TRIDENT WATER SYSTEMS

Electro Contaminant Removal (ECR) Test Kit

Operating Manual

TRIDENT WATER SYSTEMS PRIVATE LIMITED

GST & Co. Registration No.: 201635067N
33 Ubi Avenue 3, #05-63 Vertex, Singapore 408868
Tel: +65-6634-0863 | Fax: +65-6634-0862 | E-Mail: enquiries@tridentwater.com.sg
Table of Contents

1. INTRODUCTION................................................................................................................... 3

2. ECR SCIENTIFIC EXPLANATION ...................................................................................... 4

3. PURPOSE ............................................................................................................................... 7

4. KIT CONTENTS .................................................................................................................... 8

5. SAFETY INSTRUCTIONS................................................................................................... 10

6. VARIABLE PARAMETERS ................................................................................................ 13

7. PRE-TREATMENT CHECKLIST ....................................................................................... 14

8. RECORDING OF TEST PARAMETERS ............................................................................ 15

9. EQUIPMENT SETUP........................................................................................................... 16

10. CONDITIONING OF NEW ELECTRODES ...................................................................... 20

11. STANDARD TREATMENT PROCEDURES ..................................................................... 21

12. OBSERVATIONS ............................................................................................................... 23

13. TROUBLESHOOTING ...................................................................................................... 24

14. SHUT DOWN PROCEDURE ............................................................................................. 25

15. MAINTENANCE/ EQUIPMENT CLEANING ................................................................... 25

16. WARRANTY ...................................................................................................................... 26

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1. Introduction

The Electro Contaminant Removal (ECR) is TWS’ proprietary wastewater treatment solution.
It utilises a unique Electrocoagulation treatment profile which does not require the use of any
chemicals. The ECR is an effective primary treatment process which stands as an alternative
to conventional chemical and biological treatment processes. This versatile system can remove
a whole spectrum of contaminants from wastewater, including Chemical Oxygen Demand
(COD) / Biological Oxygen Demand (BOD), heavy metals, colour, oil & gas, and many other
contaminants.

The ECR is based on scientific principles of how water contaminants react when a strong
electric field is applied jointly with the appropriate treatment agents. The electrical current
releases reactive ions whilst providing the electromotive force to drive the fundamental
chemical reactions. These reactions drive the elements or compounds towards their most stable
states. Generally, this stable state is a solid that is less colloidal, susceptible to emulsion, or
less soluble than the element or compound at equilibrium values. As such, the contaminants
form hydrophobic entities such as precipitates or phase separations that are easily removed by
various secondary separation techniques.

TWS’ ECR system has been applied across multiple industries including Textile, Oil & Gas,
Food & Beverage, Automotive and many others.

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2. ECR Scientific Explanation

Electro coagulation through the reaction chamber produces several distinct electrochemical
results independently. These observed reactions could be explained as:

• Seeding resulting from the anode reduction of metal ions that become new centres for
larger, stable, insoluble complexes that precipitate as complex metal oxides.

• Emulsion breaking resulting from the oxygen and hydrogen ions that bond into the water
receptor sites of oil molecules creating a water insoluble complex separating water from
oil, driller’s mud, dyes, inks, etc.

• Halogen complexion as the metal ions bind themselves to chlorines in a chlorinated

hydrocarbon molecule resulting in a large insoluble complex separating water from
pesticides, herbicides, chlorinated PCB’s etc.

• Bleaching by the oxygen ions produced in the reaction chamber oxidizes dyes, cyanides,
bacteria, viruses, biohazards, etc.

• Electron flooding of the water eliminates the polar effect of the water complex, allowing
colloidal materials to precipitate, and the increase of electrons creates an osmotic pressure
that ruptures bacteria, cysts, and viruses;

• Oxidation - Reduction reactions are forced to their natural end point within the chamber,
which speeds up the natural process of nature that occurs in wet chemistry.

• EC induced pH swings higher.

Generally, three main processes occur serially during electro coagulation:

(a) Electrolytic reactions at electrode surfaces,

(b) Formation of coagulants in aqueous phase,

(c) Adsorption of soluble or colloidal pollutants on coagulants, and removal by sedimentation

or floatation.

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The inherent complexities of the above processes, and also the presence of secondary
processes, make electro coagulation quite complex in nature. Again, Aluminium or Steel
Electrodes are used.

Main reactions at the electrodes are:

Fe(s) → Fe3+ (aq) + 3e (anode)

2H2O + 2e → H2 + 2OH− (cathode)

Meanwhile, if anode potential is sufficiently high, secondary reactions may occur also, such as
direct oxidation of organic compounds and of Cl− ions present in wastewater:

2Cl− → Cl2 + 2e

The chlorine produced is a strong oxidant that can oxidize same organic compounds and
promote electrode reactions. In addition, the cathode may be chemically attacked by OH− ions
generated during H2 evolution at high pH values:

2H2O + 2e → H2 + 2OH-

Al3+ (aq) and OH− ions generated by electrode reactions above react to form various nonnumeric
species such as Fe(OH)2+, Fe(OH)2+ , Fe2(OH)24+ , Fe(OH)4−, and polymeric species such as
Fe(H2O)5(OH)2+, Fe(H2O)4(OH)2+, which transform finally into Fe(OH)3 according to complex
precipitation kinetics.

