*Imparts a charge to the water as
it passes through the magnetic field
*Causes calcium to be retained in solution rather than plating on
surfaces
*Reduces the odor and taste of sulfur in most cases
*Does not add anything to the water or take anything out
*Eliminates scale buildup
*Reduce the amount of chemicals needed in pools and spas
*WILL SAVE TIME, MONEY AND EFFORT IN MAINTAINING EQUIPMENT
Why is the PKU MFC the best product on the market?
Quality Control, we use the best materials available and the highest
grade of magnets. Our research has developed the most effective product
sold today and all units are checked prior to packaging to insure Zero
defects in the field.
Why do I need multiple units?
There are many factors that are critical to the performance of magnetic
water treatment products. One factor is energy imparted to the water.
PKU uses the most powerful Neodymium magnets available, not those weak
ceramic magnets that always fall off the refrigerator. They focus their
energy into the pipe which creates a long field for the water to pass
through. This power, coupled with longer contact time of the water to
the magnetic energy, equates to the most effective product available on
the market.
Will the product remove the minerals from the water?
No. The minerals that are in the water are good for your health. The
problem is that they are bad for your plumbing, the PKU MFC will keep
the minerals in solution so that they do not accumulate in your plumbing
Or on your water heater element.
How will the PKU MFC save me money?
The U.S. Bureau of Standards reports that just 3/8" of scale build-up
requires 55% more energy. That means an additional $247 more a year for
that same hot water.
I have a water softener. Can the PKU MFC be of any benefit to me?
Absolutely! Install the PKU MFC on the water line before your softener
and it will improve the efficiency of your softener by 40% to 60%. This
could save hundreds of dollars per year in water cost to back-flush, in
addition to the cost of salt. You will not be adding as much sodium to
your water or dumping sodium laden water into the waste water system.
Thereby doing your part to help conserve the environment.
What is the difference between a Salt based
softener and the PKU MFC?
PKU MFC Device
Salt Based Water
Softener
Compact unit you can install yourself
Household plumbing needs modification
Maintenance Free Operation
Requires Constant Maintenance
No Salt
No Electricity
No Plumbing
No Back Flushing
Requires Over 800 Pounds of Salt Each Year, Consumes
Electricity, Needs Plumbing Modifications and Will Waste Resources
Through Back Flushing
Controls and Minimizes Hard Water Scale
Won't Remove Existing Lime and Scale Build-up.
Will Not Corrode Water Heaters, Pipes and Fixtures.
Can Corrode Water Heaters, Pipes and Fixtures
Does Not Harm The Environment or Our Fresh Water Supply.
Pollutes Waterways, Hinders Septic Systems and Waste Water
Treatment Programs.
Feel Cleaner and Fresher After Bathing.
Feels Slippery and Unnatural and Can Irritate Sensitive Skin.
Retains Healthful Minerals.
Eliminates Healthful Minerals.
Safe For Heart Patients and Those With Hypertension.
Is Not Safe For Heart Patients and Those With Hypertension.
The PKU
System will pay for itself! It is Salt Free!
Everyone hates that crusty red or white deposit in pipes. It costs
Americans Millions of dollars per year in repairs and preventive measures
like Softwater treatment tanks and new water heaters.
We offer a device which requires NO
salt, NO electricity and NO maintenance!!!
Pipe before PKU
device
Pipe during PKU
device
Pipe after PKU device
Our MFC kit
includes everything you need to treat your house water supply. One MFC
kit for the cold water line and one MFC kit for the hot water heater inlet.
They install over your copper or plastic pipes. This system will not
work over iron pipes. The magnetic field cannot pass through the iron pipes.
Cost for 2 MFC kits is only $42.00 with free shipping
and handling.
Includes 2 MFC kits for hot and cold water.
You can pay with
check, money order, cash or www.paypal.com.
NeoMagnet.com
PO Box 3238
Oceanside, CA
92051
2 Kits Only $42.00
Pay with Visa, MC, AMEX, Discover
Our latest customer feedback below!
hi guys, i finally had a minute to let you know that i
couldnt be more happy with the water conditioning magnets that i just bought
from you. they are great! ive had them on my pipes for about three weeks now
and right from the start i had no more rust stains in my tub or sinks. thats
worth it alone! im beginning to think we can start buying white clothes
again. the tatse is better and powders mix in better,too. do your fuel line
magnets work as well? im seriously thinking about buying one. thanks again,
randy
Below is a report done by the
U.S. Department of Energy Technology
Alert # DOE/EE-0162
The U.S. Department of Energy requests that no
alterations be made without permission in any reproduction of this
report.
Non-Chemical Technologies for Scale and
Hardness Control
Technology for improving energy efficiency through the
removal or prevention of scale.
Abstract
The magnetic technology has been cited in the literature and
investigated since the turn of the 19th century, when lodestones and
naturally occurring magnetic mineral formations were used to decrease the
formation of scale in cooking and laundry applications. Today, advances in
magnetic and electrostatic scale control technologies have led to their becoming
reliable energy savers in certain applications.
For example, magnetic or electrostatic scale control
technologies can be used as a replacement for most water-softening equipment.
Specifically, chemical softening (lime or lime-soda softening), ion exchange,
and reverse osmosis, when used for the control of hardness, could potentially be
replaced by non-chemical water conditioning technology. This would include
applications both to cooling water treatment and boiler water treatment in
once-through and recirculating systems.
The primary energy savings from this technology result from
decrease in energy consumption in heating or cooling applications. This savings
is associated with the prevention or removal of scale build-up on a heat
exchange surface, where even a thin film can increase energy consumption by
nearly 10%. Secondary energy savings can be attributed to reducing the pump
load, or system pressure, required to move the water through a scale-free,
unrestricted piping system.
This Federal Technology Alert provides information and
procedures that a Federal energy manager needs to evaluate the
cost-effectiveness of this technology. The process of magnetic or eletrostatic
scale control and its energy savings and other benefits are explained.
Guidelines are provided for appropriate application and installation. In
addition, a hypothetical case study is presented to give the reader a sense of
the actual costs and energy savings. A listing of current manufacturers and
technology users is provided along with references for further reading.
The technology addressed in this FTA uses a magnetic or
electrostatic field to alter the reaction between scale-forming ions in hard
water. Hard water contains high levels of calcium, magnesium, and other divalent
cations. When subjected to heating, the divalent ions form insoluble compounds
with anions such as carbonate. These insoluble compounds have a much lower heat
transfer capability than heat transfer surfaces such as metal. They are
insulators. Thus additional fuel consumption would be required to transfer an
equivalent amount of energy.
