THE ION STICK® Alternative Environmental Water Treatment
The ION STICK materialized as an electrostatic water treatment device in 1978. Designing and marketing of this product originated with the company name of York Energy Conservation which was located in Georgetown, Ontario. By 1981, initial patents were applied for in Canada and the United States and later granted. Patents were also applied for in specific markets world-wide and subsequently granted.
At first, the ION STICK applications were limited to potable hot water and closed heating systems. Due to the cleansing ability of the product, the ION STICK often was utilized as a problem solver of fouled heating elements and exchangers. Reduction in maintenance and the improvement in heat transfer (energy conservation) provided a measurable return on investment. As the ION STICK's benefits were substantiated, it was apparent that other heat transfer recirculating systems would benefit with the product. New applications included closed loop cooling systems, open recirculating systems, and steam generators.
In 1987, marketing and sales were extended overseas. The York Energy Conservation name was retained. Manufacturing of the ION STICK was relocated to Concord, Ontario and then to a larger, expanded facility in Richmond Hill, Ontario.
In 1988, the support division for York Energy Conservation, known as Advanced Water Technology Inc. (A.W.T.) was created. This division was formed to provide the back-up services necessary to ensure the performance of the ION STICK is gradually gaining acceptance as an effective, non-chemical approach towards water treatment. With more emphasis being placed on environmental impact, safety awareness, energy conservation, and cost, the need for this type of technology is apparent. The popularity of the ION STICK® has initiated an interest in many other applications. Research and development is being conducted to meet all possible markets.
USEFUL TIPS
It is best to initiate the electrostatic treatment program with a precleaned system. The cleansing effect of the ION STICK may loosen heavily accumulated areas that could migrate and create flow restrictions in close tolerance sections (ie: spray heads or air passages).
The ION STICK should remain on at all times whether the booth has interrupted service or not. A dedicated electrical source to the unit is recommended.
The ION STICK cannot act as a cure for a poorly designed or maintained booth. Routine maintenance and operating practices must be applied as per the booth manufacturer's recommendations.
Excessive foaming and suspended solids are visual indications that the booth may soon require cleaning.
The ION STICK model IS-500 is suitable for booths up to a maximum of 10 feet in length. The IS-750 model is necessary for larger booths.
Product Applications:
An electrostatic non-chemical water treatment program can be employed in many capacities. Below is a list of some basic applications in which the ION STICK can be utilized:
· Potable (domestic) hot water system
· Closed Loop cooling/heating systems
· Steam boilers
· Cooling towers, Chillers, Condensers
· Finishing Pre-treatment Systems
· Starch systems
· Sidestream Filtration
The ION STICK can be employed in any recirculating water system. Designs of this patented electrostatic water treatment product are suited for the commercial, institutional, and industrial marketplace.
ADVANCED WATER TREATMENT FOR THE '90'S
This world-wide patented product functions by emitting an electrostatic field that conditions the contaminants in the water to prevent waterside scales and deposits. In doing so, it also has a cleansing effect ability in removing existing deposits and scales to maximize heat transfer; reduce underdeposit corrosion and extend system and equipment life. By this nature, it eliminates biocide requirements totally in some systems and reduces use in others.
The ION STICK® can be retrofitted into new or existing recirculating Systems for many years of simple, cost effective and environmentally safe treatment. There are a growing number of applications over and above the HVAC requirements; these include industrial, potable and process systems such as those found in pulp and paper, metal finishing, commercial, paint spray booth and many others.
THE ELECTROSTATIC EFFECT
There are positive and negative electrical sites throughout all areas of a water system. All particles whether they are in solution, suspension or in contact with the water, exhibit electrical properties. An equilibrium is achieved as electron transfer occurs and reactions result depending upon electrochemical and physical conditions of the system. Similar electrically charged sections are repelled whereas unlike charged sections are attracted to each other.
With the use of the ION STICK®, an electrostatic field is generated. In effect, the negative charged sites become more negative in electrical charge. This provides a shift in the system electrical equilibrium. The repulsive forces between the similar negatively charged areas is enhanced as is the attraction towards the opposite positively charged areas. Overall, the electrical interaction is intensified within the system. The repulsive action is a natural barrier towards scale and deposit formation.
Existing deposits and scales are subjected to the intensified electrical interaction as well. The enhanced attractive and repelling forces weaken deposits and scales. As the deposit surface changes ever so slightly in shape, the distortion is sufficient to alter the stress factors within the deposit. The normal water flow can dislodge the deposit as new equilibrium patterns result due to the nature of the deposit and/or scale (i.e. porosity, chemical additive binding, etc.) not all deposits and/or scales are affected.
