Pharma Process Water – Why ozone is can be the better choice

Blogging for ozone awareness   . www.otsil.net/blog/

Ozone or Chlorine  . Mechanism of action , chemistry of reactions , eco friendly  all points towards Ozone . Cost is one aspect that can be a deterrent. But when you look at the advantages you get over chlorine ( and UV) , the choice is on Ozone .  All process water treatment schemes must include ozone.  Effectiveness against gram negative Bacteria, removal of Endotoxin liberated during bacterial destruction , removal of bio films , viral deactivation ,  color and odour removal, removal of heavy metals and and physical properties such as flocculation and many more properties .

But take care . ozone is not a solution for all water treatment issues . Ozone does not perform magic and need careful consideration of design aspects and importantly safety aspects

Contact OTSIL for solutions 9840149184 ozone vs chlorine in Pharma – November 2016

Is Ozone Technology Really Expensive

Is Ozone technology really expensive ?  Not really

You look at ozone only when you exhaust all other avenues . You look at ozone as an insurance for a consistent and reliable result to confirm Statutory requirements. Ozone will allow you to remain in Business

Ozone applications can be made cost effective ( I mean value for money)  if  correct solutions are provided. Recently we were asked to evaluate an ozone proposal for reduction of COD in a chemical industry. We found that with modification of pH of the effluent , it really brings down the ozone requirement to half. The client was surprised . When you are not well , you do not go to quacks . If you go it is at your own risk. Same analogy you can relate to ozone applications . You go to persons who can provide you with solutions and give you a reliable system to compliment the solution. Not to persons who offer solutions based on internet reference .

The next aspect is health implications . Why do you see that there is so much of discussions in the reduction of THMs , removal of pesticides and micro pollutants from water- world over  ?   We see only the costs of the ozone system, but never look at the other side – Health implications and costs associated with it . We are not aware how much of health costs we can save just by providing good quality drinking water . We save costs , and make our nation healthy .  Ozone is the savior here

We introduce lots of contaminants when we conduct our business . We must have social obligations and do our bit . We must make the world a better place for next generations

Contact for reliable ozone solutions  9840149184

 

Learning From The Best

logging for Ozone Awareness

Reliability , Performance and Service- learning from the Best This was an event 10 years ago. India’s largest Ozone generator by Wedeco , arrival of a 230 kg per hour containerized system. Technological marvel . We have been involved right from this time ,till the time it was commissioned and handed over to the client . As a company we learnt so much from this installation . We knew exactly what a large ozone system has to be like, in terms of engineering , construction & safety aspects , how to , trouble shoot and how to provide quality service . Experience of a life time .We adopt similar engineering standards for all our ozone equipment. No wonder our systems are preferred wherever reliability , performance and service are prime most importance to clients   CONTACT US FOR LARGE OZONE SYSTEMS 9840149184

Single Large Ozone System V Modular Systems – Spares Requirement

There are only few ozone companies around the world who can manufacture single large ozone systems upto 50 kg ozone per hour. Just 4-5 of them . Companies who do not have technology to manufacture single large systems propose small modular system in multiple of 2 kgs .ozone manufacturers in India have limitations in their capabilities of manufacturing single large ozone systems. Claiming to manufacture one is different from producing one that has been time tested , proven reliable  is different

Water treatment consultants , EPC contractors  in India , and End users must realize that such modular proposals are out dated now. .They should stop encouraging such designs . There are ozone systems that run 24 x7 x 365 x many years without a single shut down . There are numerous installations around the world without spare ozone systems

For example only in india this happens ; requirement of say  18 kg machine is often proposed as 9×2 kg units, and often taking the stance of providing spare capacity to increase reliability in the application! Such design would in fact decrease the reliability since it would be very difficult to maintain 9
units at a time, increasing the requirement of spare parts, machine down time,
and frequency of preventive maintenance apart from increased CAPEX.