The magnetic technology has been cited in the literature and
investigated since the turn of the 19th century, when lodestones or
naturally occurring magnetic mineral formations were used to decrease the
formation of scale in cooking and laundry applications. However, the
availability of high-power, rare-earth element magnets has advanced the magnetic
technology to the point where it is more reliable. Similar advances in materials
science, such as the availability of ceramic electrodes and other durable
dielectric materials, have allowed the electrostatic technology to also become
more reliable.
The general operating principle for the magnetic technology is
a result of the physics of interaction between a magnetic field and a moving
electric charge, in this case in the form of an ion. When ions pass through the
magnetic field, a force is exerted on each ion. The forces on ions of opposite
charges are in opposite directions. The redirection of the particles tends to
increase the frequency with which ions of opposite charge collide and combine to
form a mineral precipitate, or insoluble compound. Since this reaction takes
place in a low-temperature region of a heat exchange system, the scale formed is
non-adherent. At the prevailing temperature conditions, this form is preferred
over the adherent form, which attaches to heat exchange surfaces.
The operating principles for the electrostatic units are much
different. Instead of causing the dissolved ions to come together and form
non-adherent scale, a surface charge is imposed on the ions so that they repel
instead of attract each other. Thus the two ions (positive and negative, or
cations and anions, respectively) of a kind needed to form scale are never able
to come close enough together to initiate the scale-forming reaction. The end
result for a user is the same with either technology; scale formation on heat
exchange surfaces is greatly reduced or eliminated.
Application Domain
These technologies can be used as a replacement for most
water-softening equipment. Specifically, chemical softening (lime or lime-soda
softening), ion exchange, and reverse osmosis (RO), when used for the control of
hardness, can be replaced by the non-chemical water conditioning technology.
This would include applications both to cooling water treatment and boiler water
treatment, in once-through and recirculating systems. Other applications
mentioned by the manufacturers include use on petroleum pipelines as a means of
decreasing fouling caused by wax build-up, and the ability to inhibit biofouling
and corrosion.
The magnetic technology is generally not applicable in
situations where the hard water contains "appreciable" concentrations of iron.
In this FTA, appreciable means a concentration requiring iron treatment or
removal prior to use, on the order of parts per million or mg/L. The reason for
this precaution is that the action of the magnetic field on the hardness-causing
ions is very weak. Conversely, the action of the magnetic field on the iron ions
is very strong, which interferes with the water conditioning action.
A search of the Thomas RegisterTM in conjunction with manufacturer contact yielded
eleven manufacturers of magnetic, electromagnetic or electrostatic water
conditioning equipment that fell within the scope of this investigation. The
defined scope includes commercial or industrial-type magnetic, electromagnetic
or electrostatic devices marketed for scale control. Devices intended for home
use, as well as other non-chemical means for scale control, such as reverse
osmosis, are not within the extended scope of this FTA.
Figure 1. Diagram of General Magnetic Device
Construction
Exact numbers of units deployed by these manufacturers are
virtually impossible to compile, as some of the manufacturers had been selling
the technology for up to 40 years. One manufacturer claims as many as 1,000,000
units (estimated total of all manufacturers represented here) are installed in
the field. Where not withheld by the manufacturer because of business
sensitivity reasons, customer lists included both Federal and non-Federal
installations. Those manufacturers who did withhold the customer list indicated
a willingness to disclose customer contacts to legitimate prospective customers.
Literature provided by and discussions with manufacturers
described a typical installation for a boiler water treatment scheme as
including the device installed upstream of the boiler. Manufacturers vary in
their preference of whether the device should be installed close to the water
inlet or close to the boiler. Both locations have been documented as providing
adequate performance. Generally, the preferred installation location for use
with cooling towers or heat exchangers is upstream of the heat exchange location
and upstream of the cooling tower. Downstream of the cooling tower but upstream
of the heat source was also mentioned as a possible installation location,
primarily for the use with chillers or other cooling equipment.
The primary caveat on installation of the magnetic
technology is that high voltage (230V, 3-phase or above) power lines interfere
with operation by imposing a second magnetic field on the water. (This is most
noticeable when these electric power sources are installed within three feet of
a magnetic device.) This second magnetic field most likely will not be aligned
with the magnetic field of the device, thus introducing interference and
reducing the effectiveness of the treatment. Installations near high voltage
power lines are to be avoided if possible. Where avoidance is not possible, the
installation of shielded equipment is recommended to achieve optimum operation.
Some manufacturers also have limitations on direction of installation--vertical
or horizontal--because of internal mechanical construction.
Energy-Savings Mechanism
The primary energy savings result from a decrease in energy
consumption in heating or cooling applications. This savings is associated with
the prevention or removal of scale build-up on a heat exchange surface where
even a thin film (1/32" or 0.8 mm) can increase energy consumption by nearly
10%. Example savings resulting from the removal of calcium-magnesium scales are
shown in Table 1. A secondary energy savings can be attributed to reducing the
pump load, or system pressure, required to move the water through a scale-free,
unrestricted piping system.
Table 1. Example Increases in Energy Consumption as a
Function of Scale Thickness
Scale Thickness (inches)
Increased Energy Consumption
(%)
1/32
8.5
1/16
12.4
1/8
25.0
1/4
40.0
As was discussed above, magnetic and electric fields interact
with a resultant force generated in a direction perpendicular to the plane
formed by the magnetic and electric field vectors. (See Figure 2 for an
illustration.) This force acts on the current carrying entity, the ion.
Positively charged particles will move in a direction in accord with the
Right-hand Rule, where the electric and magnetic fields are represented by the
fingers and the force by the thumb. Negatively charged particles will move in
the opposite direction. This force is in addition to any mixing in the fluid due
to turbulence.
Figure 2. Diagram Showing Positioning of Fields and
Force
The result of these forces on the ions is that, in general,
positive charged ions (calcium and magnesium, primarily) and negative charged
ions (carbonate and sulfate, primarily) are directed toward each other with
increased velocity. The increased velocity should result in an increase in the
number of collisions between the particles, with the result being formation of
insoluble particulate matter. Once a precipitate is formed, it serves as a
foundation for further growth of the scale crystal. The treatment efficiency
increases with increasing hardness since more ions are present in solution; thus
each ion will need to travel a shorter distance before encountering an ion of
opposite charge.