Since the electrostatic effect is not permanent suspended solids should be removed effectively. Failure to exit the suspended solids may result in a hardening of the accumulated material to form deposits elsewhere in the system.
In the quest to meet safety and environmental concerns and reduce the high operating cost of chemical applications, the Ion Stick fulfils these needs.
OPEN RECIRCULATING SYSTEMS (i.e.: Cooling Towers):
· Continuous side stream filtration across a cooling tower using an auxiliary pump.
· A sand filter type system must remove suspended solids as small as 10 microns and greater.
· Filtration system designed to pass total system water volume at least once per hour.
· Filtration system should be designed to backwash effectively a maximum of once every 24 hours or less regardless of back pressure readings. A simple timer can be applied to ensure this procedure.
CLOSED RECIRCULATING SYSTEMS:
· An auxiliary pump on a by-pass will prevent system from being starved for design pressures and flowrates.
· A cartridge type or bag filter will provide flexibility to effectively remove suspended solids at varied micron ratings to meet each individual system need as required.
· The filtration system should be designed to accommodate a flowrate at 10% or less of system flowrate.
TESTING AND MONITORING:
· Indicator light on the power pack informs user if electrostatic equipment is operating or not. Trouble-shooting is to be explained in the installation and operation manual.
· Electrical power supply service to the ION STICK must be dedicated and continuous.
· The water in the system is monitored to protect against excessive suspended solids accumulation. Strainers, low points and low flow areas are purged of solids.
· Control of total dissolved solids via conductivity measurement is required in evaporative systems such as cooling tower or steam generating systems. The desired level is relative to the water quality used for make-up as outlined in the Technical Manual or by water treatment consultant.
· All filtration systems in use must be properly maintained and fully operational.
SYSTEMS:
• Domestic Hot Water
• Open recirculating
• Closed Loop Heating
• Wash Humidification
FAQs:
1. WHY DO I NEED THE ION STICK®?
The efficiency of heat transfer in your facility is directly related to your operating costs. Ever increasing fuel prices are elevating production costs. Optimum heat transfer in aqueous systems (i.e.: cooling towers, boilers, etc.) will minimize a major expense, thereby reducing overhead. This allows you to be more competitive in the marketplace while extending equipment life.
2. WHAT DOES THE ION STICK DO?
It inhibits the formation of scale and deposits within recirculating heat transfer water systems. Existing deposits and scale are removed as well.
3. HOW DOES IT WORK?
The ION STICK® generates an electrostatic field (no current flow) at the probe site. It is the effects of this force that provides the benefits that the product has to offer.
4. WHAT IS AN ELECTROSTATIC FIELD?
It is a Beta force that provides 'free' electrons which increase the Zeta potential (in water) of the constituent that it is in contact with.
4. WHAT EFFECT DOES THE ION STICK HAVE ON CORROSION?
Most sources of water are scale forming and they are not a major threat towards corrosion in a clean environment. Underdeposit and microbiologically induced corrosion are the most damaging and prominent forms. Since the ION STICK® has a cleansing effect, these forms of corrosion are curtailed. Past corrosion coupon testing has verified results to be within engineers' specifications (I.e.: N.A.C.E.) for most systems.
6. DOES THE ION STICK AFFECT BACTERIA?
Due to the cleansing effect, bacteriological fouling is controlled. The rate of control is fixed, therefore, performance is limited to these systems which experience a normal type growth pattern.
7. WHERE DOES THE EXISTING SCALE AND DEPOSITS GO?
Depending on the composition and type of deposition and/or scale, it will slough off for the most part. Some of the material may resolubilize as dissolved solids. Suspended material will collect in low flow areas, close tolerance parts, strainers, etc.
8. HOW DO YOU CONTROL THE RATE OF DEPOSIT AND SCALE REMOVAL?
Although the rate of cleaning is usually over several months, it is possible that the foulant may be removed at a faster rate than desirable. The ION STICK® should be unplugged from the power source as often as necessary to maintain the required balance in the system.
9. WHAT PROCEDURES ARE NECESSARY TO RID OF ACCUMULATED SUSPENDED SOLIDS?
Filtering systems will remove the finer particulates in the recirculating water stream. Heavier particulates will need to be purged or blown down.
