Apparatus and process for water conditioning

Abstract

Conditioning processes and equipment for removing hardness from water circulated in a system. A sidestream is routed to a reactor and back. A buffer is added to the circulated water, in some embodiments in a sidestream exiting the reaction chamber, forming soluble metal complexes with metal ions of the type that cause scaling. A conditioner is added to the sidestream water which breaks the soluble metal ion-buffer complexes and precipitates and accumulates the released metal ion as a solid for accumulation and disposal. In some embodiments a polymer is added, a corrosion inhibitor blend is added and/or pre-mixed with the buffer, and a chlorine generator removes sodium chloride from the buffered sidestream, and makes chlorine gas, hydrogen gas, and sodium hydroxide for use in the process or for disposal.

1 . A process for conditioning water, the water being circulated in a system, comprising:
 adding at least one buffer to the water, the at least one buffer being capable of forming soluble complexes with metal ions of the type that cause scaling in the system, the formed soluble metal complexes being strong enough to reduce scale build up in the circulated system;   establishing a circulated water sidestream from the system to a reactor and back to the circulated system;   adding at least one conditioner in the sidestream, the at least one conditioner being capable of:
 breaking the soluble metal ion-buffer complexes the soluble metal complexes being weak enough to release the metal ions when contacted with the at least one conditioner in the sidestream; and 
 softening the water in the sidestream by precipitating and accumulating the released metal ion as a solid, the reactor creating a location for contact between the conditioner-treated sidestream water and a portion of the accumulated precipitated solids; and 
   removing a portion of the accumulated solids from the sidestream water before the sidestream water is returned to the circulation system.   
     
     
         2 . The process of  claim 1 , wherein adding at least one buffer further comprises adding the at least one buffer in the sidestream after the reactor. 
     
     
         3 . The process of  claim 1 , wherein adding at least one buffer further comprises adding the at least one buffer to the circulated water prior to circulating the water in the sidestream. 
     
     
         4 . The process of  claim 1 , wherein adding at least one conditioner in a sidestream further comprises adding the at least one conditioner to the sidestream prior to the reactor. 
     
     
         5 . The process of  claim 1 , wherein adding at least one conditioner in a sidestream further comprises adding the at least one conditioner to the sidestream in the reactor. 
     
     
         6 . The process of  claim 1 , wherein removing a portion of the accumulated solids further comprises removing the portion of the accumulated solids from the reactor. 
     
     
         7 . The process  claim 1 , wherein removing a portion of the accumulated solids further comprises removing the portion of the accumulated solids from sidestream water after the reactor. 
     
     
         8 . The process of  claim 1 , wherein the buffer is an organic acid. 
     
     
         9 . The process of  claim 1 , wherein the conditioner is caustic. 
     
     
         10 . The process of  claim 1 , wherein the circulated water contains sodium chloride, the process further comprising:
 separating at least some of the sodium chloride into chlorine gas, sodium hydroxide, and hydrogen gas;   disposing of the separated chlorine gas;   disposing of the separated sodium hydroxide; and   disposing of the separated hydrogen gas.   
     
     
         11 . The process of  claim 10 , wherein separating at least some of the sodium chloride into chlorine gas and sodium hydroxide further comprises separating at least some of the sodium chloride into chlorine gas and sodium hydroxide at a point after the at least one buffer is added to the water and before the sidestream water returns to the circulation system 
     
     
         12 . The process of  claim 10 , wherein disposing of the separated chlorine gas further comprises routing at least some of the separated chlorine gas into the circulated water. 
     
     
         13 . The process of  claim 10 , wherein disposing of the separated sodium hydroxide further comprises routing at least some of the separated sodium hydroxide for use as at least some of the at least one conditioner. 
     
     
         14 . The process of  claim 10 , wherein disposing of the separated chlorine gas further comprises disposing of at least some of the separated chlorine gas as waste. 
     
     
         15 . The process of  claim 10 , wherein disposing of the separated sodium hydroxide further comprises disposing of at least some of the separated sodium hydroxide as waste. 
     
     
         16 . The process of  claim 10 , wherein disposing of the separated hydrogen gas and the separated chlorine gas further comprises combining the separated hydrogen gas and the separated chlorine gas to form hydrochloric acid. 
     
     
         17 . The process of  claim 10 , wherein disposing of the separated sodium hydroxide and the separated chlorine gas further comprises combining the separated sodium hydroxide and the separated chlorine gas to form bleach. 
     