A similar reaction occurs at a heat exchange surface but the
force on the ions results from the heat input to the water. Heat increases the
motion of the water molecules, which in turn increases the motion of the ions,
which then collide. In addition, scale exhibits an inverse solubility
relationship with temperature, meaning that the solubility of the material
decreases as temperature increases. Therefore, at the hottest point in a heat
exchanger, the heat exchange surface, the scale is least soluble, and,
furthermore due to thermally induced currents, the ions are most likely to
collide nearest the surface. As above, the precipitate formed acts as a
foundation for further crystal growth.
When the scale-forming reaction takes place within a heat
exchanger, the mineral form of the most common scale is called calcite. Calcite
is an adherent mineral that causes the build-up of scale on the heat exchange
surface. When the reaction between positively charged and negatively charged
ions occurs at low temperature, relative to a heat exchange surface, the mineral
form is usually aragonite. Aragonite is much less adherent to heat exchange
surfaces, and tends to form smaller-grained or softer-scale deposits, as opposed
to the monolithic sheets of scale common on heat exchange surfaces.
These smaller-grained or softer-scale deposits are stable upon
heating and can be carried throughout a heating or cooling system while causing
little or no apparent damage. This transport property allows the mineral to be
moved through a system to a place where it is convenient to collect and remove
the solid precipitate. This may include removal with the wastewater in a
once-through system, with the blowdown in a recirculating system, or from a
device such as a filter, water/solids separator, sump or other device
specifically introduced into the system to capture the precipitate.
Water savings are also possible in recirculating systems
through the reduction in blowdown necessary. Blowdown is used to reduce or
balance out the minerals and chemical concentrations within the system. If the
chemical consumption for scale control is reduced, it may be possible to reduce
blowdown also. However, the management of corrosion inhibitor and/or biocide
build-up, and/or residual products or degradation by-products, may become the
controlling factor in determining blowdown frequency and volume.
Other Benefits
Aside from the energy savings, other potential areas for
savings exist. The first is elimination or significant reduction in the need for
scale and hardness control chemicals. In a typical plant, this savings could be
on the order of thousands of dollars each year when the cost of chemicals, labor
and equipment is factored in. Second, periodic descaling of the heat exchange
equipment is virtually eliminated. Thus process downtime, chemical usage, and
labor requirements are eliminated. A third potential savings is from reductions
in heat exchanger tube replacement due to failure. Failure of tubes due to scale
build-up, and the resultant temperature rise across the heat exchange surface,
will be eliminated or greatly reduced in proportion to the reduction in scale
formation.
Variations
Devices are available in two installation variations and three
operational variations. First to be discussed are the two installation
variations: invasive and non-invasive. Invasive devices are those which have
part or all of the operating equipment within the flow field. Therefore, these
devices require the removal of a section of the pipe for insertion of the
device. This, of course, necessitates an amount of time for the pipe to be out
of service. Non-invasive devices are completely external to the pipe, and thus
can be installed while the pipe is in operation. Figure 3 illustrates the two
installation variations.
Figure 3. Illustration of Classes of Magnetic Devices by
Installation Location
The operational variations have been mentioned above;
illustrations of the latter two types are shown Figure 4:
Magnetic, more correctly a permanent magnet
Electromagnetic, where the magnetic field is generated via
electromagnets
Electrostatic, where an electric field is imposed on the
water flow, which serves to attract or repel the ions and, in addition,
generates a magnetic field.
Figure 4. Illustration of Classes of Non-Permanent Magnet
Devices
Electrostatic units are always invasive. The other two types
can be either invasive or non-invasive. The devices illustrated in Figure 3 are
examples of permanent magnet devices.
Installation
Most of the devices are in-line--some invasive, some
non-invasive--as opposed to side-stream. The invasive devices require a section
of pipe to be removed and replaced with the device. Most of the invasive devices
are larger in diameter than the section of pipe they replace. The increased
diameter is partially a function of the magnetic or electromagnetic elements,
and also a function of the cross sectional flow area. The flow area through the
devices is generally equivalent to the flow area of the section of pipe
removed.
The non-invasive in-line devices are designed to be wrapped
around the pipe. Thus downtime, or line out-of-service time, is minimized or
eliminated.
The potential cost-effective savings achievable by this
technology were estimated as part of the technology assessment process of the
New Technology Demonstration Program (NTDP).
Technology Screening Process
New technologies were solicited for NTDP participation through
advertisements in the Commerce Business Daily and trade journals, and,
primarily, through direct correspondence. Responses were obtained from
manufacturers, utilities, trade associations, research institutes, Federal sites
and other interested parties. Based on these responses, the technologies were
evaluated in terms of potential Federal-sector energy savings and procurement,
installation, and maintenance costs. They were also categorized as either just
coming to market ("unproven" technologies) or as technologies for which field
data already exist ("proven" technologies).
The energy savings and market potentials of each candidate
technology were evaluated using a modified version of the Facility Energy
Decisions Screening (FEDS) software too (Dirks and Wrench, 1993).
Non-chemical water treatment technologies were judged
life-cycle cost-effective (at one or more Federal sites) in terms of
installation cost, net present value, and energy savings. In addition,
significant environmental savings from the use of many of these technologies are
likely through reductions in CO2, NOx, and SOx
emissions.
Estimated Savings and Market Potential
As part of the NTDP selection process, an initial technology
screening activity was performed to estimate the potential market impact in the
Federal sector. Two technologies were run through the assessment methodology.
The first technology was assessed assuming the technology was applied to the
treatment of boiler make-up water. The second technology was assessed assuming
the technology was applied to both the treatment of boiler make-up water and
cooling tower water treatment. The technology screenings used the economic basis
required by 10 CFR 436. The costs of the two technologies were different based
on information provided by the manufacturers, thus leading to different
results.
The technologies were ranked on a total of ten criteria. Three
of these were financial, including net present value (NPV), installed cost, and
present value of savings. One criterion was energy-related, annual site energy
savings. The remaining criteria were environmental and dealt with reductions in
air emissions due to fuel or energy savings and included SO2,
NOx, CO, CO2, particulate matter and hydrocarbon
emissions.
The ranking results from the screening process for this
technology are shown in Table 2. These values represent the maximum benefit
achieved by implementation of the technology in every Federal application where
it is considered life-cycle cost-effective. The actual benefit will be lower
because full market penetration is unlikely to ever be achieved.
