Task
The Bühler Group, a globally operating company with representatives in 140 countries, operates a state-of-the-art production facility for thin-film coating systems at its production site in Alzenau and provides customer service for Leybold Optics systems for the die casting, grinding, and dispersing markets. The systems from this location are used worldwide.
A large-volume closed cooling system is used to cool the production facilities for test operation and functionality and quality testing. However, this mode of operation also subjects the system water to special requirements in terms of cleanliness and consistent quality. The system itself is currently operated by the FM company FAMIS.
The aim of the process is to prevent corrosion, biofouling, hardness deposits, and dirt ingress throughout the entire system in the long term, while at the same time reducing water consumption through optimized retention time management and ensuring water quality. Other important requirements included compliance with the VDI 6044 guideline and easy handling of the operating materials on site.
System specifications
- Water type: Permeate with partial softening
- Materials in the system: Plastics, copper, non-ferrous metals, stainless steel, and aluminum
- Operating temperatures: 22°C +/- 2°C
- Circulation volume: 50 m³
- Feed water: Permeate
- Emergency feed: Municipal water
Solution
ALMAWATECH developed a coordinated operating resource concept based on a multifunctional protection strategy consisting of:
- Corrosion protection for mixed metal materials designed for aluminum (ALMA KK F 2200; ALMA VKA SR)
- Biocide management against microbiological growth (ALMA BIO 110)
- Fully automated monitoring and control of key water parameters via ALMATrol measurement, control, and reporting device with weekly graphical reporting and proactive alerts via email connectivity.
The dosing of operating materials and adjustment of water quality are carried out fully automatically depending on the sensor-detectable product content, conductivity, pH value, and volume flows, ensuring stable operation with minimal use of chemicals. For cleanliness, an existing system water filtration system was technically optimized to capture finer particle sizes. In addition, the backwash process was adapted for safe plant operation. Biocide dosing is adapted to the operational requirements of occupational safety.
In addition, quarterly water analysis and system maintenance by ALMAWATECH Service was established.
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