If you have the choice to go for a single large unit, why go for modular or multiple units. Today companies like ITC Bhardrachalam are operating the world’s single largest ozone system of 200 kg per hour for their process, without any spare ozone system, but with a foolproof, periodic preventive maintenance schedule . Lets learn from them. Read on

march 2014 Column OZONE – SPARE DESIGN

Sewage water reuse – Using Ozone correctly

Column OZONE -ozone dose in STP

How many times have we come cross complaints from clients that they  never get the required quality of water with ozone .  Most of the time , we have noted that ozone dose is compromised to keep the cost of system low to beat competitors . Clients fall for this trap by unscrupulous sellers . Spending a little more time in evaluating the process, equipment and the supplier would probably solve the clients headache

We can get the horse up to the pond , but drinking has to be done by the horse itself .  Ozone is not to be blamed for ones own mistake.

Call us for reliability of equipment and process 9840149184

Why Process Failures With Ozone ? A Close Look At It

With ozone , we should not have any process failures. Such is its prowess. But we keep hearing that many issues crop up with ozone applications including miserable process failures . This can be avoided if with a little consideration of  design parameters . Normally does not happen any where in Europe ,US and in other developed countries . Economy overtakes everything else in India Prospective  users , consultants , water treatment experts can stop it  and make competition more healthy .  Read on .AUGUST 2018 Process Failures

Making Ozone use safer in India . We value life

Ozone & Plastics

Ozone Applications are increasing in India. Numerous instances have been noticed that applications are decided without due considerations to the materials of construction of pipes , containers etc  .We provide below some information on the use of different type of plastics and Ozone’s effect on them.

Two group of plastics are discussed here ; Plastics  termed  as Thermoplastic materials and other group of plastics are the Thermosetting Plastics.  They find numerous use in Industries  and each type of plastics are used  for different purposes dependent on the physical & chemical properties of each.

The effects of ozone on each of these materials will depend totally on the configuration of  the polymers that  make up the plastics. Crossed linked plastics such as poly polypropylene, poly- ethylene , poly- vinyl chloride and silicone or fluorine combined plastics are sufficiently impervious to ozone to enable their use in direct contact.

Most of the packaged  water plants all over the world use plastics in some form or the other and the knowledge of each of these will help understand the likely effects with the use of ozone.

From a careful  study of  different kind of plastics  , some forms of polymers are readily attacked by ozone and are not recommended , there are other forms that are quite resistant and  take a longer time for effects of ozone. and others attacked immediately and not recommended.

Since most of the packaged water manufacturers prefer residual ozone, and they invariably use PET Bottles, Poly Carbonate Jars,   PP Filters, that are all polymer materials , the question of whether they are safe with ozone is frequently asked. The effects of ozone in the long run could unzip some of these polymers  to form by- products , Even though  they are all dose, concentration  and time related , we should never take this risk

For example poly-carbonate has been shown to be very resistant to UV and like water is  classified as an universal solvent. Ozone can also be classified as an universal reactant-  the only question is how much does it react. Through practical experience, it is very insignificant.  For that matter ,  Ozone is also supposed to be Corrosive to Stainless Steel .But the corrosion is concentration and time related and therefore Stainless steel is regarded safe  with the use of Ozone. In fact many ordinary plastics that give out smell (the popular PVC tank) can also be held suspicious,  more than ozone which imparts no flavor to the water. The action of ozone on plastics also depends on whether Ozone is used as a gas  or solution..  For example Nylon appears to break down faster when in contact with  ozone-air mixture than ozone solution

Some care that could be observed while using ozone would include:

  • Do not use ozone before cartridge filtration in packaged water process
  • Do not store fresh ozonated water in PVC containers ( use ploy carbonate instead)
  • Use CPVC /SS pipes preferably if water is being used for drinking.
  • Store freshly ozonated drinking water in SS containers instead
  • For prospective ozone users check for ozone reactions on MOC of containers/pipes before you use them.

Many of the  reported ozone reactions on materials are time concentration related and many of the toxic effects have never been proven .

ozone users to note . why ozone measurement is a must

Ozone is a gas . So is Nitrogen, oxygen , Carbon dioxide , helium, Argon .But what is the difference between ozone and the other gases ?    Other gases are prepared by air separation and they all can be stored in cylinders as they are very stable gases. When you can store the gases , they can be measured , especially because they are in the pure form  .  So using them is easier and measurable .