Table 2. Screening Criteria Results
Screen Criteria
Results
First Screen
Second Screen
Net Present Value ($) Installed Cost ($) Present
Value of Savings ($) Annual Site Energy Savings (Mbtu)
SO2 Emissions Reduction (lb/yr) NOx
Emissions Reduction (lb/yr) CO Emissions Reduction (lb/yr)
CO2 Emissions Reduction (lb/yr) Particulate Emissions
Reduction (lb/yr) Hydrocarbon Emissions Reduction (lb/yr)
Note: First Screen: Boiler make-up water
treatment. Second Screen: Cooling tower water treatment and boiler
make-up water treatment.
Laboratory Perspective
The primary question to be answered is "Does the technology
work as advertised?" The history of the technologies, as illustrated through
primarily qualitative--but some quantitative--assessment in many case studies,
has shown that when properly installed, a decrease in or elimination of scale
formation will be found. While the evidence supporting the technologies may be
thought of as mainly anecdotal, the fact remains that upon visual inspection
after installation of these devices the formation of new scale deposits has been
inhibited. In addition, in most cases, scale deposits present within the system
at the time of installation have been removed.
The key here is properly installed. By this it is meant
that a manufacturer or their qualified representative is responsible for
equipment integration. Unlike many other technologies where much of the
knowledge has been reduced to a quantitative model, the non-chemical water
treatment industry still relies largely on experience as the means of providing
quality installation, service and, consequently, customer satisfaction.
Of particular interest to the manufacturer would be physical
parameters such as water flow rate, and water quality parameters such as
hardness, alkalinity, and iron concentration. These parameters will help
determine the optimum size and the extent of treatment.
The manufacturer may also want to know whether the installation
is for use in conjunction with a boiler or a cooling tower, and for once-through
or recirculating water systems. These parameters will help determine the optimum
location within the system.
Other factors of interest may include whether the cooling or
heating system is sensitive to particulate matter, and if so what particle
sizes. The device works by initiating the precipitation of scale, thus
particulate matter will be present in the treated water. If the system is
sensitive to particulate matter there may be a need for a solid separation
device such as a filter, a settling basin, a cyclone, or a sump to collect
solids and to allow for their easy removal from the system.
This section addresses the technical aspects of applying the
technology. The range of applications and climates in which the technology can
be applied are addressed. The advantages, limitations, and benefits in each
application are enumerated. Design and integration considerations for the
technology are discussed, including equipment and installation costs,
installation details, maintenance impacts, and relevant codes and standards.
Utility incentives and support are also discussed.
Application Screening
As mentioned previously, the technology can be applied wherever
hard water is found to cause scale. Since the technology is a physical process,
as opposed to chemical water softening, it is expected to perform best in
locations with harder water. In general, only a few locations do not require or
would not benefit from some type of hardness control. Hard water is one in which
the hardness is greater than 60 mg/L (or ppm) as calcium carbonate. This
corresponds to approximately 3.5 grains of hardness per U.S. gallon. The Pacific
Northwest states, the North Atlantic coastal states, and the Southeast states,
excluding Florida, are locations where naturally occurring soft water is most
likely to be found. The balance of the United States could benefit from some
type of water treatment to control scale formation, using either one of the
traditional technologies such as lime softening or ion exchange, or the
non-chemical technology discussed in this FTA.
Where to Apply
Non-chemical scale control technologies can be used for either
boiler scale control or cooling tower scale control. Boiler scale control
applications are the majority of the installations, but the control of silica
scale in cooling water applications is also possible. Experience has been cited
with both retrofit installations and in new installations (see References for a
brief listing of applicable reports and publications).
Non-chemical scale control technologies are best applied:
When the use of chemicals for water treatment is to be
minimized or eliminated. Lime, salt and acid for cleaning can be reduced or
eliminated.
When space requirements do not allow installation of lime
softening equipment or ion exchange equipment. The non-chemical technologies
are generally very space efficient.
When particulate matter in the water can be tolerated by the
process; otherwise solids separation is required.
When frequent system shutdowns are required for descaling
even with a diligent chemical scale control program.
In remote locations where delivery of chemicals and labor
cost makes conventional water softening or scale control methods cost
prohibitive.
What to Avoid
There are a few precautions to be noted before selecting the
technology:
This technology is littered with disreputable manufacturers
or vendors, the actions of whom have given the technology an undesirable
history in the eyes of many. Work with a reputable manufacturer (such as those
included herein) through their engineering department or their designated
installer. These people have much more experience with the technology than the
typical water treatment engineering firm.
Be aware of process water requirements since these
requirements may dictate the need to install solids separation equipment or
iron removal equipment in order to maximize the performance of the technology.
Installation near high voltage electrical equipment or strong
magnetic fields is to be avoided since these fields will interfere with the
performance of the technology. (Near is relative to the voltage; for
208/220/240V it means within 36 inches; for higher voltages it is
proportionally more distant.) Also, check the pipeline for its use as an
electrical ground. Stray electrical current in the pipe will have the same
effect as installation near a strong electrical or magnetic field.
Installation
Installation issues with these devices are few. The first issue
is whether a permanent magnet or one of the electronic devices is chosen. The
latter needs a suitable supply of electricity.
The second issue is device capacity, which will dictate space
requirements and pipe size. The pipe size generally determines the fittings.
Smaller devices, up to approximately 2" pipe size, are available with solder or
pipe thread fittings. Larger devices may have flange fittings that would
necessitate the installation of matching flanges in the current pipe
arrangement.
The third issue is the potential for downtime, which needs to
be coordinated with other facility activities. However, this should not be a
major impediment since downtime for cleaning and maintenance of cooling towers,
or boiler inspection is part of the regularly scheduled activities for most
installations.
A fourth issue would arise with the corrosion control
chemistry, which will likely need some adjustment under a non-chemical scale
control technology. In many cases the layer of scale on heat transfer surfaces
is beneficial from a corrosion control standpoint. With this layer not present
when using a non-chemical technology, the concentration of corrosion control
chemicals may need adjustment in order to provide the proper protection. On the
reverse side, many users are claiming the presence of a fine powdery film on the
surfaces the treated water contacts. This powder has been attributed to serve as
a corrosion inhibitor.
