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CuZn System Economics
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The
CuZn water filtration system eliminates the need for
chemical treatment by using the metalox
process. By using our system building owners
can reduce operating costs of there boiler and cooling
tower systems as well as eliminate down time. |
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Cost Comparison
Chemical Technology vs. CuZn
Based on Typical Operating
Costs of a 500 ton Chiller and Tower
| Various Costs |
Chemical Technology |
CuZn System |
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Chemicals
|
$
5,000 1 |
$ 0 2 |
| Compressor
Electricity (4¢) |
$115,200 3 |
$ 96,000
4 |
| Water and Sewage |
$ 20,520 5 |
$ 16,416
6 |
| Tower/Condenser
Maint. |
$
5,500 7 |
$ 0 8 |
| Tower Electricity (4¢) |
$
8,076 9 |
$ 5,854 10 |
| Totals |
$154,296 |
$ 118,270 |
| Avg. Operating Cost
per Ton |
$ 308.59/ Ton |
$
236.54/ Ton |
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Table
Explanation |
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Chemical
Costs
1. Chemical
Treatment.
Average Cost: $5,000
Chemicals cost an average of $10/ton/yr. in systems
operating 6,000 hours per year. Chemicals used include
bio-cide, algaecide, corrosion and scale inhibitors, and
scale dispersant. This estimate includes annual costs of
field monitoring and chemicals needed to recharge system
after periodic bleeding to remove mineral concentrations.
2. .CuZn
system $0
Compressor Electricity ($.04) Costs
3. Chemical
Treatment.
Average Cost: $115,200
Notes: The U.S. Department of Energy estimates that a
1/8" buildup of scale on a heat exchange surface will
reduce the efficiency by 25%. Cooling towers and condenser
sections using chemical treatment of the cooling water
inevitably generate scale in the sump and the piping of
the chiller and/or heat exchangers. 500 ton X 0.8KWH/ton
(conversion rate of electrical to mechanical energy) X
6,000 hrs X $0.04/KWH X 1 (load factor) = $96,000/yr X
120% (20% loss to scale or film) =$115,200.
4. CuZn Treatment Costs
Cost: $96,000.00
Notes: The CyZn
technology will remove existing scale from the cooling
tower sump and the piping. To be conservative, a 10%
figure is used for efficiency improvement even though, as
noted above, DOE estimates that 1/8" scale on
condenser tubes can reduce operating efficiency by 25%.
Chiller electricity savings and costs are calculated as
$115,200 / 80% = 96.000.
Water and Sewage Costs
5. Chemical
Treatment.
Average Cost:$20,520 (based on estimate of $2.40/1,000
gal)
Evaporation: 0.038gpm/ton X 500ton X 60min X 6,000hrs =
6,840,000gal/yr.
Water/sewage costs = $2.40/1,000gal \evaporation costs =
$16,416
Blowdown: 10.0095 gpm/ton X 500 ton X 60 min. X 6,000 hrs
= 1,710,000 gal/yr.
Water/sewage costs = $2.40/1,000 gal \Blowdown costs =
$4,104
6. CuZn Treatment.
Cost: $16,416.
Notes: The CuZn System
will reduce or eliminate Blowdown that results in water
and sewage savings of $4,104.
Tower/Condenser Maintenance Costs
7. Chemical
Treatment.
Average Cost: $5,500 per year
Notes Tower maintenance is estimated to require an annual
effort of 76 hours to scrape, clean and recoat. The
estimated time to disassemble and reassemble the tower
diffusion plates and the condenser bells is 24 hours.
At a labor rate of $55/hr. this maintenance costs $5,500
per year. No estimates are made for periodic flushing of
the entire piping system with muriatic acid and then a
neutralizer to reduce scale buildup.
8. CuZn Treatment.
Cost: 0.
Tower Electricity
9. Chemical
Treatment.
Average Cost: $8,076 per year
Notes: Electrical costs associated with the
operation of the cooling tower are based on
a 15 hp motor to drive the pump and a 30 hp motor to
drive the cooling fan. These
assumptions yield a cost of: 45hp X 0.748/hp X
6,000hrs X $0.04/kwh = $8,076.
10. CuZn Treatment.
Cost: $5,854 per year
* These formulas are derived from Perry's Chemical
Engineers' Handbook, 6th Edition {50th anniversary
edition}
pp 12-17.
Notes: The CuZn system is expected to reduce
operating costs for the cooling
tower by slightly less than 34 percent. Combining 66
percent of the cost of electricity for
the existing system and adding the cost of a two
horsepower motor to operate the
CuZn system, obtain this estimate. The calculations
are: $8,076 X 66% = $5,330/yr
plus operating costs for the CuZn system (2hp X
0.748/hp X 8,760hrs/yr X
$.040/KWH = $524.00). Total costs are, therefore:
$5,330 + $524 = $5,854.
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