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Freytech Oil Water Separators in Car Wash Applications

Debra Gorgos • Mar 01, 2009

Water reclamation systems not only help the environment, but also your bottom line.

Saving water is a good thing. Saving money is a great thing. Combine the two and it seems as if a water  reclamation  system  is  a  win-win.  But  there  are  misconceptions  about  systems,  from their  price  to  their  maintenance,  with  some  operators  claiming  they’re  too  expensive,  others thinking they are too much trouble and some worried about the water’s quality.

Professional Car washing & Detailing® spoke with a multitude of industry experts to get to the bottom  of  these  misconceptions  to  help  operators  in  learning  how  to  maximize  their  water reclaim systems.

The Common Misconceptions

Jim  Keller,  president  of  Con-Serv  Water  Recovery  Systems,  said  that  in  the  35  years  he’s worked in the water recovery equipment industry, the most common misconception is in regard to the cost.

“In  most  cases  to  dispute  the  myth  about  cost  and  to  implement  a  system,  calculate  current water and sewer rates in your area,” he said. “Don’t forget to inquire about any increases that might be in the forecast for your municipality’s future. I’ve been in the industry for quite a few years and I have never seen a rate decrease.”

Joel  Wollin,  the  director  of  Sales  and  Marketing  at  Autowash  Systems,  Inc.,  said  the  biggest misconception he has heard has to do with water quality and “that you cannot use one without degrading  the  quality  of  the  wash  and/or  experiencing  a  sewer  odor  that  is  traditionally associated with inadequate reclaim systems,.”

If  a  reclaim  system  is  installed  correctly,  Wollin  said  it  can  be  one  of  the  greatest  assets  to  a carwash. To truly maximize effectiveness the operator must have plenty of underground settling capacity,  use  a  strong  disinfectant  (such  as  ozone),  and  properly  maintain  the  system  on  a regular schedule.

Charles Borchard, the vice president of operations for New Wave Industries, said there is still a lot  of  resistance  among  operators  despite  rising  water  and  sewer  costs.  As  these  expenses increase, Borchard expects more operators will look to reclaim systems to realize a payback that can occur in less than two years with a 60 percent recovery rate.


Out with the Old

Some  manufacturers  believe  the  negative  reputation  for  reclaim  systems  is  owed  to  earlier models, which didn’t work as well. Dean Taylor, who serves as the system application specialist for  CATEC  Water  Recovery  and  Ozone  Systems,  said  reclaim  systems  have  improved  greatly over the years and deserve a second look.

“Early  systems  were  unsophisticated  and  produced  water  that  looked  and  smelled  awful.  Such systems are still being sold today, and they continue to be very detrimental to a car wash facility by  turning  away  customers  and  causing  premature  equipment  failures  and/or  maintenance nightmares,” he said.

According  to  Taylor,  the  substandard  systems  continue  to  give  reclaim  a  bad  name.  Over  the last  10  years,  Taylor  said,  a  hand  full  of  reclaim  system  manufacturers  have  made  leaps  and bounds with reclaim technology.

Today,  there  are  systems  that  will  produce  clean,  odor-free  water  and  with  very  little maintenance. These systems can deliver water clean enough that their customers can’t even tell reclaim water is being used on their car.

“The recent trend to “go green” with car washing shows no sign of ending anytime soon,” Wollin said.  But  once  upon  a  time,  he  had  an  operator  decline  to  give  a  letter  of  recommendation because he didn’t want anybody to know he reused his water.

“I  now  have  new  operators  proudly  advertising  that  they  do  so.  As  water  and  sewer  costs continue to increase, I see the future of water reclamation as very strong ... and not just in the carwash industry ... we are starting to look at water reclamation for the ethanol industry as well as the health club industry,” Wollin explained.

Picking the Right System

Picking the correct system comes down to your carwash’s size and the amount of water that will be reclaimed.