The most significant issue may be whether a solids separation
device is needed to remove the particulates formed. Filters, hydrocyclones, and
settling basins are all compatible with the technology. The choice among these
or other solids separation technologies should be made in conjunction with the
manufacturer who will have the best idea of particle size distribution, and thus
the relative efficiencies of the separation technologies.
Maintenance Impact
There is a significant, positive impact on maintenance. Field
applications have shown the technology to be capable of controlling scale for
extended periods of time, months or years, eliminating the periodic cleaning or
descaling of process equipment that is typical of conventional, chemical-based
scale control technologies. The resources--time, chemicals, and
equipment--previously devoted to periodic scale removal from heat exchange
surfaces will be made available for other tasks. Note, however, the need for
periodic inspection of the heat exchange surfaces is not reduced or
eliminated.
The electrostatic devices also require periodic inspection of
the electrodes. This scheduled maintenance activity can be performed in
conjunction with the heat exchange surface inspection and requires less than a
person-day to disassemble and inspect the system.
Equipment Warranties
All of the manufacturers offer some type of warranty on their
respective device. The range is from 90 days to as much as 10 years.
Another perspective is the potential impact upon warranties for installed
equipment. No information was uncovered as part of this effort to indicate any
instance where a boiler or cooling tower equipment manufacturer voided a
warranty for equipment. However, no specific effort was made to contact
manufacturers of boilers and cooling tower equipment to assess specific warranty
conditions or policies.
Codes and Standards
Only one code or standard specific to the non-chemical
technologies was identified in the course of preparing this FTA: API 960,
Evaluation of the Principles of Magnetic Water Treatment, 09/1985,
89 pages. Of course, all applicable plumbing, piping, mechanical, and/or
electrical codes and standards would still apply.
Costs
Cost information was requested from each manufacturer for three
different-size units, based on flow rate: 1 gpm (gallons per minute), 100 gpm
and 1,000 gpm. As is typical of process equipment, cost per unit of treatment
decreases with increasing capacity. To treat 1 gpm, a typical cost was on the
order of $100, or about $100 per gpm. To treat 1,000 gpm a typical cost was on
the order of $10,000, or about $10 per gpm.
In general, the electronic units were more costly than the
magnetic units for an equivalent flow rate. Costs also ranged considerably with
unit size, with the 1-gpm units ranging in cost up to $500. For the 1,000-gpm
units the range of costs was considerably greater, from $900 to over
$1,000,000.
Installation costs also varied widely, in conjunction with
equipment size. The lower flow rate units will mate with 3/4" to 1" pipe sizes
with soldered, flanged or threaded (NPT) fittings. Installation time estimates
were on the order of one hour, with additional parts costing less than $10. The
larger-size units (1,000 gpm) were typically designed to mate with a 12" to 18"
pipe using a flange fitting. Estimated installation time ranged from one to four
person-days, requiring less than $1,000 in additional materials.
Weight was an important characteristic in the installation
estimate because the permanent magnet units may exceed 1,000 pounds. There is a
trade-off between installing a heavier permanent magnet unit requiring no
outside power versus a lighter electronic unit for which an electrical
connection needs to be made, and possibly electrical lines run to the point of
installation. The net effect is expected to be neutral with regard to
installation time estimates.
Since these units are typically delivered in the sizes quoted
off-the-shelf, there is no design cost by the manufacturer. Facilities
engineering and design for calculations and updating plant drawings should
amount to less than two person-days for the large units, and less than an hour
for the small units.
Utility Incentives and Support
Although no specific incentive programs were identified, the
Department of Energy and the Advanced Research Projects Agency have funded
research in this area. Some utility or trade associations have supported the
electronic technologies with funds and exposure. For example, the American Water
Works Association sponsored a conference to discuss the non-traditional
treatment technologies. In addition, as California municipalities face water
shortages, they have turned to a number of measures to lower water consumption
and increase water quality. Many have prohibited the use of water softeners and
may offer assistance infunding conversion to low/no salt water conditioning
technologies.
Additional Considerations
There are additional considerations to be taken into account.
Primary among these is the reduction in chemical use at the facility for water
softening. The chemical use reduction may lead to reduced safety, training and
reporting requirements.
Electricity consumption will also be reduced. The actual
reduction is highly dependent upon the technology employed. Permanent magnets
use no electricity, so both the on-site electricity used for chemical treatment
as well as the off-site energy required to produce and transport the chemicals
will be eliminated. For the electronic units, on-site energy requirements may
vary from as little as 10% of the chemical-based treatment system energy
consumption--typical, to 10 times the energy consumed by the chemical-based
treatment system.
Energy consumption reductions will lead directly to reductions
in air combustion emissions. There will also be additional indirect reductions
due to decreased transportation of fuels and decreased fuel processing. The
latter will also lead to reductions in water use, water pollution, and solid
wastes from mining and processing operations.
The information in this section was compiled primarily from
case studies, along with selected contact with users and third party
researchers. As mentioned previously, the use of magnetic or electric fields to
treat water had its origins near the turn of the 19th century.
Commercialization of the technology began after World War II, with the largest
advances coming in the last 20 years with the development of rare earth magnets
and inexpensive electronic controls.
There are records of installation of the technology in the
United States from about 1950. Manufacturers claim to have installations
operating satisfactorily for as long as 30 years. No good statistics were
available on the total number of installations over this period. However, using
the estimates of one manufacturer as a basis, there could be upwards of
1,000,000 units installed in the United States in commercial or industrial
facilities, inclusive of all units installed by all manufacturers.
Field Experience
As has been alluded to above, user experience has been
positive. Two experiences have been common. First, users have noted a dramatic
reduction in scale formation to the point where the need for chemical scale
control is eliminated. Second, the prior build-up of scale on heat exchange
surfaces has been removed over time. This last process has been noted as taking
from 30 days to over a year, depending upon the thickness and composition of the
scale.
This is not to say there have not been less than successful
installations or applications. The non-chemical technologies may not be
universally applicable for scale control, just as any technology may not be a
universally applicable solution to the problem it was designed to solve.
The magnetic technologies are not as effective when silica is
present in the system. Nor do they work as efficiently when iron is present, as
was mentioned above, or when other magnetic minerals are present. The history of
the technology is also littered with cases where the magnet field was applied
incorrectly or did not have sufficient strength to affect the reaction. This
latter was especially true early in the life cycle of the technology when
ferrous-based magnets were the norm. High levels of particulate matter will also
negatively influence the efficiency of the technology by reducing the collision
frequency of the desirable reactions.
