Plate Life

The longest plate life known to KASELCO to date is 1,100 hours, and the shortest is 168 hours of energized treating time.  The most common is greater than 350 hours, and 350 hours is the number used by KASELCO for planning purposes.  A number of things affect plate life.  The greatest is the amount of energy applied to the plates, with plate life shorter when high current density (amperage) is used.  Higher than normal current is used when a wastewater is very concentrated, when the pH responds poorly (as when buffering agents are present), or when chelating agents are present.  The presence of chlorides also may reduce plate life as the chloride ion may form hydrogen chloride in the reactor, etching the plates.  The presence of oils or low concentrations of organic chemicals tends to extend the plate life.

Steel consumption at estimated 350 hours replacement interval:

• •SUR-FLO Reactors: 1.3 lb./1000 gal (2.5, 5, 10 and 25 GPM reactors)

• •HI-FLO Reactors: 0.43 lb./1000 gal (250 GPM to 1,500 GPM reactors)

Energy Consumption

Treatment Energy Consumption: These figures are typical energy consumption figures and are what KASELCO uses for planning purposes:

These numbers are approximately 50% of the maximum possible current and voltage capacity of our plate configuration. Customers often operate as low as one fourth the maximum, or about 0.7 kwh per cubic meter (or 0.00265 kwh/gal, or 2.65 kwh/1,000 gallons). The cruise ship, for example, operates at less than one fourth the maximum.

Example of Typical Electrical Consumption - 10 GPM KASELCO system:
(10 GPM) X (60 minute/hour) = 600 gallons/hour treated. (600 gallons/hr) X (0.00568 kwh/gallon) = 3.41 kw.

Electrical Installation Design: When designing a system’s electrical component capacities and installation requirements KASELCO assumes the maximum energy that can be put into the water by the reactor. The maximum is almost impossible as it assumes the maximum amperage occurs simultaneously with the maximum voltage. This is very rare. This results in a robust, reliable system.

For electrical power supply design consider the maximum theoretical consumption from this following table adjusted by the rectifier efficiency:

Take the efficiency of the rectifier circuitry into consideration in planning the electrical consumption and in sizing the electrical power lines to the EC system. Maximum possible power would occur with settings on “High”.

• •One-Pass EC Mini-Package (or other small engineered systems with single-phase rectifiers): 65% efficiency at “Low” treatment settings, to 74% at “High”.

• •Larger engineered systems with 3-phase SCR rectifiers: 78% efficiency at “Low” treatment settings to 86% at “High” treatment settings.

Example of System Sizing - 10 GPM KASELCO system – this is theoretical maximum power:
(10 GPM) X (60 minute/hour) = 600 gallons/hour treated. (600 gallons/hr) X (0.0109 kwh/gallon) = 6.54 kw. (6.54kw max power) / (0.74) = 8.34 kw.