By  pre-determining  what  equipment  you  will  use  reclaim  with  and  how  much  water  that equipment will need, Keller said you can properly anticipate the size of your system. “If you are planning on recovering only 50 percent of your carwash water, tank size, pipe size, pump and motor size will be significantly smaller and so will the cost of the recovery system you will need to purchase,” he said.

Wollin recommends choosing a system that comes with a drain. He also said operators should look for a system with a filter purge “so that filter changes can be performed safely and with no mess.”

“Systems  that  are  designed  to  depressurize  automatically  when  you  turn  them  off  can  be unreliable  and  dangerous,”  Wollin  cautioned.  “Never  assume  that  a  system  is  depressurized before opening the filter vessel ... it could take your arm, or worse, your head off. If your system  has  a  manual  drain  valve  on  it,  you  know  that  when  you  open  that  drain,  it  is depressurized.”

As for its size, Wollin said an operator needs to be prepared. “Keep in mind,” he said, “that we recommend  9,000  gallons  of  underground  settling  capacity  to  make  a  reclaim  system  really,truly  function  well,  and  this  means  that  an  operator  has  to  make  a  significant  investment  not just in dollars, but in space, to put one in.”

Maintaining While Reclaiming

As with all equipment, good maintenance is important and must be done regularly and correctly.

Wollin said that filter, strainer and nozzle maintenance is a must, and reclaim water will typically
leave a muddy residue in and on the equipment it is used on. “While the filters are designed to remove most of this, dirt particles that are smaller than the micron rating of the filters will still get through,” he said.

Wollin stated these particles eventually accumulate and will plug strainers and nozzles, which naturally leads to other, more serious maintenance problems. The same goes for the filters themselves. “Failure to maintain these items leads to premature equipment failure ... usually an expensive pump,” he said.

Gideon Brunn, an Application Engineer with Automatic Filters, inc. said, “leftover particles will cause maintenance nightmares when they get into a system.” He said unscheduled shut downs for cleaning and maintenance will then occur. Particles will also cause spotting and coloration on cars and will eventually plug the spraying nozzles, Brunn added.

According to Taylor, proper maintenance is key to keeping the water clean. He said to be loyal to your preventive maintenance program. “Just as with a swimming pool, some things must be maintained to keep the water nice,” he said. “Many reclaim systems of today require much less maintenance than those of the past. Five to 10 minutes of simple maintenance once a week will help keep your system operating at its peak performance.”

Taylor also said that really understanding the system is a good way to keep it working, and some manufacturers offer an onsite visit for set-up and training when you purchase your reclaim equipment. “Take full advantage of this visit. Take time to learn your system, how itoperates and what is required to maintain it. It will save you time, money and headaches in the long run,” Taylor said.

Borchard agreed and said operators should plan to hold onto their owner’s manual. “After you have read the manual, do what it says, check or clean filter elements, media. Verify operations.If  there  is  periodic  maintenance,  do  it,”  he  warned.  “Almost  all  systems  will  have  a  strainer basket in front of the pump and all systems will benefit from keeping it clean; once a week inmost cases.”

Parts to Consider

Knowing that oil can get into the reclaim water, David F. Roberts, the president of Freytech Inc.,recommends the use of an enhanced coalescing oil water separator. “Even trace amounts of oil in the recycled water can diminish the quality of the wash,” he said. “An ‘oil trap’ is not enough since it is simply a tank with baffled walls which does trap some of the oil floating on the surface of the water, but it will not trap all of the oil present below the surface.”

In  addition,  using  such  an  antiquated  method  does  not  offer  adequate  protection  against potential fines for discharging oil beyond the legal limits, according to Roberts. As for self serve carwashes, he said an oil water separator is strongly recommended since it is not uncommon to come  across  patrons  changing  their  oil  and  dumping  it  into  the  carwash  drain.  He  said  that retrofitting  existing  tanks  and  installing  a  turnkey  separator  kit  is  a  simple,  affordable  option that not only improves the wash quality and protects the environment but also offers peace of mind to the operator.