10. IS THE ION STICK A SUBSTITUTE FOR A COMPLETE CHEMICAL WATER TREATMENT PROGRAM?
In most recirculating water systems the ION STICK® will act as an alternative to a complete chemical water treatment program. It is apt to have some limitations (particularly where there is a persistent and specific problem) which is apparent.
11. IS MONITORING REQUIRED UPON USING THE ION STICK®?
Any water treatment program requires monitoring. A program using the ION STICK® is no exception.
12. WHAT IS THE MAJOR DIFFERENCE BETWEEN A CHEMICAL AND AN ION STICK® PROGRAM?
With chemical use, the objective is to prevent the formation of precipitates whereas, the ION STICK® does not inhibit precipitation. The chemical laws of solubility are not affected by the ION STICK®.
13. ARE THE ELECTROSTATIC EFFECTS PERMANENT?
No, they are not. This is why the product must be installed in a recirculating section of the system. Suspended material which is permitted to accumulate indefinitely will revert to a hard deposit or scale.
14. HOW CAN YOU TELL IF THE ION STICK IS OPERATING PROPERLY?
The pilot light on the power pack will be on when electricity is engaged. A high voltage meter (D.C.) can be used to test output voltage. This procedure must be carefully conducted by a qualified person.
15. HOW MUCH ELECTRICAL ENERGY DOES THE ION STICK® CONSUME?
The ION STICK® consumes approximately 10 watts of power. This is similar to a dim night light.
16. IS THIS PRODUCT ELECTRICALLY SAFE?
Yes. The ION STICK® is approved by the Canadian Standards Association (CSA) and listed with Underwriter's Laboratories (UL).
17. WHAT WILL HAPPEN TO THE PRODUCT IF I GET AN ELECTRICAL SURGE OR SPIKE?
This product is fuse protected. If a spike occurs, the fuse will blow. Concurrently, the pilot light will be off until the fuse is replaced.
18. HOW WILL IMPROPER GROUNDING AFFECT THE WATER SYSTEM?
Improper grounding of electrical equipment in any piping system can cause electrolysis, whether or not an ION STICK® is employed. The ION STICK® itself is electrically grounded and cannot be a source of stray current.
19. IS THERE ANY DANGER IN OPERATING THE ION STICK® WITHOUT WATER IN THE SYSTEM?
No, but the unit may as well be unplugged since water is not being treated. There is less wear on the transformer life.
20. SHOULD THE ION STICK® BE OPERATIONAL ONLY WHEN THE WATER SYSTEM IS CIRCULATING?
Although the effects of the electrostatic field will be optimum during circulation, the results will be better with the product on all the time rather than partial use.
21. ARE THERE ANY INCOMPATIBILITIES WITH APPLIED WATER TREATMENT CHEMICALS?
To our knowledge, we are not aware of any incompatibility with chemical usage. Unless there is a specific problem area which necessitates specialized attention, it is counterproductive to use a complete chemical program with the ION STICK®.
22. WHAT IS THE EXPECTED LIFE OF THE ION STICK®?
There are units which are operating after 10 years of service. The anticipated life is within 10 to 15 years.
23. WHAT IS THE WARRANTY?
The ION STICK® is warranted against defects in material and workmanship for a period of two years from date of purchase.
24. WHAT LIMITATIONS DOES THE ION STICK® HAVE?
The product is limited based on the system volume, water quality, temperature pressure and system retention. A qualified dealer or distributor should be consulted for recommendations.
25. HOW DO YOU JUSTIFY THE USE OF THE ION STICK®?
Use of ION STICK® encompass the following benefits:
· ENERGY SAVINGS - Due to cleansing action, heat transfer improves.
· CHEMICAL SAVINGS - The ION STICK® will act as a substitute for a complete chemical program. In some cases, it will reduce chemical requirements. There are no containers to dispose of.
· OPERATING AND MAINTENANCE COST SAVINGS - Less man-hours to administer and maintain program (i.e.: in comparison to chemical applications). On stream cleaning without additional costs. Equipment life is enhanced.
· IMPROVED IMAGE - With no adverse safety or environmental impact, administrative costs are minimized (i.e.: workman's compensation and WHMIS regulations) while forming a positive image in the public eye.
ION STICK® Case Studies:
· Chillers - Canada
· Plating - Montreal Canada
· Emulsions - Montreal Canada
· Metal Working Fluid System - Canning Industry
Cooling Towers, Chillers, Condensers
TECHNICAL (SYSTEM) INFORMATION: Within the research facility of a large company in Ontario, the air conditioning operation experiensed some unsuspected waterside problems.
