •   Reduce the risk of Legionnaires’ disease,
    •   Guarantee deep and lasting cleaning,
    •   Protect the environment.

    THE PROBLEM

    Evaporative towers, also known as “cooling towers,” must be monitored periodically to avoid the risk of bacterial contamination, such as Legionella, and environmental damage.

    Current water control and conditioning systems based on chemicals and biocides have a strong environmental impact and often fail to completely eliminate the risk. The main contaminants of the evaporation towers are mainly of organic and microbiological origin (bacteria, algae, mud, and fungi) and result in the formation of a highly resistant biofilm.

    Furthermore, the temperatures of the exchangers favor the crystallization of limescale, compromising the efficiency of the system. Although biocidal products currently in use can significantly reduce the number of organisms, they are not able to guarantee their complete removal.

    Pathogenic microorganisms, typically more resistant are able to survive the disinfectants and, with each cycle, reproduce more rapidly, colonizing more space on the surface or in the tank and increasing their colony and associated risks.

    IDEA

    Replace the biocides with a formulation based on ALRBIO probiotic bacteria capable of guaranteeing natural, stable and long-lasting microbiological protection and deep cleaning.

    SOLUTION

    ALRBIO has developed a new scientific microbiological methodology that involves the insertion of live microorganisms into the process.

    KEY BENEFITS

    Deeper and longer lasting hygiene, Recovery of system efficiency, Sustainability and environmental protection, Greater protection from contamination by pathogenic microorganisms.

    PROBIOTICS

    •  Activate a natural mechanism that decomposes and metabolizes organic contaminants and biofilm,
    •  Colonize the environment, preventing pathogenic bacteria from taking over,
    •  Create a healthy and regenerative microbiotic environment, hinder the formation of new bad bacteria and germs.

    CASE STUDY

    Object of the study: 

    Analysis and monitoring of the containment capacity of the proliferation of pathogenic bacteria in the water systems of evaporative towers, following the use of probiotic products in place of chemical biocides.

    The test is performed on evaporative towers under ordinary conditions of use. The microbiological aspects and the chemical-physical parameters of the water are monitored. Visual inspections are carried out to assess the cleanliness of the internal surfaces, the heat exchange surfaces, and deposits (contamination due to mud, algae, mold, etc.).

    In this case, evaporative towers were monitored to service the Freon Tower 1 and Tower 2 and NH3 systems for cooling cold rooms. The towers are powered by groundwater without softening or filtration systems. The make-up water is recalled from the evaporative towers by means of a float inside the individual towers. The make-up water was previously treated with a system of dosing pumps for the proportional dosage of antiscalant and dispersant solution and a solution of biocide (hydrogen peroxide).

    METODOLOGY

    The process begins with a verification of the effective disposal of biocides through colorimetric maps of the tower water. The metering pump previously used for the hydrogen peroxide, properly rinsed and cleaned, is fed with the probiotic-based formulation.

    A first quantity of product is introduced directly into the tanks of the evaporative towers in order to accelerate the colonization process of the tanks. We then proceed with a proportional dosage of water for the first 3 weeks. At the end of the 3 weeks, a maintenance dosage is continued.

    NOTES: The test began in the last week of February with ambient temperatures below 10°C. Throughout the months of March and April, the temperatures were below the seasonal averages with consequent poor lighting of the towers. From the month of May, the temperatures have risen significantly, and the towers have operated with greater continuity.

    Time T1: 03/15/2021

    MONITORING

    During the start-up phase of the plant, a weekly visual inspection and monitoring of the chemical and physical parameters were carried out to ensure the correct functioning of the evaporative tower. Subsequently, monitoring and microbiological analyses were carried out monthly.

    TIME t1: 21/04/2021

    TIME t2: 24/05/2021

    PHASE 1

    Tower 1 tank: Through microbiological monitoring and periodic technical checks, the results obtained through the adoption of the ALRBIO probiotic protocol are summarized below.

    Phase 1 (Time to colonization): The internal surfaces of the tank and the exchanger of the towers have organic formations: algae and mud; the water is cloudy, and microbiological analyses show the presence of Pseudomonas and mycotic charges, although no Legionella is found.

