The following are several reasons to purchase an Ebbco Closed Loop Conditioning System:

1. No drain in facility or cannot overflow to machine tool drain: these

customers have no choice but to go with a closed loop system.

2. Water and sewage costs are very expensive: Most areas this is not an issue, with water and sewage cost under 1¢ per gallon

            or less. However, some areas we’ve seen are paying between 6¢ and 8¢ per gallon. If that is the case, a closed loop system

            will pay for itself because the consumables used will be less than the water/sewage cost. (Remember in most cases the costs

            on consumables for the closed loop system will exceed the water and sewage costs. This is obviously not the main

            selling feature for the closed loop system).

       3.  Well and septic system water quality: Typically well water is very hard with hardness and TDS between 300 and 800 PPM. This

            water must be treated before it goes to the high-pressure pump. These are normally treated with reverse osmosis systems.

            (Remember water softeners only reduce hardness, they do nothing for TDS). Whereas reverse osmosis systems will treat both.

            However, most R.O. systems require twice the water to generate the amount needed. In other words, if your waterjet machine needs

            1 gallon per minute run, then your R.O. system may need 2 gpm to produce the 1 gpm needed for your machine. This amount of water

            may overwhelm your septic field, especially when water is needed to cool the hydraulics on an intensifier pump.

            NOTE: A waterjet using 1 gpm running 50 hours per week for 50 weeks per year will use 150,000 gallons of water. Using an

                          R.O. system the yearly total will be 300,000 gallons of water.

        4.  Make up water treatment such as softeners, reverse osmosis, or DI water systems:

       5. There are five main reasons why a closed loop system should be considered for your abrasive waterjet systems.

1. Eliminate the drain completely! No dissolved solids go to drain. All overflow water is filtered and reused.

2. Reduce water consumption drastically – usually only 2% - 10% of normal usage.

3. Drastically reduce the requirement for make up water treatment such as softeners, reverse osmosis, or DI water systems. The small amount of make up water needed is treated before it goes to the high-pressure pump.

4. Maximize orifice life, reducing machine maintenance, maximizing machine performance.

5. Protect your high-pressure pump! The Ebbco closed loop system always supplies the pump manufacturers specified water conditioning water quality to the high-pressure pump. The results are reduced pump maintenance and machine tool downtime.

EBBCO'S CLOSED LOOP – HOW IT WORKS

The waterjet table overflows into the dirty side of the Ebbco closed loop system. This dirty water is pumped through a series of filters, filtering the water down to .35 micron (nominal). This water is sent through a chiller removing the heat incurred from the machining process. The water then passes through a filter, which controls the TDS, then into the clean tank. The clean tank overflows into the dirty tank constantly recirculating and filtering the water. A delivery pump is mounted in the clean tank to deliver the water to the high-pressure pump. The Ebbco closed loop system addresses the four main issues concerning water quality:

1. Suspended solids – garnet and metal particles are filtered through a series of filters.
2. Dissolved solids – metals dissolved in water from the machine process as well as make up water are controlled with our TDS filter monitory system.
3. Organic fouling – these systems include an ozone generator, which injects ozone (0₃) into the water to control bacteria growth (same used on hot tubs and pools). Biocides (such as chlorine or algaecide cannot be used because the TDS filter will remove these chemicals.
4. Controlling temperature – a chiller is used to maintain 70ºF temperature water which is delivered back to the high-pressure pump.

These four issues must be addressed by a closed loop system, because any one of these can be detrimental to the high-pressure pump.

The intensifier pump typically uses city water to cool the pump hydraulics. Ebbco’s closed loop system chiller can be sized to remove heat from the catch tank overflow as well as cooling the hydraulics on the intensifier pump (see figure 2). Ebbco Inc. does other waterjet filtration such as garnet removal systems, overflow to drain systems, and various chiller packages. See figure (3). Ebbco can also design and engineer central closed loop systems for shops with multiple machines. Many waterjet OEM’s are recommending Ebbco systems as options or as part of the system package. If you are considering a waterjet system or have a table where some of the above issues are a concern, please ask your machine dealer or call the Ebbco Waterjet Department direct at 586-716-5151.

1. No drain in facility
2. Drain not accessible
3. High water/ sewage costs
4. Poor make-up water quality (Above 200 PPM)
5. Well and septic water system
6. Over flow water to waste treatment (Chemical treatment or evaporator)
7. Cutting hazardous material (cannot discharge into local water supply)
8. Potential water rationing geographic area
9. Short seal life on high pressure pump
10. . Short orifice/ mixing tube life
11. . ISO 14000 (Company standard for environmental management)
12. . Incoming water supply not sufficient

• Take a sample (usually four or five pounds will do) of the spent abrasive to a local certified test lab for a TCLP test.
• A toxicity characteristic leeching procedure (TCLP) will give a breakdown of heavy metals from your spent abrasive sample.
• Contact your local waste (Waste Management, BFI, etc.) hauler Representative.
• Explain to your local waste hauler representative what you have (spent abrasive sample and TCLP results).
• Have your rep give you a legal allowable limit sheet on hazardous metals for your local Landfill.
• You and your rep will determine if your company is within the guidelines for normal waste hauling.