In the spring and fall months when the airconditioning demand was tempermental, river water was pumped once through the chilled water piping system. This system included seven coils which supplied different areas of the building.
When the outside temperature was consistently high enough, and the river water temperature was excessive, the Carrire Delta T centrifugal water loop was closed and the system operated in the conventional manner.
PROBLEMS: The chilled water piping after 17 years with very little or no treatment deposition had reduced the piping diameter in places from 4" to 1". The decreased flow caused the system to become ineffective and heat transfer was minimal.
SOLUTIONS AVAILABLE:
Chemical Cleaning: Cost in excess of $20,000.00
Physical Removal: Rejected due to mess
Replacement: Cost in excess of $100,000.00
ION STICK : $3,400.00 cost + labour which can be carried out by present staff
PROCEDURES: Although dubious, it was decided to try the ION STICK since it was the least costly solution and with time over the Winter season the following procedure was followed:
· The ION STICK was installed in the piping system in the penthouse by the chiller.
· The coils and chiller evaporators were bypassed to make one closed loop circle of the larger piping.
· A 100 gallon tank was installed as part of the bottom of the system in the basement mechanical room with a 21/2 to 3" drain valve and hose to drain attached.
· A 3" hose was set up on the pump strainers in the penthouse to drain.
· The ION STICK's were turned on and the blow down and bleed points run daily from November to March over the Winter season.
· No chemicals at all were added and a section of pipe in the basement mechanical room was monitored periodically.
RESULTS:
Before ION STICK After ION STICK
As of March, 1988 the section of pipe being monitored had been opened up to almost its full diameter with only spotted sections of scale and over 90% of the sludge and scale removed. Replacement of the piping was not necessary. Efficiency and operation improved dramatically.
Plating Rinse Tank Algae Control
CASE STUDY
Company has a large storage tank (3000 gal) for deionized water used in the plating process of electronic parts.
Their problem was the growth of algae in this tank and the necessity to empty and clean the tank with javel about every two weeks and in summer sometimes every week. They cannot use any chemicals in this water to control the growth of algae (i.e. algaecides)
An ION STICK was installed in the deionized water storage tank and has effectively controlled the growth of algae (same type of installation as for starch storage)
Company has many small (100-200 gal) rinse tanks in the plating shop with the same algae problem. Rinse water continuously overflows at a small flow.
An ION STICK (IS-750) was installed in an expansion chamber that was installed on the incoming fresh water line to control the algae in the various rinse tanks fed from this water line (1" pipe).
Bacteria Control in Water/Oil Emulsions Used For Machining
CASE STUDY
This company has a large central system of 50,000 gal. Wire drawing emulsion for copper wire drawing. Emulsion consists of approximately 95% water and the rest an emulsifiable lubricant containing fats, emulsifiers, etc. The emulsion is circulated at 1500 gpm from holding tank through an indexed paper filter to remove the metal fines before returning to the machines. The company was using large amounts of biocide to control the growth of bacteria in the emulsion.
The company installed an ION STICK (IS-750) on the return line from the filter in May 1992 to help control the growth of bacteria.Their usage of biocide has been reduced to occasional use to control upsets in the system. Because of the success, they installed a second ION STICK (IS-750) in June 1996 on another central system that was installed at this time.
Metal Working Fluid System
COMPANY: Can Manufacturing Operation in Montreal, Quebec
APPLICATION: Plating Rinse Tank Algae Control
DETAILS: Up to date, can forming equipment mechanically punches the product into the desired shape. This process uses an organic based fluid for appropriate lubricating action. The metal working fluid is recirculated as a closed loop system. As a result of contamination and exposure to plant surroundings, this fluid is subject to microbiological activity. Not only does the fluid deteriorate, it does become a health hazard to plant personnel.
Typical measures to control the microbiological growth had been to utilize biocides. Although this approach works, the expense is significant. The fluid becomes a hazard if skin contact is made as well because of the very high dosages of biocides that are used.
SOLUTION: With the use of the ION STICK, the triazine based biocide dosage was reduced from 1500 ppm. to 600 ppm. Very good performance was realized despite the biocide reduction. Payback of the ION STICK was within 6 months after installation.
Best performance using the ION STICK requires continuous recirculation in an area of laminar flow. Start with a sterilized system and decrease the biocide dosage gradually over several weeks.