     
         18 . The process of  claim 10 , wherein disposing of the separated hydrogen gas further comprises disposing of at least some of the separated hydrogen gas as fuel for burning. 
     
     
         19 . The process of  claim 10 , wherein disposing of the separated hydrogen gas further comprises disposing of at least some of the separated hydrogen gas as energy for a fuel cell. 
     
     
         20 . The process of  claim 1 , further comprising periodically adding a polymer to the sidestream water. 
     
     
         21 . The process of  claim 20 , wherein the amount of polymer added is sufficient to substantially clarify sidestream water prior to the sidestream water being circulated back to the system circulation. 
     
     
         22 . The process of  claim 20 , wherein the amount of polymer added results in a polymer concentration in the range of 0.4-0.75 ppm with respect to the accumulated solids removed from the sidestream water. 
     
     
         23 . The process of  claim 20 , wherein the polymer is pre-mixed with a polymer reaction accelerator additive. 
     
     
         24 . The process of  claim 23 , wherein the additive is selected from the group consisting of aluminum sulfate, aluminum chloride, ferric sulfate, and ferric chloride. 
     
     
         25 . The process of  claim 1 , further comprising adding a corrosion inhibitor blend to the water. 
     
     
         26 . The process of  claim 25 , wherein the corrosion inhibitor blend is added to the sidestream water. 
     
     
         27 . The process of  claim 25 , wherein the corrosion inhibitor blend is added to the circulated water prior to circulating the water in the sidestream. 
     
     
         28 . The process of  claim 25 , wherein the corrosion inhibitor blend comprises approximately 30 percent orthophosphate and 70 percent polyphosphate in a 50 percent water solution. 
     
     
         29 . The process of  claim 25 , wherein adding a corrosion inhibitor blend to the water further comprises adding the corrosion inhibitor blend to the at least one buffer before the at least one buffer is added. 
     
     
         30 . The process of  claim 29 , wherein the corrosion inhibitor blend comprises approximately 30 percent orthophosphate and 70 percent polyphosphate in a 50 percent water solution, and the ratio of corrosion inhibitor blend to the at least one buffer is approximately 1 liter to 19-39 liters. 
     
     
         31 . The process of  claim 1 , wherein:
 the reactor further comprises an upper portion, a lower portion, and an inlet, the inlet receiving the sidestream water, the inlet being configured to route the sidestream water through the reactor upper portion and discharge the sidestream water in the reactor lower portion; and   adding at least one conditioner in the sidestream further comprises adding the at least one conditioner to the reactor lower portion.   
     
     
         32 . The process of  claim 31 , wherein adding the at least one conditioner to the reactor lower portion further comprises routing the at least one conditioner through a conduit extending through at least a portion of the inlet. 
     
     
         33 . The process of  claim 32 , further comprising adding a polymer to the sidestream water in the reactor inlet, the polymer being routed through the conduit. 
     
     
         34 . The process of  claim 31 , further comprising the step of causing a swirling of the sidestream water as the sidestream water is being routed through the reactor upper portion. 
     
     
         35 . The process of  claim 31 , wherein the reactor comprises an upper outlet for discharging the sidestream water back to the system, the process further comprising monitoring the pH of the water returning to the system circulation using a pH sensor, the step of adding a buffer to the sidestream water further comprising the step of adding the buffer to the sidestream water at a point between the reactor and the pH sensor. 
     
     
         36 . A conditioning system for conditioning water, the water being circulated in another system, comprising:
 means for adding at least one buffer to the water, the at least one buffer being capable of forming soluble complexes with metal ions of the type that cause scaling in the system, the formed soluble metal complexes being strong enough to reduce scale build up in the circulated system;   means for establishing a water sidestream from the circulated system to a reactor and back to the circulated system;   means for adding at least one conditioner in the sidestream, the at least one conditioner being capable of:
 breaking the soluble metal ion-buffer complexes the soluble metal complexes being weak enough to release the metal ions when contacted with the at least one conditioner in the sidestream; and 
 softening the water in the sidestream by precipitating and accumulating the released metal ion as a solid, the reactor creating a location for contact between the conditioner-treated sidestream water and a portion of the accumulated precipitated solids; and 
   means for removing a portion of the accumulated solids from the sidestream water before the sidestream water is returned to the circulation system.   
     
     
         37 . The system of  claim 36 , wherein the circulated water contains sodium chloride, the process further comprising:
 means for separating at least some of the sodium chloride into chlorine gas, sodium hydroxide, and hydrogen gas;   means for disposing of the separated chlorine gas;   means for disposing of the separated sodium hydroxide; and   means for disposing of the separated hydrogen gas.   
     
