fumaGen LS®

fumaGen LS®
Effective and Reliable Disinfection for Food & Beverage Processes
2 | Effective and reliable non chemical disinfectant / fumaGen® LSseries
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The demand for improved and excellent water quality has been a fundamental need since time immemorial and is also a
prediction for optimal results in various aspects of world and life. The technological and legal requirements for an optimal
water treatment are constantly rising.
The new innovative fumaGen® LS – A “green technology”
In most of the industrial processes water is an essential raw material. Particular in the Food & Beverage Industry most of
the production activities require good water quality. As the microbiological contamination of the process water is a critical
issue a reliable and optimal control of all biological parameter is indispensable.
All of the classical ECA devices offered in the market are using a brine solution (NaCl) in order to produce a disin­fectant
­material via cathodic and anodic reactions. In such electrolysis only 20 % max. of the brine solution are going to be
­converted into a disinfectant (HOCl).
With the newly developed “fumaGen®LS HC” generator
series BWT and FumaTech offer a new innovative system
for the on-site production of a highly effective disinfectant,
which meets all the requested criteria due to its unique and
stand alone design. The device is generating Hypochlorous Acid, which is well known as a real strong disinfection
agent.
The significant downside and threats whilst operating such devices are obviously high corrosion risks, because of the
­carryover of chlorides. This effect is relevant to all commercial offered devices. Due to the material used, particular in the
Food & Beverage Industry such a disinfectant was not applicable for the industry because of the risks.
Electrochemical Activation with FumaGen®:
The fumaGen® generator is an advanced electrolysis process whilst using water only for the products. The necessary
and needed salt is provided from a third chamber which
is hydraulic separated from product compartments. With
the process there are two different water based products
generated:
With the unique and stand alone 3 chamber system and
the patented cell design of the fumaGen® LS device the
amount of chloride impurities in the disinfectant solution is
the lowest possible and close to the theoretical limits. Any
usage of the fumaGen® Anolyte will not have an effect to
the corrosion potential in the system.
Hypochlorous Acid (HOCl) > Anolyte
Diluted Caustic Soda (NaOH)
> Catholyte
Pure
This result is remarkable as with such a system almost any
user is able to produce a highly effective and reliable disinfectant (pure HOCl) on-site. Based on this any usage of the
fumaGen® Anolyte will not increase the corrosion potential
of the SIP/CIP cycle medium.
The standard warranty specifications of the Food & Beverage manufactures with respect to the acceptable chloride
levels to use with their equipment will not be exceeded
whilst using the fumaGen disinfectant at a concentration
of 40 mg/l FAC.
NaOH
0,05 – 5,00 %
H2
The difference to the conventional electrolysis system is the
unique and patented chlorinestable Anion exchange Membrane from FumaTech. The membrane results in a solution with the lowest amount possible of chloride impurities
in the disinfection solution.
In addition to the described membrane the special and
­innovative design of the anode guarantees the excellent
and stand alone conversion rate of 1:1 (salt: chlorides).
Saturated
Brine
HOCl
minimum salt
impurities
anolyte
catholyte
HOCl
+
H2
O2
Na+
OH‐
Cl‐
Saturated
Brine
H 2O
anode reaction:
cathode reaction:
2Cl‐ + H2O
+
‐
CATHODE
The electrochemical activation technology (ECA) is the generation of activated solutions (Anolyte & Catolyte) whilst
using a diluted salt solution (sodium chloride NaCl). This
electrolysis process is an applicable alternative in the area
of disinfection to the dosage of conventional chemicals
in case the technology is able to produce a disinfectant
­without critical by-products.
Based on its well known core competence in electrochemical technologies FumaTech in cooperation with the BWT
R&D department has developed an advanced electrolysis
process for producing an effective and reliable disinfectant
on demand.
ANODE
In many operation the water quality is currently controlled whilst using halogen-based chemical disinfectants and
cleaning agents. Those chemicals used (Chlorine and its
chemical compounds) are acting as effective disinfectants
in order to ensure the microbiological quality of the water.
There are some remarkable disadvantages with operating
chemicals such as the handling (e.g Chlorine Gas) and the
environmental impact.
‐
2Na + 2 H2O + 2e
H2O
→
HOCl + H+ + 2e‐
→
2 NaOH + H2
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Effective Disinfection
The “new” innovative ECA technology results in high
­performing components
Feed solution
softened water *
Active specie
hypochlorous acid (HOCl)
Mechanism
diffusion into the cell osmotic effects &
degradation
Disinfectant
100 – 500 ppm FAC
Purities
sodium chloride (low quantities)
As the fumaGen generator produces pure HOCl of the
requested high quality, the disinfection is ensured whilst
there are no safety issues to be considered. The anolyte is
non-toxic against oral toxicity, skin sensitization, eye or
skin irritation or bacterial assay.
