Steam Equipment Application Information

Below is information on water related problems in steam equipment and how OptiPure FX and QT systems solve those problems.

• The filtration system includes the right treatment technology for your type of steam equipment. There are different types of steam generating equipment that require different treatment technologies.
• The system performance is ‘balanced’; this means each of the different treatment methods, i.e. chlorine reduction, and scale inhibition are properly sequenced so that each will deliver consistent results based the stated capacity (in gallons) of the system.
• The system will perform at the required flow rate.
• The system capacity is proportional to the actual water usage of the steam equipment between recommended filter change intervals.

Whether your decision to purchase a water filtration system is driven by the desire to improve operating efficiency and cooking consistency or to protect your equipment against expensive service calls and downtime, the outcome is similar: a more successful and profitable business.

Become an expert - Educate yourself about both the water contaminants that can affect your steam equipment, and the treatment options available. Understand the performance features of the filtration system you are considering. Compare the rated capacity of the system and your actual water usage to determine filter life and change frequency. The bottom line is: if you don't understand what filtration does, and how it will protect you and your business, it's tough to make the best choice.

It's a lot like buying insurance –Water treatment protects your equipment and your business against the cost and hassle of water-related problems. Just one day of service interruption can be far more expensive than guarding against it. Water treatment insures that your equipment is producing when you need it most.

Common water contaminants that cause problems with steam equipment are:

Dirt, Sediment | Chlorine (Corrosion) | Minerals (Scale)

Dirt, Sediment, Rust (particulate matter)

Suspended particulate matter in water is detrimental to the condition and performance of steam equipment. Particulates in water cause added wear on parts, and can clog solenoids, screens, valves and other fittings. Fine silt, dirt, rust and other debris settle as sediment and can be a catalyst for scale build-up.

OptiPure's ScaleX2 and IsoNet filtration systems filter out the majority of suspended particulate matter down to .5 micron in size. To get an idea how small this is, one micron is equivalent to .000001 meter, a human hair is about 90 microns thick and, the smallest speck you can see is about 40 microns.

OptiPure filtration systems utilize gradient density-depth filtration. This means that water flowing through the filter passes through nearly ¾” of media that traps particulates within its entire depth (about 20,000 microns deep). The larger dirt particles are trapped in the outer layers of the filter. As the gradient becomes progressively denser, smaller particles are trapped in the deeper layers of the filter. This filtration technology provides exceptional ‘dirt load’ capacity, and allows excellent flow with minimal pressure drop between recommended filter change intervals

Chlorine

Most municipal water utilities use chlorine to kill pathogenic organisms and to provide a residual concentration of disinfectant throughout the distribution system. While chlorine makes our water safe to drink, it can contribute to pitting and corrosion in steam equipment. Activated carbon is the best technology for removing disinfectant chlorine.

The media structure of the OptiPure cartridge is entirely composed of fibers coated with powdered activated carbon (PAC). Thousands of these carbon coated fibers make up the entire depth of the CTO and CTOS cartridges used in OptiPure systems. The high mass of powdered activated carbon, along with the gradient-depth structure of these cartridges, provides tremendous surface area and contact time as water flows through. OptiPure’s activated carbon chlorine reduction media contributes to the exceptional NSF Certified performance and capacity of OptiPure systems.

Scale (Limescale) – Water Hardness

A common and expensive water related problem with steam equipment is the formation and accumulation of scale. Varying amounts of scale-forming compounds (primarily calcium and magnesium in the form of carbonates) are present in water supplies. These dissolved mineral compounds, measured as “water hardness”, become concentrated in water due to evaporation. Concentration and heat force them out of solution onto heat transfer surfaces where they form a hard, adherent, rock-like layer. Scale acts as an insulating layer and prevents an efficient transfer of heat. Over time scale build-up impedes steam production, reduces energy efficiency, increases maintenance requirements and eventually causes equipment shut-down requiring expensive service.

Different physical characteristics of water such as total dissolved solids, hardness as CaCO3, pH, temperature, alkalinity, sulphates and silicates influence the amount of hardness in water and its tendency to form scale. OptiPure offers three different technologies for the treatment of scale in steam equipment: Advanced Membrane Separation (AMS), ScaleX2® and IsoNet®. An analysis of the following five water parameters should be considered to choose the best treatment technology for your application:  Hardness – Alkalinity – pH - Total Dissolved Solids - Silica.