     
         38 . The conditioning system of  claim 37 , wherein the at least some of the sodium chloride is separated into chlorine gas and sodium hydroxide at a point after the at least one buffer is added to the water and before the sidestream water returns to the circulation system 
     
     
         39 . The conditioning system of  claim 37 , wherein the means for disposing of the separated chlorine gas further comprises means for routing at least some of the separated chlorine gas into the circulated water. 
     
     
         40 . The conditioning system of  claim 37 , wherein the means for disposing of the separated sodium hydroxide further comprises means for routing at least some of the separated sodium hydroxide for use as at least some of the at least one conditioner. 
     
     
         41 . The conditioning system  claim 37 , wherein the means for disposing of the separated chlorine gas further comprises means for disposing of at least some of the separated chlorine gas as waste. 
     
     
         42 . The conditioning system  claim 37 , wherein the means for disposing of the separated sodium hydroxide further comprises means for disposing of at least some of the separated sodium hydroxide as waste. 
     
     
         43 . The conditioning system  claim 37 , wherein the means for disposing of the separated hydrogen gas and the separated chlorine gas further comprises means for combining the separated hydrogen gas and the separated chlorine gas to form hydrochloric acid. 
     
     
         44 . The conditioning system  claim 37 , wherein the means for disposing of the separated sodium hydroxide and the separated chlorine gas further comprises means for combining the separated sodium hydroxide and the separated chlorine gas to form bleach. 
     
     
         45 . The conditioning system  claim 37 , wherein the means for disposing of the separated hydrogen gas further comprises means for disposing of at least some of the separated hydrogen gas as fuel for burning. 
     
     
         46 . The conditioning system  claim 37 , wherein the means for disposing of the separated hydrogen gas further comprises means for disposing of at least some of the separated hydrogen gas as energy for a fuel cell. 
     
     
         47 . The conditioner system of  claim 36 , further comprising means for periodically adding a polymer to the sidestream water. 
     
     
         48 . The conditioning system of  claim 47 , wherein the amount of polymer added is sufficient to substantially clarify sidestream water prior to the sidestream water being circulated back to the system circulation. 
     
     
         49 . The conditioning system of  claim 47 , wherein the amount of polymer added results in a polymer concentration in the range of 0.4-0.75 ppm during with respect to the accumulated solids removed from the reactor. 
     
     
         50 . The conditioning system of  claim 47 , wherein the polymer is pre-mixed with a polymer reaction accelerator additive. 
     
     
         51 . The conditioning system of  50 , wherein the additive is selected from the group consisting of aluminum sulfate, aluminum chloride, ferric sulfate, and ferric chloride. 
     
     
         52 . The conditioning system of  claim 47 , wherein:
 the sidestream water being circulated to the reactor has a total hardness;   the conditioner supply further comprises means for electronically measuring the hardness;   the sidestream water being circulated to the reactor contains polymer-combinable particles, the particles interfering with the electronic hardness measurement accuracy and causing measurement inaccuracy; and   the amount of polymer added is sufficient to combine with and remove at least some of the interfering particles, such that the electronic hardness measurement accuracy is improved.   
     
     
         53 . The conditioning system of  claim 47 , wherein:
 the sidestream water being circulated back to the cooling water system from the reactor has a total hardness;   the conditioning system further comprises a means for obtaining sidestream water samples from sidestream water being circulated back to the cooling water system from the reactor for chemically measuring the hardness;   the sidestream water being circulated back to the cooling water system from the reactor contains polymer-combinable particles, the particles interfering with the chemical hardness measurement accuracy and causing measurement inaccuracy; and   the amount of polymer added is sufficient to combine with and remove at least some of the interfering particles, such that the chemical hardness measurement accuracy is improved.   
     
     
         54 . The conditioning system of  claim 36 , further comprising means for adding a corrosion inhibitor blend to the water. 
     
     
         55 . The conditioning system of  claim 54 , wherein the corrosion inhibitor blend is added to the sidestream water. 
     
     
         56 . The conditioning system of  claim 54 , wherein the corrosion inhibitor blend is added to the circulated water prior to circulating the water in the side stream. 
     
     
         57 . The conditioning system of  claim 54 , wherein the corrosion inhibitor blend comprises approximately 30 percent orthophosphate and 70 percent polyphosphate in a 50 percent water solution. 
     
     
         58 . The conditioning system of  claim 54 , wherein means for adding a corrosion inhibitor blend accommodates a mixture of the at least one buffer and a corrosion inhibitor blend, the mixture being dischargeable from the buffer supply into the sidestream water. 
     