In the industry it is essential to work with a disinfectant
which meets the criteria at all time to ensure an effective
microbiological control of all systems. Extensive tests are
performed out of operating production plant or the F&B
industry showing outstanding results:
FAC vs. chloride concentration of different anolyte solutions
chlorate concentration of different anolyte solutions in relation to permitted value of TVO
(5,4 %m/m related to FAC)
* Due to the unique design and stand-alone FumaTech technology, there will be
no transfer of salt solutions into the anolyte compartment.
concentraion
(mg/l)
fumaGen® is a patented electrolysis technology manufactured by BWT. As various unit capacities are available it is
ensured that the amount of on-site produced disinfectants is equivalent to the individual plant requirements.
200,00
150,00
100,00
50,00
-
anolyte 1
anolyte 2
anolyte 3
2
2
4
5
200
160
300
180
400
200
500
g/h
30
48
72
96
Salt content (Chloride in the Anolyte)
mg/l
150
170
190
210
Chlorate
mg/l
< 3.5
< 3.5
< 3.5
< 3.5
Chlorite
mg/l
< 0.3
< 0.3
< 0.3
< 0.3
> 1000
> 1000
> 1000
> 1000
14
13
12
11
Electricity consumption / kg FAC*
mV
KWh/kg
ph value
5.5
5.5
5.5
5.5
g/h
90
143
215
260
kg/24h
2.2
3.2
5.2
6.2
Salt consumption
NaCl consumption
daily salt consumption
40.000,00
Bacillus subtilis
(Sp./ml)
l/h
150
30.000,00
2,00
-
anolyte 1
anolyte 2
anolyte 3
anolyte 4
TVO
permitted
report VLB october 2009, september 2010,
report SGS october 2010
summery
average concentration FAC
average ORP of 1:10 dilution
killing ratio
stability of anolyte
FAC to chloride
chlorate
anolyte 2
10.000,00
anolyte 1
0 min.
>
>
>
<
180
1000
log4
2
1:1
3,6
ppm
mV
weeks
mg/l
10 min.
stability of oxidation-reduction potential during disinfection
1.000,00
800,00
600,00
400,00
200,00
-
source:
anolyte 3
20.000,00
-
ORP
mg/l
Mass flow (FAC)
ORP
4,00
killing ratio of more than log 4 proven for different anolyte solutions
Disinfection Solution Anolyte
Flow rate (FAC)
6,00
fumaGen 30 LS fumaGen 48 LS fumaGen 72 LS fumaGen 96 LS
Number of cells
Free Chlorine (FAC)*
8,00
anolyte 4
degradation of FAC during disinfection and persistence of FAC for deposit effect
20,00
ORP (mV) after 10 min.
ORP (mV) start
anolyte 1
anolyte 2
anolyte 3
FAC
fumaGen LS series
Chloride (mg/l)
FAC (ppm)
Chlorate (mg/l)
10,00
250,00
15,00
10,00
FAC (ppm) afer 10 min
5,00
-
FAC (ppm) start
anolyte 1
anolyte 2
anolyte 3
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Schematic view of onsite production
It is essential, that every installed device should cover all
safety features to ensure a smooth and user friendly operation. Every fumaGen generator provides – apart from
its outstanding technical performances all ­necessary safety
features.
Work methode ECA production:
Another differential highlight of the fumaGen device is the
catalytic destruction of the produced hydrogen ­(installed
hydrogen sensor in the cabinet). Because of this the
­generator can be installed in closed room and integrated
in almost all existing processes. This is validated with a
­certificate from TÜV South West.
Potable Water supply
min. 3 to max. 6 bar
Anolyte Concentrate 200 ppm FAC
Safety features:
Catalytic hydrogen destruction plus hydrogen sensor in the
cabinet
Catholyte Concentrate 2 wt% NaOH
Dilute 1:20
CIP Tank
10ppm FAC
Buffer Tank
Buffer Tank
Catholyte
Concentrate
Anolyte
Concentrate
Cold Short CIP:
CIP cleaning with electrochemical activated water ECA is
known as “Cold cleaning”:
Replacement of hot water cleaning (85 °C)
Replacement of hot caustic detergent (1.5 wt.%)
Replacement of chlorinated alkaline detergents
Significant Savings
Reduced cleaning time
Decreased energy & water consumption
Decreased chemical usage
The cold CIP procedure could be implemented successfully
for carbonated non-sensitive products (e.g. the syrup tank,
the mixer, the filler and pipe lines)
Cold Short CIP Cleaning Procedures:
Step 1
Rinsing with cold water
Step 2
Cleaning with anolyte 10 – 20 ppm FAC
Total cleaning time appr. 20 minutes
Controlled by RedOx potentialORP > 900 mV
Step 3
Cold water rinse 0.3 – 1.2 ppm
FAC
FAC given by e.g. TVO
Almost no waste water. The entire amount of the
cleaning solution is recirculated.
