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BacComber Cooling System:

A Chemical Free Cooling Tower

• Project was conceived at Senior management level.


• Uniqueness of project : It is a non-chemical technology that has proven
results over the control of scaling, corrosion and microbiological growth in
cooling water. This has eliminated the use of acid dosing and chemical
dosing.

Date of commencement : 6.06.2016


Date of completion : 5.08.2016

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MAJOR COMPONENTS

• An electromagnetic descaler

• An electromagnetic magnetite generator

• A copper silver ionisation unitionisation unit

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MAJOR BENEFITS WITH BACCOMBER

• Saving of recurring annual chemical treatment costs

• Saving of energy due to scale control

• Higher cycle of concentration

• Saving of water : when zero discharge is implemented

• Saving of life of condensers with avoidance of descaling

• Saving of cost of treatment of bleed off water before discharge

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ENERGY SAVINGS DUE TO CONTROL OF HARD SCALE

Variable Unit Value Considered

Tons of Refrigeration TR 800

No of hours of usage per year Hrs 7776

Power Consumption KWH 3110400

Estimated Energy Saving ( 2% KWH 62208


per year)
Cost of electricity Rs./KWH 8

Annual Saving Rs. 497664

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WATER SAVINGS DUE TO INCREASED COC

Variable Unit Value Considered

Tons of Refrigeration TR 800

Blow down /year at 5 COC KL 11520

Blow down /year at 8 COC KL 6480

Estimated water savings KL 5040

Cost of Water Rs./KL 27

Annual Saving Rs. 136080

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INTANGIBLE BENEFITS

• Saving of human effort in maintaining daily treatment.

• No chemical treated water discharge to environment.

• Good Corporate Social Responsibility (CSR) image.

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Replication Potential

• The cooling tower is so common in industries and lot of money and


chemicals are spending to maintain the cooling tower. This technology
can eliminate the cost associated with it.
• Presently it is being installed in the New Astec Plant in Mahad.

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BacComber is also installed in the following Godrej Group Companies :

• GIL Valia : Last year installed.

• GIL Ambernath : Last year installed.

• GCPL Malanpur : Last year installed.

• Godrej One : Installed in April this year.

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REPLICATION POTENTIAL WITHIN SECTOR

 BacComber System can be implemented in any type of cooling


towers.
 It can be installed in boiler water treatment and chilled water
system.
 It is ideal for zero discharge plant.
 Can be used for agriculture and irrigation system.

Oil Refineries and Thermal Power Stations


Petrochemical

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Challenges Faced Counter

High Amount of Blowdown • Increased cycle of concentration


• Zero Chemical Treatment

Low Cycle of Concentration • Reduce Scaling and descaling


• TDS Monitoring

Treatment of Blowdown water • Recycling of blowdown water


since it is free of chemicals

Biofilm and organic growth • Copper Silver Ionisation unit

High Maintenance requirement • No maintenance due to scaling


and corrosion prevention

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PRIORITY PLANS FOR +1 YEARS

 Plan is to install BacComber System in all the associated companies.

 Awareness about the advantages of this technology at social


platforms.

 To install in the chilling plant and check efficiency.

 Trial for the boiler feedwater treatment.

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MAJOR LEARNINGS

 Keep looking for the alternative solution.

 Awareness of latest technology and its implementation.

 Adapting new technology.

 Green way to treat cooling water.

 Better management of cooling towers.

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THANK YOU FOR YOUR TIME AND CONSIDERATION

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