     
         59 . The conditioning system of  claim 58 , wherein the ratio of corrosion inhibitor blend to the at least one buffer is approximately 1 liter to 19-39 liters. 
     
     
         60 . The conditioning system of  claim 36 , wherein:
 the reactor further comprises an upper portion, a lower portion, and an inlet, the inlet receiving the sidestream water, the inlet being configured to route the sidestream water through the reactor upper portion and discharge the sidestream water in the reactor lower portion; and   means for adding at least one conditioner to sidestream further comprises adding the at least one conditioner to the reactor lower portion.   
     
     
         61 . The conditioning system of  claim 60 , wherein the means for adding the at least one conditioner to the reactor lower portion further comprises means for routing the at least one conditioner through a conduit extending through at least a portion of the inlet. 
     
     
         62 . The conditioning system of  claim 61 , further comprising means for adding a polymer to the sidestream water in the reactor inlet, the polymer being routed through the conduit. 
     
     
         63 . The conditioning system of  claim 60 , further comprising means for causing a swirling of the sidestream water as the sidestream water is being routed through the reactor upper portion. 
     
     
         64 . The conditioning system of  claim 60 , wherein the reactor comprises an upper outlet for discharging the sidestream water back to the system, the conditioning system further comprising monitoring the pH of the water returning to the system circulation using a pH sensor, the step of adding a buffer to the sidestream water further comprising the step of adding the buffer to the sidestream water at a point between the reactor and the pH sensor. 
     
     
         65 . A conditioning system for conditioning water, the water being circulated in a circulation system, comprising:
 a buffer supply for adding at least one buffer to the water, the at least one buffer being capable of forming soluble complexes with metal ions of the type that cause scaling in the system, the formed soluble metal complexes being strong enough to reduce scale build up in the circulated system;   a reactor;   sidestream piping for establishing a water sidestream from the circulation system to the reactor and back to the circulated system;   a conditioner supply for adding at least one conditioner in the sidestream, the at least one conditioner being capable of:
 breaking the soluble metal ion-buffer complexes the soluble metal complexes being weak enough to release the metal ions when contacted with the at least one conditioner in the sidestream; and 
 softening the water in the sidestream by precipitating and accumulating the released metal ion as a solid, the reactor creating a location for contact between the conditioner-treated sidestream water and a portion of the accumulated precipitated solids; 
   wherein a portion of the accumulated solids is removed from the reactor before the sidestream water is returned to the circulation system.   
     
     
         66 . The system of  claim 65 , wherein the reactor comprises a mixer wherein the conditioner is added to the sidestream water and a liquid/solid separator for receiving the mixed sidestream water and conditioner, such that accumulated solids in the sidestream water are positioned for drainage from the liquid/solid separator. 
     
     
         67 . The system of  claim 65 , wherein the circulated water contains sodium chloride, the system further comprising:
 a chlorine generator for receiving sidestream water and for separating at least some of the sodium chloride into chlorine gas, sodium hydroxide, and hydrogen gas;   piping for disposing of the separated chlorine gas;   piping for disposing of the separated sodium hydroxide; and   piping for disposing of the separated hydrogen gas.   
     
     
         68 . The conditioning system of  claim 65 , further comprising a polymer addition system for periodically adding a polymer to the sidestream water. 
     
     
         69 . The conditioning system of  claim 68 , wherein the amount of polymer added is sufficient to substantially clarify sidestream water prior to the sidestream water being circulated back to the system circulation. 
     
     
         70 . The conditioning system of  claim 68 , wherein the amount of polymer added results in a polymer concentration in the range of 0.4-0.75 ppm with respect to the accumulated solids removed from the reactor. 
     
     
         71 . The conditioning system of  claim 68 , wherein the polymer is pre-mixed with a polymer reaction accelerator additive. 
     
     
         72 . The conditioning system of  71 , wherein the additive is selected from the group consisting of aluminum sulfate, aluminum chloride, ferric sulfate, and ferric chloride. 
     
     
         73 . The conditioning system of  claim 68 , wherein:
 the sidestream water being circulated to the reactor has a total hardness;   the conditioner supply further comprises a hardness measurement assembly for electronically measuring the hardness;   the sidestream water being circulated to the reactor contains polymer-combinable particles, the particles interfering with the electronic hardness measurement accuracy and causing measurement inaccuracy; and   the amount of polymer added is sufficient to combine with and remove at least some of the interfering particles, such that the electronic hardness measurement accuracy is improved.   
     