Chlorides (corrosion)

Corrosion is the deterioration of materials due to reactions within the environment. In general, the corrosive nature of water increases as conductivity (TDS) increases. Chloride is a compound that becomes particularly reactive at higher temperatures (140-212º F) and can penetrate the passive film on stainless steel allowing a corrosive attack to occur. Common types of corrosion associated with chlorides are pitting, crevice corrosion and stress corrosion. The degree to which chlorides present a problem depends upon the overall chemical characteristics of your water, but chlorides can be corrosive to stainless steel even at low levels. Corrosion can be rapid, destructive and expensive with steam equipment drastically reducing equipment life. Along with the previous five parameters, chloride should be considered in deciding the best treatment technology to protect steam equipment.

OptiPure Advanced Membrane Separation (AMS) systems remove chlorides that cause corrosion. Chloride removal is beneficial with steam equipment at levels above 30 ppm.
OptiPure IsoNet is a special blend of media that inhibits chloride corrosion.
Along with a polyphosphate scale inhibitor, the media imparts a small amount of sodium silicate that forms a microscopic barrier layer on metal surfaces to help guard against a corrosive attack.

Important Considerations Regarding Dissolved Minerals and Steam Equipment

Water is nature’s solvent. It contains, to some degree, everything it can dissolve on the way to your tap. Calcium, magnesium, chlorides, sodium and carbonates are a few of the many different dissolved solids found in water. Heat, evaporation and concentration cause chemical reactions that force these minerals out of solution where they form scale in boilers, valves and fittings; and on elements, cabinet walls and glass.

There are two fundamental ways to treat dissolved solids in water.

1.  Inhibit mineral problems with chemistry

Inhibitingtechnologies do not remove dissolved minerals. Inhibitor media interfere with water chemistry to inhibit the formation of hardness compounds, reduce the tendency of minerals to accumulate as hard scale, and make routine cleaning easier; but inhibition is not removal. It is important to follow all manufacturer recommended routine cleaning and periodic descaling recommendations. If deposits are allowed to accumulate they will eventually become problematic.

2.  Remove problematic minerals

OptiPure Offers 3 Different Water Treatment Technologies for Steam Application

Inhibiting Technology
• ScaleX2®
• IsoNet® (patented)

Removal Technology :
• OPM and OPW series AMS (Advanced Membrane Separation)

Selecting the right treatment option for your application is as easy as 1 – 2 - 3

Step 1 – Analyze Water and Diagnose Potential Water-Related Problems.
It is impossible to choose the best treatment technology without an understanding of the physical and chemical characteristics of water. Analyses of the following parameters are recommended.

Water Hardness (as CaCO3) – is a measure of the scale forming compounds of calcium and magnesium. The amount of hardness is often expressed in ppm (parts per million) or mg/L (milligrams per liter). Ppm and mg/L are equivalent measurements that express the number of parts of calcium carbonate (CaCO3) per 1,000,000 parts of water. Water hardness is also expressed in grains per gallon (gpg). One grain of water hardness is equivalent to 17.1 ppm of calcium or magnesium carbonate. For example, 171 ppm CaCO3 = 10 grains of hardness.

Total Dissolved Solids (TDS) – Also expressed in ppm or mg/L, total dissolved solids are all of the inorganic and organic substances in water that are present in their molecular or ionized form. For example, table salt - NaCl, when dissolved in water become Na+ and Cl- ions. Dissolved ions, such as Cl-, make up the majority of TDS and are what allow electricity to pass through water (electrical conductivity).

Alkalinity – As it pertains to steam equipment, alkalinity is an indicator of the potential, or tendency for hardness minerals to form scale. Bicarbonate (alkalinity) breaks down when heated and combines with calcium and magnesium to form hard scale on metal surfaces.

pH – is a measure of the relative balance between acid and alkaline substances in water. It is an indicator of whether water has a scale-forming tendency or a propensity to be corrosive. The pH of water is considered, in conjunction with other water parameters, to determine the best water treatment technology.

Silica – is a very hard mineral found in nature in quartz and opal, and is a common constituent of sand. Glass is silica-based material. Small amounts of silica can form very hard scale in steam equipment that is difficult to remove.

Chloride – Chlorides are one of the most common elements in nature. They are soluble, active ions that make a basis for good electrolytes that can trigger a corrosive attack. Chlorides present the greatest threat for corrosion in steam equipment.

This information may be available from your water company. pH will be expressed as a number between 0 and 14 (most likely between 6.5 and 9.0). The other parameters will be a number value expressed in mg/L (milligrams per liter), or ppm (parts per million).  If the water quality report shows a high/low range (due to seasonal changes or blending of wells) use the ‘high’ level for the analysis.

If not available, OptiPure can provide a complete water analysis and recommendation. 