    The towers were cleaned by mechanical action a few months before the start of the study, but the interventions did not remove the deposits present on the tube bundles due to their consistency and adhesion. The treatment begins with a dosage of probiotics to carry out the first colonization of the evaporative towers.

    Notes: The water temperatures in early March were below 20°C, and the lighting of the towers, especially that of the Freon 2 tower (supporting Tower 1), was infrequent.

    There is the presence of algae and organic biofilm in the lower part of the tower, while on the tube bundles there is a strong encrustation of limestone and organic material that could not be removed mechanically.

    Tower 1

    Tower 1
    Tower 1
    Tower 1

    Tower 2

    Tower 1
    Tower 1
    Tower 1

    Tube Bundles

    Tower 1
    Tower 1

    RESULTS

    Phase 2 (Time t1 breakage, detachment, and biofilm digestion): 

    Probiotics begin their activity of colonization and production of specific enzymes for the type of biofilm and organic material they encounter. The biofilm is composed of several layers of organic and inorganic materials, such as calcium carbonate, which makes it adhere to surfaces.

    The action of probiotics progressively breaks the bonds of the biofilm, starting from the outermost layers and progressing towards the innermost ones. The organic matter contained in the biofilm becomes nourishment for the probiotics, which multiply and continue their cleansing action. The water becomes more turbid, and there is a greater presence of deposits due to the progressive detachment of encrustations.

    For this reason, based on the degree of encrustations and biofilm present in the system, it is necessary to carry out a programmed control of the filters. If the detached material is so abundant that the probiotics cannot dispose of it in a short time, it is possible to intervene with washing and mechanical removal of the deposits.

    The duration of this phase depends on the degree of contamination and dirt accumulated on the walls, tube bundles, and inside the pipes. The bacterial load grows due to the multiplication of probiotic bacteria (desired effect) and a greater presence of bacteria (non-probiotics) and fungi due to the breakdown of the biofilm.

    The increase in probiotics accelerates the cleaning action and the process of dissolving the biofilm and detaching the matter in which it is nested.

    phase 2: detachment of encrustations and dissolution of the biofilm

    Tower 1

    MAINTENANCE

    Phase – Maintenance: The water becomes clear again, and the surfaces of the tank, walls, and tube bundles appear clean and free of biofilm or encrustations.

    The organic material, loose deposits, and silt have been removed mechanically to accelerate the effect of probiotic digestion (in the case of new or clean towers, the mechanical phase is not necessary).

    We are witnessing a reduction of unwanted bacterial loads and fungi; algae are no longer present, and even organic nourishment is scarce. The effect of cleaning and eliminating nutrients leads to the death of microorganisms due to lack of sustenance and the reduction of all monitored microbiological parameters.

    A maintenance dosage is continued in the make-up water to maintain a probiotic colony, present although dormant or reduced in number due to the absence of nutrients.

    The elimination of biofilm and organic contaminants (nutrients) prevents the proliferation of pathogenic organisms. The probiotics introduced in this phase will remain inactive (in the form of spores) until new nutrients arrive, continuing their cleaning action.

    Phase 3: Maintenance, cleaning and energy efficiency

    Tower 1
    Tower 1
    Tower 1
    Tower 1

    THE ALRBIO METHOD

    The ALRBIO probiotic technology, included in the management plan of the tower water treatment process, duly set up and monitored, allows you to manage the processes in a natural way, containing pathogenic bacterial proliferation and increasing the efficiency of the evaporative towers. The continuous cleaning action of the probiotics allows energy efficiency, enabling the evaporative tower to achieve better heat exchange.

    BENEFITS

    ENVIRONMENT

    The products are 100% natural and have a beneficial effect on the environment even when they are released down the drain. They allow the elimination of chemical biocides and have a long-lasting effect.

    ENERGY

    The removal of the biofilm on the surfaces and in the ducts, and the detachment of encrustations, which reduce the heat exchange of the systems, allow a recovery of the system’s energy efficiency.

    SAVINGS

    The energy efficiency and the constant self-cleaning action of the probiotics allow energy savings and a reduction in major plant maintenance.

    SAFETY

    The digestive action of nutrients, the colonization of surfaces, and the elimination of biofilm allow a natural control of pathogenic bacteria and unwanted microorganisms.

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