Energy Savings
Energy savings result from both reductions in pumping energy
input to the system and reduction in fuel consumption. The first aspect has not
been well quantified by the users or in any of the case studies. It is thought
of as a secondary benefit.
Fuel consumption has been lowered in every situation. The exact
savings are a result of a number of factors:
How effective the chemical scale control program may have
been relative to the input water hardness
How often the heat exchange system was taken down for
maintenance and cleaning.
On systems that were descaled frequently or had low scale
formation, due to low hardness and/or an effective chemical scale control
program, the savings in fuel consumption was lower, often from a few percent to
as much as 15%. The lower savings were at an installation using ion exchange
softening of moderately hard water (less than 150 mg/L as calcium carbonate
hardness). On systems where descaling was infrequent or absent altogether, or
where the chemical scale control program was not as effective in controlling
scale formation, fuel consumption savings ranged up to 30%. This was found to be
the case in an installation using very hard water (hardness in excess of 300
mg/L as calcium carbonate), andd a chemical scale control program, with heat
exchanger tubes closing due to scale formation after less than one year. In each
case the fuel consumption savings was proportional to the thickness of the scale
layer removed.
One important note was that fuel consumption savings often
trailed installation of the technology by a significant period due to the fact
that the savings is driven by the amount of scale on the heat exchange surface.
The accumulated scale will erode over time, resulting in fuel consumption
reductions. For this reason, many of the manufacturers recommend installing the
technology only after the system has been descaled, thus savings in fuel
consumption would be immediate.
Maintenance
As mentioned above, maintenance requirements typically are
reduced upon implementation of the non-chemical technology. First, periodic
maintenance of the water-softening equipment and chemicals is eliminated.
Second, the periodic heat exchanger inspection and cleaning cycle is reduced to
an inspection cycle. The handling and storage requirements for the
chemicals--lime, soda ash, salt and acid--have been eliminated, as has training
for their use, storage and handling. The reduction in these periodic activities
frees up the previously time allocated for application to other activities.
There are maintenance activities associated with this
technology. For the electromagnetic and electrostatic units, a daily check that
the power is on is necessary (a "power on" indicator light is included with
most, if not all, units). The electrostatic units need to have the electrodes
checked periodically, semi-annually, and the electrodes replaced when noticeably
worn or damaged, perhaps every five years. The reader should speak to the
manufacturer for details which may vary.
When solids or particulates accumulate in the system, they will
need to be removed. Automatic blowdown of the system should control the daily
accumulation. If the system is not cleaned prior to installation of the
non-chemical technology, the scale in the system will detach and its removal
will be necessary. Filters, sumps and hydrocyclones are all effective means of
capturing the solids, but each will require periodic cleaning.
Environmental Impacts
There are areas where the technology mitigates environmental
impacts. The first is air quality due to emissions reduction associated with
decreases in fuel consumption. The second is a corresponding decrease in solid
wastes, ash and other fuel combustion residues to be disposed. Of course, this
will only be applicable in the situation in which an end user combusts fuels
on-site for the production of power. A third area is the reduction in release,
or potential for release, of water treatment chemicals stored at a facility.
Since chemical consumption will decrease, emissions from storage will also
decrease. The wastes associated with disposal and management of used chemical
containers will also be reduced.
For the case study, a hypothetical facility is used and the
application of a permanent magnet device is described. The conditions are based
on information gathered during the user interviews and reading of published and
unpublished case studies. The purpose is to illustrate the types of data
required to prepare a site-specific cost analysis, not to illustrate what any
particular user might experience in the way of cost savings.
Facility Description
The facility currently uses extremely hard water (hardness of
350 mg/L as calcium carbonate) and employs lime softening. The process water is
used in a recirculating boiler water system with flow of 1,000 gpm or 1.4 MGD
(million gallons per day). Makeup and blowdown were estimated at 10% of the
flow, or 140,000 gallons per day. The water-softening process removes a
significant fraction of the hardness, but not all, leading to semiannual
inspections and annual cleaning of the heat exchanger. This frequency is thought
to be fairly typical.
Cost for the lime used in the process is estimated at $10/ton
delivered. Cost for natural gas is $5.80/1000 ft3. Acetic acid, used
for cleaning, costs $2 per gallon.
Existing Technology Description
The current system is a conventional lime softening plant
consisting of lime storage facilities, a slaker where the powered lime is mixed
with water, a mixing basin for adding controlled amounts of the lime solution to
the water, and a settling basin where the precipitated solids are removed.
Downstream of the water treatment facilities is a conventional shell-and-tube
heat exchanger used to heat the water for both building heat and process
water.
Lime consumption for softening is 48 tons/year. In this case,
alkalinity is sufficient so as to not require the addition of soda ash during
the softening process. Natural gas consumption for process water heating is
400,000 MBtu/year. Electricity consumption for the softening process was
estimated at 3,100 kWh per year. Acetic acid is used during cleaning,
approximately 100 gallons per cleaning. Production losses due to system downtime
are not being included in this analysis.
(If the system had instead used ion exchange softening, the
applicable chemical use information would have been the regenerant, typically
salt but possibly acid, and the consumption of ion exchange resin. This last
item is calculated as the mass replaced divided by the total volume of water
treated.)
Data on lime consumption can typically be found in purchasing
records, or also in a water treatment system operator's log. The latter would be
more accurate since it would more closely reflect lime used for water softening,
whereas the former would list only lime purchases including those for water
softening, pH adjustment and other uses.
Natural gas consumption, or other fuel consumption data, can be
taken from accounting records, if the only use of natural gas is for process
water, or from operation data, (e.g., firing rate data), or calculated from an
energy balance for a portion of the production system. The firing rate data or
other operation data would be the most accurate but might not always be
available.
Electricity consumption information can be calculated from
nameplate capacity of the mixing and pumping equipment involved. For this
report, it was derived from information compiled by the Electric Power Research
Institute. In some cases there may be energy or monitoring data available for
the process that would be available as part of the water treatment system
operator's records.
New Technology Equipment Selection
A magnetic scale control device will be investigated as an
alternative to chemical scale control. The first step was consultation with the
manufacturer, including submitting water analysis data and a schematic of the
current system showing the proposed location of the equipment to facilitate
manufacturer selection and equipment sizing. (A magnetic device was chosen
because the preferred installation location was remote, with electrical power
not readily available.)