Good filters and the replacing of those filters is also a key step. Wollin said that most of his sites are changing filters every 1,000-1,500 cars. Some newer models can handle 5,000 cars on a set of filters. He also recommends good felt filter bags, which nowadays go for about $4 a piece.

“If your reclaim system has three bags, and you change your filters every 1,000 cars, the cost of this maintenance is slightly more than a penny per car,” he said. “I have seen sites wash and reuse  their  filters,”  which,  in  his  opinion,  quickly  degrades  the  ability  of  the  filters  to  remove particles they are rated to catch.

“Considering the negligible expense of the filters,” Wollin said,” it is not worth the time or the hassle  to  do  this,  and  in  fact,  the  cost  of  washing  these  filters  probably  exceeds  the  value  of doing so.”

By Deborah Blum 12 Oct, 2013
The cans of baby formula invaded Brian Jackson’s Dartmouth College lab late in 2010. His team picked up an armful of popular brands at the food co-op in Hanover, N.H. Then another armload. Eventually Jackson had a cabinet full of the brightly labeled canisters. Today, he still keeps a few in his office. Not as clutter — that’s not his style. He just likes to keep his toxicology evidence close at hand. A 47-year-old analytical chemist with sandy-gray hair and blue eyes, Jackson has a chemist’s passion for the picky details of analysis, the skill his colleagues tapped when they asked him to investigate a disturbing possibility: that baby foods and formulas made with rice might contain arsenic, a known carcinogen. Ingested even at the trace levels the scientists suspected, devastating health outcomes could result. In a first round of tests, arsenic levels in all the products Jackson’s group studied fell within the 10 parts per billion safety limit the EPA sets for water. (There is no limit for arsenic for most foods.) But a short time later, while shopping at the co-op, Jackson noticed two brands of toddler formula, both high-end organic products, that his team had missed on the first sweep. This time, to the team’s surprise, the arsenic readings flew off the chart. “My first thought,” Jackson says, “was that I’d better reanalyze these samples in case I’d screwed up.” His second thought, after confirming the readings, was to wonder: What made the arsenic levels spike in those two cans? In answering that question, Jackson traced not just the story of the metal-loving rice plant, but also the tangled and troubling path of a notorious poison through our past and present. A naturally occurring metallic element, arsenic permeates the Earth’s crust. Glinting silver-gray in rocks and soils, it mixes with other minerals as it seeps into water supplies, drifts on the dusty plumes of volcanic eruptions and travels on the wind. It also spreads through industrial use, from mining to agriculture. Arsenic coils like a dark smoke through our history. The word derives from the ancient Greek arsenikon, meaning “potent.” It was used to describe the compound arsenic trioxide, which can be lethal at 100 milligrams, about one-fiftieth of a teaspoon. Arsenic trioxide is famously tasteless and odorless, which helped make it one of the most frequently used homicidal poisons in history. But in recent years, studies have revealed that exposure to far smaller doses poses a more subtle — but also insidious — threat. The pure element arsenic mixes into many compounds, either organic (in chemical lingo, meaning that it contains carbon) or inorganic (without carbon). And even at concentrations of parts per billion (ppb), closer to a drop in a swimming pool than a drop in a teacup, long-term exposure to inorganic arsenic — generally considered the most toxic form — has been linked to an increased risk of cancer and other life-threatening illnesses. Although arsenic hasn’t been studied in as much detail as other toxins found in industrial materials, such as mercury or PCBs, scientists say it underscores the finding that minute exposures to such substances can do great harm. At low doses, arsenic doesn’t overwhelm body systems immediately or even cause death over the course of months. Rather, explains Dartmouth molecular toxicologist Joshua Hamilton, chronic exposure to trace arsenic inflicts damage at a cellular level, increasing the body’s vulnerability to a wide array of sicknesses, including cancer, cardiovascular disease and diabetes. While trace arsenic won’t kill on its own, he says, it “seems to make everything worse.” For decades, officials have focused on trace arsenic in drinking water as the chemical’s primary