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Utilities & Water Treatment Mini Case Histories

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Case Study #1 - Equipping for safety

The Challenge: Concerned about the risk to safety and the high maintenance costs of its bleach and bromine treatment program, a paper mill turned to Buckman and the Oxamine influent program.
Why Oxamine®The Oxamine program includes proprietary feed equipment with industry-leading safety features:
  • Leak detection
  • A built-in separator to keep active ingredients apart in the case of a line break or other issue
  • Automatic flushing in case power is lost
  • Regular inspection by Buckman personnel to ensure efficient, safe operation
This equipment is owned and maintained by Buckman.
The Results: After the Oxamine program was initiated, the potential for human to chemical contact at the mill was greatly reduced. Equipment costs and the costs to maintain them were eliminated. The mill also saw better per formance. Spiking chlorine residuals were stabilized. And the ATP average was reduced from 430 to 125 RLU.
Return on Investment:
  • 10% reduction in chemical costs for a savings of $70 per day
  • Elimination of equipment maintenance costs
  • Savings of time—no more constant measuring and adjusting
  • Better microbiological control
Return on Environment:
  • Increased worker safety
  • 75% reduction in bleach chemical feed daily for improved effluent and reduced demineralizer loading in the boiler feedwater system

Case Study #2 - Putting less into the environment and more on the bottom line

The Challenge: A mill with a two-step influent treatment process involving a UV generation system and chlorine gas wanted to replace the gas step with a safer, less costly, and more environmentally friendly process.
Why Oxamine: Oxamine is safer than chlorine gas and doesn’t contain trihalomethanes (THMs), byproducts of chlorine gas, bromine or bleach treatments, which means no regulator y reporting. Oxamine is environmentally friendly, reducing the potential toxicity of the mill’s effluent and producing far less potential carcinogens than other treatments. It’s much easier to handle too. Perhaps best of all, it provides superior microbiological control at a lower cost.
The Results: Once Buckman installed the new Oxamine system, the safety risks associated with the transportation and handling of chlorine gas were eliminated, and the cost of the second step was reduced by 27%.
Return on Investment:
  • Cost of the chlorine gas program: $82,507
  • Cost of Oxamine in its place: $59,815
  • Return on investment: $22,692
Return on Environment:
  • Reduction in health risks for carriers, distributors, contractors, mill employees and the community
  • Elimination of AOX (Adsorbable Organic Halides) from the water plant, reducing toxins released into the environment
  • Reduced risk of fires, explosions, and accidental releases

Case Study #3 - Eliminating organic demand

The Challenge: A paperboard mill was treating 21 million gallons of river water a day with a chlorine dioxide influent treatment system and satellite bleach feeding stations. The mill experienced chlorine residuals and free halogen residuals that were either so low they promoted microbiological growth in the paper machines or so high they increased the corrosion rate. In addition, the oxidation of coagulant and flocculants resulted in poor clarification.
Why Oxamine: Unlike conventional treatments, Oxamine is unaffected by organic demand so it works better and longer, allowing the mill to reduce chemical use, reduce corrosion, achieve better microbiological control and save money.
The Results: After the Oxamine program was applied, ATP levels were kept below 150 RLU. Total chlorine residuals in the mill storage tank and color plant were reduced to an average of 0.3 ppm. Microbiological growth was halted.
Return on Investment:
Oxamine reduced total program costs by:
  • Program savings of $50,000 /yr vs. chlorine dioxide
  • Reduced pH variability to boiler feedwater eliminated need to pH adjust the water
  • Eliminating satellite chlorine feed stations
  • Reducing corrosion potential
  • Eliminating oxidation of coagulant and polymers
  • Reducing microbiological activity and bacteria load at the paper machines
  • Improving dosage control and reducing biocide demand

Case Study #4 - Boosting paper machine performance

The Challenge: A mill with an influent water plant processing 4000 to 7200 gallons per minute of river water was experiencing filamentous bacteria growth on its machines. They asked Buckman for help.
Why Oxamine: Wide variations in raw water organic demand from rivers can wreak havoc on microbicide effectiveness and result in increased turbidity. Oxamine applied to the clarifier can bring turbidity in spec, greatly reduce bacteria-promoting ATP levels, prevent alum carryover and, ultimately, reduce filamentous bacteria on the machines.
The Results: Once Oxamine was applied, ATP counts in the clarified water decreased from 300 RLU to 20 RLU. Process water ATP decreased from 225 to 20 RLU. Turbidity was reduced from 7.8 to 1.3 NTU. And the polishing bed settled better than ever, even in high flow conditions.
Return on Investment:
  • $150,000/yr decrease in paper machine biocide usage
  • $150,000/yr decrease in wet strength resin usage
  • $25,000 /yr decrease in polymer usage at the clarifier
  • Cleaner paper machines, resulting in reduced breaks, enhanced quality and increased production
  • Significant reduction in bleach consumption

Case Study #5 - Preventing chemical interference

The Challenge: An integrated coated paper mill experienced high variability in the quality of its source water. As a result, it’s sodium hypochlorite system was subject to high nonbiological organic demand. That, in turn, required raising the dosages to levels that degraded the performance of press felts and system additives.
Why Oxamine: Oxamine won’t undermine the efficacy of other chemicals such as raw water clarification chemistries. And it’s easy on equipment that can corrode or degrade due to high sodium hypochlorite use.
The Results: With Oxamine, management of the influent treatment was much simpler and less time consuming. The mill no longer had to worry about corrosion, premature press felt failure or the effectiveness of system additives. ATP counts were less than 400 RLU and plate counts were less than 50 CFU/ml.
Return on Investment:
  • No brightness reversion from the pulp mill, which eliminated the need for titanium dioxide in the wet end, resulting in a savings of $20,000/month
  • Improvement in paper machine runnability, with fewer breaks
  • Reduction of potential for corrosion, downtime and costly equipment repair
  • Reduction in time spent monitoring and adjusting dosage
  • Eliminated risk of press felts damage from high chlorine residual
  • Improvement of system additive efficacy
  • Better safety and reduced risk

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