For the proposed location and required flow rate, a unit was
identified that would fit the current piping configuration without a need for
adapters. The unit cost is $10,000 including shipping. The estimate by the
in-house facilities engineering staff calls for three days to install the
system, one-half day each for set-up and clean-up, one day to remove a section
of pipe to make space for the device (including installing flanges), and one day
for installation and leak testing. Three people are required, as well as a
device capable of lifting 1,000 pounds in order to position the device and
facilitate removal of the old section of pipe.
One of the key elements to sizing these devices is the water
velocity through the device. Manufacturers recommend, typically, at least a 7
feet per second water velocity. If the water velocity through a section of pipe
is too low, it will be necessary to use adapters to decrease the size of the
pipe through the device, thus increasing the velocity. Water velocity in feet
per second can be calculated as follows, where Diameter is in feet:
Savings are expected to result from discontinuance of chemical
consumption and decreased energy consumption (10% of process energy and all of
the water treatment energy). Inspection will still occur.
Savings Potential
Energy savings can result from two areas. First is the
reduction in fuel used in generating heat. Methods for calculating the fuel
consumption were discussed above in the technology descriptions. The fuel
consumption savings is simply the net difference, in this case estimated equal
to 10% of the baseline fuel consumption. (This estimated savings was used to
illustrate a case where there was a fairly uniform 1/16" thick layer of scale
across a heat exchanger surface. Of course, it is realized that the scale layer,
and therefore energy consumption, builds over time and is not an instantaneous
effect.) This savings is also equal to the loss in heat transfer efficiency due
to scale formation on the heat exchange surface.
Second is the energy savings resulting from decreased pressure
drop within the heat exchanger. This is not quantified here, but could be
quantified if the pressure drop through the current system was known, along with
the energy characteristics of the pump so that reductions in pressure could be
related to energy consumption.
Cost savings also result from reductions in chemical use.
Chemical softening will be reduced, and likely eliminated, by the use of
non-chemical treatment technologies. There will also be a corresponding energy
decrease from the shutdown of chemical mixing equipment and water treatment
equipment used in the softening process. The estimated chemical savings here was
480 tons per year and the corresponding electricity savings was 31,000 kWh per
year.
Table 3 illustrates typical consumption data for the baseline
and alternative and the potential annual costs savings. Not shown are water
consumption and water discharge, which do not change between the alternatives.
Capital cost for the alternative treatment system, estimated at $10,000 at the
beginning of the 15-year analysis period, is not shown either. Fifteen years was
chosen because it was typical of the life of field units.
The full results of the BLCC computations are shown in Appendix
B. A discussion of the BLCC software is given in Appendix A. The BLCC
Comparative Economic Analysis is shown in Figure 5. Installation cost for the
magnetic treatment device is estimated at $10,360, calculated as $10,000 for the
device and $360 for design and installation labor. Operating costs for the
technology are estimated at $2,088,000 per year versus costs of $2,320,635 per
year for the conventional lime-softening technology, both exclusive of water
consumption and discharge. Life-cycle costs for each of the technologies as
calculated by the BLCC software are $27,524,500 for the magnetic technology
versus $30,283,500 for the conventional technology. (This includes the cost of
water and wastewater disposal of $2,605,292.) This represents a life-cycle cost
savings of $2,759,000. The Simple Payback from BLCC is less than one year, and
the Adjusted Internal Rate of Return is 50.66%.
The future of non-chemical water treatment technologies is
promising. As public awareness of the environmental effects of chemicals
increases there will be an increasing demand to deploy alternative, more
environmentally beneficial technologies. As a means of reducing energy
consumption and stretching the available personnel resources in the days of
ever-shrinking budgets, non-chemical technologies make sense as both cost
effective and having demonstrated performance.
The Technology's Development
Magnetic and electrical effects on water were first noticed
prior to the turn of the 20th century. Considerable research is being
conducted on magnetohydrodynamics by the Japanese as a means of propulsion, and
similar research has been conducted in the past in the United States and other
industrialized countries. This research has been facilitated by the advent of
rare earth magnets, solid state electronics, and advanced ceramic or polymeric
materials after World War II. Only after these advances has non-chemical water
treatment shown promise and come into more widespread use.
Of the manufacturers listed in this FTA most have come into
existence since the advent of the environmental movement in the United States in
the early 1970s. This can be attributed both to the advent of cost-effective
components (e.g., magnets, electronics) and to the public desire for more
"green" or environmentally friendly alternatives to chemical treatment.
Relation to Other Technologies
The use of the non-chemical technologies does not prohibit the
use of any other technology or equipment. As was mentioned previously, the
change from chemical to non-chemical scale control may warrant investigation of
other means of corrosion or biofouling control, as these three chemical scale
treatment or control strategies or applications are often balanced amongst each
other.
An increase in cycles of concentration was also noted by one
user as another water saving measure that was employed. The ability to increase
the cycles of concentration was attributed to the stability of scale-forming
ions or scale particles in suspension. Water consumption was halved in this
multi-pass system.
Technology Outlook
There is no basis to assume that the technologies are going to
disappear anytime soon. Each has a historical basis of successful installations.
Advances in materials science should only serve to improve each of the
technologies. More powerful magnets will allow the magnetic devices to become
smaller and/or more efficacious. More durable electrodes and dielectric
compounds will improve the life of the electrostatic units.
Probably the most significant trend is the move away from
chemical treatment technologies. This trend has begun at the consumer level, is
becoming apparent at the corporate level, and will continue to grow. Increased
availability of information on the technologies, the environment, and human
health will only serve to feed this trend.
The following is a listing of manufacturers of these
technologies compiled from the Thomas Register and those who have contacted FEMP
directly. It has been limited to U.S. manufacturers; foreign manufacturers or
U.S. affiliates of foreign manufacturers were not included. No effort was made
to locate and include manufacturers not listed in the Thomas Register. This
listing does not purport to be complete, to indicate the right to practice the
technology, or to reflect future market conditions.
Included here are but a few of the installations provided by
the manufacturers. For a full listing the reader is advised to contact a
manufacturer directly. Some manufacturers expressed concern about printing
customer names in a public list such as this Federal Technology Alert but
indicated they could provide such customer references to interested potential
buyers. Most manufacturers specify having hundreds to almost 10,000
installations. Not all of these sites were contacted during the course of
preparing this FTA.