public health threat; in 2001, the EPA dropped the limit for arsenic in water from 50 ppb to 10 ppb. But in the past few years, regulators have also begun to worry about exposure from foods and beverages. This summer, concerned about arsenic in pesticide residues found in imported juices, the FDA announced it will limit the amount of arsenic allowed in apple juice to 10 ppb, the same amount permitted in water. The FDA has also investigated arsenic’s presence in other foods. Chicken, for example, has come under scrutiny because of the longtime use of an arsenic additive in poultry feed. But the top-priority food on the list is rice, which became a focus when researchers realized that it takes up inorganic arsenic from soil far more efficiently than other grains. A July study revealed the first evidence directly linking consumption of rice containing arsenic to genetic damage in humans. Such findings are especially alarming because rice is a major part of the diet in certain communities, such as those with an Asian heritage, and because rice is a staple for infants and young children, whose developing bodies and brains are especially vulnerable to harm. It’s that last concern that sparked the formula studies in Jackson’s Dartmouth lab.
By PHILLIP LAWLESS 01 Oct, 2011
Many self-serve carwash owners think that going green is just a dream. The dozing duo of re-pair costs and utility bills make it seem im-possible for operators to wake the sleeping beauty of forward-thinking investments. What owners need now is a knight in shin-ing armor, a gallant hero astride a steed of eco-friendly savings. In this instance, the dreamy knight gal-loping forth could be a water reclaim sys-tem. A reclaim system is rare in that it helps a carwash go green while revitalizing profi ts and paying for itself. The systems enable a 50 percent to 75 percent reduction in water usage, and they can signifi cantly reduce or eliminate sewer costs as well. As owners can tell you, savings like these will help any car-wash’s story end with “happily ever after.” Cutting consumption and discharge Today, the price and availability of water has become one of the most stressing oper-ator concerns. Conservation measures such as restricted operating hours, shut downs, drastic increases in water and sewer pric-es and outrageous impact fees or fi nes have most owners desperately looking for ways to conserve water, according to Dean Taylor with CATEC Water Recovery and Ozone Systems. Taylor said recycling water is the most effective method to reduce water consump-tion, sewer discharge and high sewer impact fees in new construction. “These sav-ings are typically substantially more than the cost of a recycling system itself, and they offer a quick return on investment and a substantial increase in profi ts,” he said. In most areas, sewer fees are calculated directly from water consumption, and the fees often run 200 percent to 300 percent more than water costs, Taylor said. Thus, when water consumption is reduced up to 70 percent, high sewer costs should be reduced at the same time. Further, with a good water reclaim system, a self-serve carwash can be built that will not need to discharge anything into sewers. Uses and Installation Reclaimed water is basically wash water that has been filtered and treated with bacteria control. This recycled water should generally be good for high-pressure applications, and this can include high-pressure soap and other functions, Taylor explained. Depending on the final rinse options, re-claim can sometimes be used as a first rinse, which is usually a high-pressure application as well. In a self-serve wash, fresh water usage will typically be needed only for low-consumption options. These include pre-soak, tire and wheel applications and foaming brush uses, Taylor said. The water used here is minimal, and the necessary chemicals mix better with fresh water. The difficulty of retrofitting a system into an existing wash depends on a lot of variables. First, Taylor said process tanks will need to be placed in-ground or above-ground. Other questions to consider are: How far can the tanks be from the equipment? Is there space in the equipment room? Where do the trenches need to be cut for pipes? In new construction, a reclaim system can be designed into the site plan. The tanks and system can usually be located close, and most piping is completed prior to asphalt or concrete being laid. “Once the piping and tanks are in place, it usually takes a plumber a day or two to install and have the unit operating,” Taylor said.
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