Step 2 – Determine How Your Equipment Generates Steam?

Different methods of making steam can require different treatment technologies. It is important to know how your equipment generates steam to choose the best water treatment technology. What matters most is whether the oven contains a volume of water that is ‘boiled’ to generate steam or whether it takes in water that is instantly ‘flashed’ into steam.

Boiler – A volume of water is contained and heated to a boil to generate steam.
This method includes ovens with boilers, steam generators and boilerless ovens with open, accessible reservoirs. Most equipment with a boiler or steam generator has an automatic blow-down (drain & flush) feature and many have a built-in descaling system. A key feature of the boilerless reservoir design is that open visible access makes it simple to visually monitor and clean sediment, scale and other precipitated solids from the reservoir before scale build-up becomes problematic.

Flash – Water is dispensed onto a heated surface and instantly ‘flashed’ into steam.
This method involves some mechanism for dispensing water directly onto a heated surface or element that is hot enough to rapidly vaporize, or “flash” the water into steam.

Step 3 – Choose the Best Water Treatment Technology

OptiPure application recommendations are based upon the systems tested and proven ability to help protect equipment against undesirable water characteristics. It is important to note that water chemistry, and the physics of using heat energy to convert water from a liquid to a gaseous state, is very complex. Many variables can influence the overall impact water will have on equipment in a given application.

The purpose of this document is to help OptiPure users understand how water contaminants can affect their steam equipment and the treatment options available; and to share important considerations for making an informed decision about selecting the best water treatment for their application. The water quality parameters presented here are general application guidelines. Recommendations may vary based upon application specifics, and equipment design and features.

Filtering out particulate contaminants and reducing chlorine is recommended for all steam applications. OptiPure’s AMS, ScaleX2 and IsoNet systems for managing hardness and TDS problems are integrated, multi-stage systems that include particulate filtration and activated carbon for chlorine reduction.

Equipment manufacturers have established “water quality minimum standards” to help customers understand the importance of water quality with steam equipment and to protect against water-related warranty issues. These standards can be found in specification sheets and owners manuals. The following chart depicts the range of water quality parameters published by ten major manufacturers of combi-ovens and steamers. In most cases, exceeding these parameters voids the warranty against water-related problems.

The majority of water supplies in North America will not meet these minimum standards without treatment. In fact total dissolved solids, hardness, alkalinity and/or chloride levels in many areas can be 5 or even 10 times higher than this.

Is it unreasonable and unrealistic to expect treated water to meet these standards? No. Water with these chemical characteristics will virtually eliminate water related problems and assure many years of consistent, trouble-free performance from your steam equipment.

It’s important to understand the potential water-related problems in your situation, and assess the impact it can have on your equipment and your business. Once the financial impact is considered, simply weigh the value of maximizing equipment life and minimizing maintenance against shortened equipment life and more frequent maintenance and service.

• How frequently will your equipment require service, and at what cost?
• Are water-related problems covered under the equipment warranty?
• Will downtime and service interruption affect business?
• How does scale build-up affect equipment operating efficiency?
• How many years your equipment last and what is the replacement cost?

For a combi oven that uses 50 gallons of water per day for steam generation, the cost of treating your water with OptiPure over a five year period is 22¢ to $1.60 a day. Your actual cost depends on the characteristics of your water and the treatment technology you choose. . . What will not treating your water cost you?

Application: Boiler & Flash Steam

Technology Recommendation: Optipure AMS

These are general application considerations - Contact your OptiPure distributor or OptiPure for a specific application recommendation.

Advanced Membrane Separation (AMS) –Unlike filtration, which is a process of trapping and holding contaminants within a filter media, membrane separation is a process where contaminants rejected by the membrane are continually flushed away to the drain. Nothing is trapped and held in the membrane media. It is a separation process.

It is incorrect to refer to all membrane-type systems as “RO”. Reverse Osmosis (RO) is a near absolute removal process that takes out virtually all dissolved solids and ions in water. Water with this degree of purity can be aggressive in environments with metals and lacks the conductivity required for electrical sensors and level probes. Reverse Osmosis is not recommended for steam equipment.

OptiPure AMS systems utilize a special type of membrane with different filtration and rejection characteristics than RO. OptiPure membranes are very effective at reducing high TDS and removing minerals that form hardness while allowing a calculated permeation of non-hardness minerals. This allows for needed conductivity and reduces the aggressive nature of pure water. A simple way of viewing the characteristics of this technology is that these membranes are “selective” about what and how much they reject.