GSA, Suitland, MD
National Aeronautics and Space Administration, multiple
locations United States Coast Guard, multiple locations
United States Air Force, Luke AFB, Phoenix, AZ
United States Army Corps of Engineers, Sacramento District,
Sacramento, CA
United States Environmental Protection Agency, Andrew W.
Breidenbach Environmental Research Center, Cincinnati, OH (Rich Koch and Bob
Banner, Cleveland Telecommunications Corporation)
United States Postal Service, multiple locations
Non-Federal Sites
Arnold Printing, Cincinnati, OH (Hank Majeushi, 513/533-9600)
No trade associations exist that are specific to the
non-chemical water treatment technology manufacturers. The following
associations are general water quality associations.
American Water Works Association 6666 West Quincy Ave Denver, CO
80235 303/794-7711
Cooling Tower Institute P.O. Box 73383 Houston, TX 77273
713/583-4087
Water Quality Association 4151 Naperville Road Lisle, IL 60532
708/505-0160
Consultants
Robert A. Marth 340 Central Avenue Sunnyvale, CA 94086
408/746-0964 Fax: 408-737-0291
T. Craig Molden Water Service Technology/NWI P.O. Box 545 Michigan
City, IN 46361 219/879-8425 Fax: 219/879-8852
User and Third Party Field Test Reports
The following references represent only a small sample of the
published work on these technologies. The references here are intended to give
the reader an indication of the history of scientific research on the topic as
well as the sponsoring agencies and interested audiences.
Alleman, J. 1985. Quantitative Assessment of the
Effectiveness of Permanent Magnet Water Conditioning Devices. Purdue
University. Sponsored by and protocol by Water Quality Association.
American Petroleum Institute. 1985. Evaluation of the
Principles of Magnetic Water Treatment, Publication 960.
Baker, J.S., and S.J. Judd. 1996. "Magnetic Amelioration of
Scale Formation." Water Research, 30(2):247-260.
Benson, R.F., B.B. Martin, and D.F. Martin. 1994. "Management
of Scale Deposits by Diamagnetism. A Working Hypothesis." Journal
Environmental Science and Health, A29(8):1553-1564.
Busch, K. W., M. A. Busch, D. H. Parker, R. E. Darling, and J.
L. McAtee, Jr. 1986. "Studies of a Water Treatment Device That Uses Magnetic
Fields," In Proceedings Corrosion/85, Boston MA.
Dirks, J.A., and L.E. Wrench. 1993. "Facility Energy Decision
Screening (FEDS) Software System." PNL-SA-22780. In Proceedings of the Energy
and Environmental Congress. Minneapolis, Minnesota, August 4-5, 1993.
Fryer, L. 1995. "Magnetic Water Treatment A Coming Attraction?"
E-Source, TU-95-7
Gruber and Carda. 1981. Performance Analysis of Permanent
Magnet Type Water Treatment Devices. South Dakota School of Mines and
Technology. Sponsored by and protocol by Water Quality Association.
Hibben, S.G. 1973. Magnetic Treatment of Water. Advanced
Research Projects Agency of the Department of Defense.
Marth, R.A. 1997. A Scientific Definition of the Magnetic
Treatment of Water: Its Subsequent Use in Preventing Scale Formation and
Removing Scale. Research Conducted for Descal-A-Matic Corporation.
Parsons, S.A., Bao-Lung Wang, S.J. Judd, and T. Stephenson.
1997. "Magnetic Treatment of Calcium Carbonate Scale -- Effect of pH Control."
Water Research, 31(2): 339-342.
Quinn, C.J., T.C. Molden, and C.W. Sanderson. 1996.
"Nonchemical Approach to Hard Water Scale, Corrosion and White Rust Control." In
Proceedings Iron and Steel Engineer, Chicago IL, September 30, 1996.
Reimers, R.S., P. S. DeKernion, and D. B. Leftwich. 1979.
"Sonics and Electrostatics - An Innovative Approach to Water and Waste
Treatment." In Proceedings Water Reuse Symposium, Volume 2. American
Water Works Research Association Research Evaluation, Denver, CO.
Rubin, A.J. 1973. To Determine if Magnetic Water Treatment
is Effective in Preventing Scale. The Ohio State University, Columbus,
OH.
Schmutzer, M. A., and G. W. Hull. 1969. Examination to
Determine the Physical or Chemical Differences Between Untreated and
Magnetically Treated Water. United States Testing Center, Inc. Hoboken,
NJ.
Simpson. L. G. 1980. "Control Scale and Save Energy." The
Coast Guard Engineer's Digest, Volume 20, Number 205, pp. 32-35.
Design and Installation Guides
Many of the manufacturers have guides for internal use or use
by their recommended installer or sales agent. Contained in these guides are
listings of customers, design and installation notes, warranty information, and
answers to many user questions. Most or all of this information may not be
available to customers. However, the manufactures do make available sales
brochures and summaries of specific applications or case studies. Also included
with the units will be owner's manuals and other end user installation and
maintenance documentation.
Ted Collins New Technology Demonstration Program Program
Manager Federal Energy Management Program U.S. Department of
Energy 1000 Independence Avenue, SW, EE-92 Washington, DC 20585 (202)
586-8017 Fax: (202) 586-3000 theodore.collins@hq.doe.gov
Steven A. Parker Pacific Northwest National Laboratory P.O. Box 999,
MSIN: K5-08 Richland, Washington 99352 (509) 375-6366 Fax: (509)
375-3614 steven.parker@pnl.gov
Technical Contact
David Evers Battelle Columbus Operations 505 King Avenue Columbus,
Ohio 43201 (614) 424-4921 dave.evers@bco.gov
Produced for the U.S. Department of Energy by Battelle Columbus
Operations
The Federal Technology Alerts are sponsored by the United
States Department of Energy, Office of Federal Energy Management Programs.
Neither the United States Government nor any agency or contractor thereof, nor
any of their employees, makes any warranty, express or implied, or assumes any
liability or responsibility for the accuracy, completeness, or usefulness of any
information, apparatus, product, or process disclosed, or represents that its
use would not infringe privately owned rights. Reference herein to any specific
commercial product, process, or service by trade name, mark, manufacturer, or
otherwise, does not necessarily constitute or imply its endorsement,
recommendation, or favoring by the United States Government or any agency or
contractor thereof. The view and opinions of authors expressed herein do not
necessarily state or reflect those of the United States Government or any agency
or contractor thereof.
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