Note: In many parts of the country, even if your local waste hauler cannot or will not take the spent abrasive, it does not mean that it is classified as hazardous. Many states have "lined" landfills for industrial waste with heavy metals yet not hazardous waste. Your local waste hauler should be able to make a recommendation.

• If your rep determines that you can dispose of it in your dumpster, have him put it in writing,.
• This letter along with your TCLP test should be kept on file in your facility, if by chance your company was ever questioned by local authorities or the EPA.
• Normally, TCLP test are good for one full year from the test date as long as your cutting procedure has not changed. Consult your local testing lab for validity of test length and make sure it's dated.

WATER SAMPLE FROM TABLE OVERFLOW

• Take a sample (usually a pint or quart will do) of your table overflow water to a local test lab for a TCLP test.
• Contact your local wastewater facility. (Normally where you pay or send your water bill to).
• Ask them for a legal allowable limit sheet for your local wastewater.
• Verify your TCLP test results with your local wastewater spec sheet. If you are within the guidelines you can discharge into the drain.
• If you're not within local guidelines a try settling system and have the water re-tested and compare with your local wastewater spec sheet.
• If you still are not within the local guidelines you have two options.

1. Treat the water (DI or chemical treatment) and then perform another TCLP test and discharge into the drain. If it fails see option 2.
2. Purchase a closed loop recirculation system and reuse all the process water.

Note: In most cases the operating (filter) costs on a closed loop system are lower than treating the water and going to drain.

CLOSED LOOP RECYCLING SYSTEM

GENERAL INFORMATION

Machine Make / Model ______________________________________________

Pump Information__________H.P. Direct Drive or Interfere

Cutting Heads_________ Garnet Used (MFG.) __________________________

Approximate # of hrs. per week machine is used. ______hrs.

Existing Garnet Removal? Yes / No Existing Overflow System? Yes / No

Existing Chiller on System? Yes / No Existing Makeup Water System for Pump? Yes / No

If Yes, R.O / DI / Soft Is customers Makeup Water: City Water or Well Water

GARNET REMOVAL PAYBACK

How often do you service Catch Tank? ______weeks.

How much down time for draining/cleaning/refilling Catch Tank? _______________hrs.

How many employees used for Catch Tank service? ______

Is down time for Catch Tank cleaning a factor? Yes / No

Is disposal cost a factor? Yes / No

Is the handling of spent garnet a factor? Yes / No

Is morale of employees who service Catch Tank a factor? Yes / No

PAYBACK FORMULA

Down time _____hrs. x $150.00 per hr + ___# employees(hrs x $25) x 52 ÷ ___weeks.

Ex: 8 hrs x $150.00 = $1200.00 + 2(8 x $25) = $400.00 x 52 / 4= 13

$1200.00 + $400.00 = 1600 x 13 = $20,800.00

$20,800.00 / 12 months = $1733.33 per month

If system cost is $18,000.00 / $1733.33 = 10 ½ months payback

CLOSED LOOP RECIRCULATION PAYBACK

Average Seal life of pump? ________hrs. Approximate down time for pump service?____hrs.

Is down time for pump service a factor? Yes / No

Approximate Oriface/Jewel Life? _____hrs. Mixing tube_____hrs.

Cost of existing Water treatment? (If any)$________ Cost of Overflow System? (If any)$________

Is local Water/Sewage costs a concern? Yes / No TDS (Total Dissolved Solids) of city water_____p.p.m

Has Customer had overflow water tested? Yes / No

Water Consumption Calculation

Cutting Head(s) (Approximate 1 GPM per head)

_____# cutting heads x 60 min/hr x ___ hrs/week x 52 wk./yr. = ______ Total Year

Cooling Water

____GPM (Hydraulic cooling) x 60 min/hr x ___hr./wk x 52 wk./yr. = _____Year Total

Ex: Dual head table w/100 h.p. intensifier = 50hrs per week

(Cutting) 2 GPM x 60 min/hr x 50 hr/week x 52 wk./yr. = 312,000 gallons

(Cooling) 4 GPM x 60 min/hr x 50hr/wk x 52 wk/yr. = 624,000 gallons

Total per year = 936,000 gallons

Customers Floor Plan: Remember to show tank, pump, chiller, walls, aisles, overhead doors,

dimensions, etc.