What about ozone ?  Ozone is the only gas that is synthesized . Ozone gas does not occur naturally unlike other gases . Ozone gas is very unstable , cannot be stored and hence need to be produced and utilized in situ . Also Unlike other gases , ozone gas is never pure and does not exist alone. It carries with it oxygen gas  /other gases . Hence you can not measure ozone separately like other gases . Hence you measure concentration only and use this is determine the ozone weight.

Here is the catch. since measurement of concentration of ozone is possible only with expensive analyzers , the industry is faced with a problem that is the root cause of process failures . Users of large ozone systems do not want to pay a little more for the analyzer and end up loosing the whole . Unscrupulous manufacturers thrive    .

Recently there was an issue faced by a CEPT  of a tannery effluent  , which had the most experienced member in leather technology , failing to observe these precautions. They purchased and installed 15 Kg ozone system from a Mumbai ozone manufacturer ( that too 15 numbers , 1 Kg system) and found out that each of the 1 Kg system is producing just 200 grams . This is a government funded project .  A little bit of awareness could have saved crores of investment . The loss was only  to the end user organization ( tax payers money)   and they nearly concluded another large order to the same supplier until awareness was forced onto them .

Lesson to be learnt : Don’t adopt modular systems. If you want 15 Kg , go for a 15 kg system. Always ensure you buy an ozone analyzer along with the ozone system and demand process guarantees . Buy ozone only from companies who are technology based and who have history of good world wide references .  Get ozone specialists evaluate specifications

A Large ozone Generator with an Ozone Analyzer ( yellow instrument)

If you still consider economy as the only criteria , than no one is to be blamed except you .

Blogging for ozone awareness – Contact OTSIL for consultations,  DPR for ozone projects ,  Technical evaluations etc.   It could save you lots of money   9840149184

Making Ozone Use safer In India – We value life

Designing a Safe vent ozone distructor

Ozone distructors have compromised design if they

1) are not designed for the flow of water flow and capacity of the contact tank

2) If catalysts are used and they are not sized appropriately. They need sufficient surface area , sufficient particle size and sufficient air velocity to work efficiently. A manufacturer of these catalyst will tell you all about this

3) they do not incorporate a moisture separator if required by design of contact tank

4) They do not take care of temperature control

Vent ozone distructors for SS tanks: These are for smaller applications where the capacity of the ozone contact tanks vary from 3 KL to 30 KL total capacity. It is normal to incorporate in the design of these contact tanks off gas vent that facilitates tank breathing during filling and emptying. The size of these vents is in accordance to the capacity of the contact tank.   the contact tanks vents have to be correctly designed , else there could be an implosion of the contact tank .

Vent ozone distructors are of 2 types .The thermal ozone distructors utilize heat to destroy ozone.  The temperature that has to be reached for 100% ozone destruction within a few seconds would be as high as above 250-350 Deg cel . This is very challenging as the surface of the distructor gets extremely hot and effective control of the temperature rise assumes importance. The power requirement will be sometimes more than the power required for the ozone production.  Thermal type vent distructors are not very common for small applications and are very difficult to source. Few reputed companies manufacture larger thermal type but they are very expensive and high on operation costs

The catalytic ozone distructors are most common and very reliable if designed well

,

Note the Ozone distructor mounted on a skid on the left side of the picture

They are easy to install, operate and maintain. operate and maintain. They contain specialized catalyst that have proven record of destroying ozone . These catalyst lasts a long time  ( 3-4 years) if the ozone distructors  are designed well.

Catalysts used in vent ozone distructors have to be used carefully. They are poisonous and so the design and the installation of the vent ozone distructor should prevent this catalyst of falling into the tank when they crumble. Moisture from the ozone tank can clog these catalysts, and prevent tank breathing, causing implosion of ozone contact tanks. The ozone distructor design must prevent crumbling and clogging of the catalyst, enable free tank breathing.

These are small steps we at OTSIL take to make ozone use safer in India . Contact us for well designed ozone distructors . Be safe .