     
         74 . The conditioning system of  claim 68 , wherein:
 the sidestream water being circulated back to the cooling water system from the reactor has a total hardness;   the conditioning system further comprises a sampling valve for obtaining sidestream water samples from sidestream water being circulated back to the cooling water system from the reactor for chemically measuring the hardness;   the sidestream water being circulated back to the cooling water system from the reactor contains polymer-combinable particles, the particles interfering with the chemical hardness measurement accuracy and causing measurement inaccuracy; and   the amount of polymer added is sufficient to combine with and remove at least some of the interfering particles, such that the chemical hardness measurement accuracy is improved.   
     
     
         75 . The conditioning system of  claim 65 , wherein the reactor is not internally pressurable. 
     
     
         76 . The conditioning system of  claim 65 , wherein the reactor is internally pressurable. 
     
     
         77 . The conditioning system of  claim 65 , further comprising a drain for periodically draining accumulated solids from the reactor. 
     
     
         78 . The conditioning system of  claim 65 , further comprising a corrosion inhibitor supply for adding a corrosion inhibitor blend to the water. 
     
     
         79 . The conditioning system of  claim 78 , wherein the corrosion inhibitor blend is added to the sidestream water. 
     
     
         80 . The conditioning system of  claim 78 , wherein the corrosion inhibitor blend is added to the circulated water prior to circulating the water in the side stream. 
     
     
         81 . The conditioning system of  claim 78 , wherein the corrosion inhibitor blend comprises approximately 30 percent orthophosphate and 70 percent polyphosphate in a 50 percent water solution. 
     
     
         82 . The conditioning system of  claim 78 , wherein the buffer supply accommodates a mixture of the at least one buffer and a corrosion inhibitor blend, the mixture being dischargeable from the buffer supply into the sidestream water. 
     
     
         83 . The conditioning system of  claim 82 , wherein the ratio of corrosion inhibitor blend to the at least one buffer is approximately 1 liter to 19-39 liters. 
     
     
         84 . The conditioning system of  claim 65 , wherein:
 the reactor further comprising an upper portion, a lower portion, and an inlet, the inlet receiving the sidestream water, the inlet being configured to route the sidestream water through the reactor upper portion and discharge the sidestream water in the reactor lower portion; and   the conditioner supply adds the at least one conditioner to the reactor lower portion.   
     
     
         85 . The conditioning system of  claim 84 , wherein the conditioner supply further comprises a conditioner supply conduit extending through at least a portion of the inlet, the at least one conditioner flowing through the conditioner supply conduit. 
     
     
         86 . The conditioning system of  claim 85 , further comprising a polymer addition system having a polymer supply, and a polymer delivery assembly, wherein the reactor inlet further comprises a port for receiving the polymer from the polymer delivery assembly for addition to the sidestream water in the inlet, the polymer being routed through the conduit. 
     
     
         87 . The conditioning system of  claim 85 , wherein the reactor lower portion has a bottom and the inlet discharges the sidestream water approximately 12 inches from the reactor bottom. 
     
     
         88 . The conditioning system of  claim 85 , wherein the discharged sidestream water circulates in a substantially circular, inwardly directed pattern about the inlet. 
     
     
         89 . The conditioning system of  claim 84 , wherein the reactor lower portion has a bottom, and the reactor lower portion bottom is substantially flat. 
     
     
         90 . The conditioning system of  claim 84 , wherein the reactor lower portion has a bottom, and the reactor lower portion bottom is substantially conical. 
     
     
         91 . The conditioning system of  claim 84 , wherein the reactor lower portion has a bottom, and the reactor lower portion bottom is substantially convex. 
     
     
         92 . The conditioning system of  claim 84 , wherein the inlet is configured to receive the sidestream water and induce a swirling of the sidestream water as the sidestream water is being routed through the reactor upper portion. 
     
     
         93 . The conditioning system of  claim 84 , wherein the reactor comprises an upper outlet for discharging the sidestream water back to the circulation system, the conditioning system further comprising a pH sensor for monitoring the pH of the water returning to the circulation system, and further wherein the buffer is added to the sidestream water between the reactor and the pH sensor. 
     
     
         94 . (canceled) 
     
     
         95 . (canceled) 
     
     
         96 . (canceled) 
     
     
         97 . (canceled) 
     
     
         98 . (canceled) 
     
     
         99 . (canceled) 
     
     
         100 . (canceled) 
     
     
         101 . (canceled) 
     
     
         102 . (canceled)