With AMS, water-related problems with steam equipment are virtually eliminated. OptiPure AMS systems deal with a broad range of contaminants that are detrimental to steam equipment. Each system includes sediment and activated carbon prefiltration, AMS processor, storage tank, and water repressurization.
OptiPure OPW-Series are compact wall mounted systems. Six models offer from 100 to 1600 gallon per day production with storage and repressurization options ranging from 55 to 500 gallon capacity.
OptiPure OPM models are completely self-contained, free standing units with 150 and 300 gallon per day production and 25 or 50 gallon storage options.
NOTE: OptiPure AMS treatment is highly recommended for ‘flash’ steam equipment.

Application: Boiler Steam

Technology Recommendation: ScaleX2

 

These are general application considerations. Contact your OptiPure distributor or OptiPure for a specific application recommendation.

ScaleX2 is a proven filtration technology that protects steam equipment against the formation and accumulation of hard scale.

ScaleX2 instantly transforms dissolved hardness ions into microscopic particles through a process called “template assisted crystallization”. The particles, suspended in solution can no longer form hardness compounds. The microscopic particle formations become stronger as water temperature increases. This further enhances ScaleX2’s ability to prevent scale formation in boilers, steam generators and boilerless combi’s with open reservoirs.

• becomes even more effective as water temperature increases
• is not negatively affected by pH variations
• does not add sodium or chemicals to water
• requires changing the filter only once a year in most cases

ScaleX2 systems are available in various configurations to meet different application requirements. Models SX2-21 and SX2-22 are Tested and Certified by NSF International.

Application: Boiler and Flash Steam

Technology Recommendation: IsoNet

 
These are general application considerations - Contact your OptiPure distributor or OptiPure for a specific application recommendation.

IsoNet is a patented scale inhibiting and corrosion protection technology.
IsoNet interferes with the formation of hardness compounds which inhibits the formation and accumulation of scale. What makes IsoNet unique is its patented design that allows for consistent delivery of media and greater capacity. It also forms a protective barrier layer on metal surfaces to help guard against corrosion.

With boilers, steam generators and open reservoirs the ‘sequestered’ hardness minerals and other suspended particles are flushed away during automatic or routine draining procedures.

With flash-type steam equipment none of the water leaves the oven, and all of the dissolved solids in the water are forced out of solution. IsoNet interferes with the formation of the solids by making them less adherent and less hard. This reduces scale related problems and makes it easier to clean mineral deposits from areas where they form.

IsoNet ensures consistent dosing by trapping and holding the right blend of scale & corrosion inhibitor media in the ideal position within the core of the cartridge.
Inhibitor media dissolves into the water stream where it reacts with dissolved minerals and interferes with the formation of hardness compounds. IsoNet’s corrosion inhibitor protects metal surfaces.

• Consistent Delivery - All the water flowing through the cartridge comes in contact with the inhibitor media.
• High Capacity - IsoNet sustains sufficient media surface area to provide consistent dosing and protection for the period between filter changes.

IsoNet systems are available in various sizes to meet different application requirements. OptiPure offers a variety of systems utilizing IsoNet that are Tested and Certified by NSF International.

System Sizing

Once you choose the best treatment technology for your application, you must select a system that will meet your usage requirements.

Capacity – How much water will your steam equipment use?

Water is used with combi ovens and steamers for generating steam and to cool condensate water released to the drain.  Some models also include automatic cleaning systems and hand-held rinse wands. Manufacturers often provide separate water connections.
Does your equipment have a separate water connections for steam and for drain condensate water?

• If it does, check to see what other water using devices might be plumbed into the ‘steam water’ connection, such as the hand shower and/or a built-in automatic cleaning system. It is important to calculate all treated water requirements when deciding system capacity.
• If it does not, be sure to calculate all the water used by the equipment including the drain condensate water, the rinse wand, and water used with built-in cleaning systems. Water used for these functions is typically more than the amount of water used to make steam and must be included in your water usage calculations.

NOTE: You may have to contact the factory to get this information, but it is important to calculate actual capacity requirements to properly size your treatment system. And, if you are using OptiPure AMS (advanced membrane separation) it is essential to understand usage requirements in order to select a system with the proper production and storage capacity.

Flow and Pressure – Flow rates (in gallons per minute – GPM) can be found on equipment specification sheets and equipment manuals. Minimum and maximum pressure requirements are usually given along with the flow requirements. When selecting a filtration system, make sure its flow rate exceeds the requirements for your steam water connection. Specified flow rates often include required flow for condensate water and built-in cleaning systems. Actual flow requirements for steam generation are typically less.

Contact your OptiPure distributor or OptiPure for assistance selecting the right system for your business.