8 | Effective and reliable non chemical disinfectant / fumaGen® LSseries
Advantages & Benefits
Safety
Because of the replacement of traditional halogen based chemicals no additional equipment required
No health issues with the produced disinfectant
No eye or skin irritation
Microbiological Efficacy
HOCl as a strong disinfectant effectively destroys phenols, which could influence the taste
An on-site produced disinfectant which controls all kind of bacteria as well as viruses
The Anolyte is effective against Legionella
It prevents and removes biofilm
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Our Customer Service Cares for Ongoing Partnership
Even after the handover and the start-up of the fumaGen®
generator BWT remains at your side as a reliable partner.
Our customer service offers various support and maintenance packages with different levels of support. In addition to the technical advantages and therefore commercial
benefits the offered service capabilities of the BWT group
are outstanding and unique. International experienced and
practically orientated staff members are going to ensure
that the installed units are delivering the necessary and
requested results. Amongst the annual maintenance and
service of the units an on-line monitoring of the cells is possible if desired.
During the evaluation of the needed capacity of the generator and engineering task for a successful integration our
staff will work out together with you an individual service
and maintenance plan in order to ensure the success.
As BWT/Fuma-Tech are partnering with the leading CIP
and system integrators in the industry the FuMA-Tech®
Generator will be integrated and installed in almost each
different plant design.
Survey and validation of all current plant data
Project Management
Process Engineering and design
Installation
Start- up and training of the plant staff
Documentation
On-going Support and Service
Return on Investment
Replacement of the traditional used chemicals and reduction of operational cost
As the generator is not producing any critcal by-products (such as chlorate) and the corrosion potential is extremely low
the advantage is having a reliable and strong disinfectant available at any time. This results in significant reduction of
­water and hot water usage.
Energy saving and increased production availability are generating significant higher profitability.
Together with our partners we offer the entire integration
project:
Druck: 140331DK
BWT – The Company
The Best Water Technology Group is Europe’s leading water technology company with 2,800 employees and a vast network of
partner companies, service staff, installers, planners, architects
and hygiene experts. Our R&D teams apply state-of-the-art methods and use the latest processes and materials to create products
that are both economical and green. One of the key objectives is
to reduce the resource and energy consumption levels of our
­pro­ducts, resulting in a reduction in CO2 emissions.
Practically everywhere where water is involved,
BWT’s pioneering products have proved their
worth millions of times over; where domestic water enters a building (‘point of
entry’) and at its tapping point
(‘point of use’), for the treatment
of seawater, drinking water, mineral water, ultrapure water for
pharmaceuticals, water for
swimming pools, heating and
process water, boiler water,
cooling water and water for airconditioning systems. Our numerous innovations enable our
customers to enjoy the highest levels of safety, hygiene and health
in their daily use of water – the precious elixir of life. Among these
are: SEPTRON®, the world’s first Electrodeionisation module (EDI)
with spiral winding, the MDA (manganese oxide activation) method
for effective removal of manganese, AQA total bipolar technology
for chemical-free limescale protection, SANISAL – the world’s first
regeneration salt for softening systems that also disinfects at the
same time, and the revolutionary new Mg2+ technology for better
tasting filtered water, coffee and tea. BWT, with its
unique, high-performance membranes for fuel
cells and batteries, is setting the 21st century
standard for the supply of clean energy.
For further information:
FuMA-Tech Gesellschaft für
funktionelle Membranen und
Anlagentechnologie mbH
Carl-Benz-Straße 4
D-74321 Bietigheim-Bissingen
Tel.: +49/7142/3737-900
Fax: +49/7142/3737-999
E-Mail: office@fumatech.de
www.fumatech.de
BWT Aktiengesellschaft
Walter-Simmer-Straße 4
A-5310 Mondsee
Tel.: +43/6232/5011-0
Fax: +43/6232/4058
E-Mail: office@bwt-group.com
www.bwt-group.com
BWT – For You and Planet Blue signifies our mission to take ecological,
economic and social responsibility,
and to provide our customers with
the best products, systems, technologies and services in all areas of
water treatment, while making a
valuable contribution to the preservation of our blue planet’s global
resources.