Ultimately, most of the above species will rapidly convert into the more stable ferric hydroxide,
Fe(OH)3. The chemical characteristics of Fe(OH)3 allow it to aggressively attack the
contaminants in the incoming wastewater stream. It, along with the electrical field, is the main
treatment agents that drive the myriad of chemical reactions fundamental to this technology.
The significance of each reaction type is elaborated on below.

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 Reaction Main
Pathway Target Significance
Parameter
The generation of reactive species like Fe3+ and Fe(OH)3
COD, TP, speeds up the various oxidation-reduction (Redox) reactions,
Redox
TN allowing the ECR stage to achieve faster reaction rates for
most contaminants
The oxygen and hydrogen ions, formed in-situ, bind to water
Emulsion Oil &
receptor sites of oil molecules, creating a water-insoluble
Breaking Grease
complex for easy separation
The resultant metal complexes also serve the dual role of
coagulant and flocculant. First, they neutralise the surface
charges of contaminant particles, facilitating their
Flocculation All
precipitation. Subsequently, they act as the centres around
which these precipitates congregate, forming larger flocs
suitable for removal
The main electrolysis process generates powerful agents such
Bacteria/ as ozone, oxygen and chlorine that disrupt the cellular
Disinfection
Viruses integrity of bacteria and viruses, resulting in the disinfection
of the water stream
The same agents of disinfection also are involved in the
Bleaching Colour reactions that cleave dyes and other persistent compounds that
constitute the colour component of industrial effluent

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Via the above reaction pathways, the contaminants are converted to simpler insoluble
compounds. In these stable states, they are crucially less colloidal, less susceptible to emulsion,
or less soluble as compared to their original states. This creates the ideal conditions for removal
via settling or floatation in the ECR clarifier that follows.

Overall, the highly charged environment created within the reaction chamber enables good
removal efficiencies to be achieved with markedly shorter retention time as compared to other
secondary treatment processes. This trait sees the ECR requiring less spatial footprint as
compared to the chemical and biological stages for a similar volume of wastewater.

Another key strength of the ECR is its adaptability. For certain wastewaters, the deployment
of a customised electrode set comprising of iron and aluminium electrodes further enhances
removal efficiencies for certain parameters such as heavy metals. Hence, the configuration of
the ECR stage is designed on a case-by-case basis to meet each customer’s specific treatment
needs.

3. Purpose

The ECR test kit is a benched-sized system which allows the user to assess the treatability of
waste water using the ECR. Based on the results achieved from the treatment, contaminant
(parameters such as COD, BOD for example) removal rates in waste water can be measured.
In addition, the test kit allows the user to observe the treatment settings which is useful when
upscaling for the commercial scale system. The advantages it has over our full-sized systems
are its portability, ease in varying treatment settings and ability to work with small volume of
samples. The purpose of this manual is to provide information about the test kit regarding
safety, setup, operating, maintenance and troubleshooting.

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4. Kit Contents

Carefully unpack the ECR test kit. Check against the content list below. The following
components are the basic equipment received upon purchase of the test kit.

No. Components Quantity Remarks

1 set Mild steel, 1 set Aluminium (each
1 Electrodes 2 sets
set:2 x power blades, 17 x electrodes)
2 Power Supply box 1
3 ECR chamber 1
4 Pump drive with head 1
5 Pump Tubing 1 Silicon tubing
6 Pelican Case w/ Foam 1
7 11 Micron Filter Paper 1
8 TDS Meter 1 Calibration done
9 Discharge Hose 1 reinforced clear vinyl hose
10 pH meter 1 Calibration done
11 Power cable w/ crocodile clips 1 set 1 for double chamber

Further Equipment Description

1. Power blades size: 20 (L) x 3.0 (W) x 0.3 (T) cm.

Electrode size: 15 (L) x 3.0 (W) x 0.3 (T) cm.

2. The 30 x 22 x 13 cm power supply box come with a fully encased plastic body and consist
of 2 x digital meters, 2 x input ports (positive = red, negative = black), a knob to adjust
voltage, an on/off switch, a power cable with 1 x power inlet and a fuse.

Power rating: 250 V, 10A

3. The dimensions of the acrylic chamber is 21 x 16 x 24 cm and consist of 2 x power blades

and 17 x electrodes. There are 2 sets - 1 x mild steel and 1 x aluminium.

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4. Pump specifications are as such:

Speed: 20 – 600 RPM

Dimension: 230 (L) x 183 (W) x 134mm (H)
Flow rate: 1.7 l/min
Speed 6: 1 l/min
Motor 1/20 HP, 37 watts
Power: 180 – 260 VAC
IP rating: IP 22

5. Pelican case allows for safe storage and transportation of the test kit.

6. The cellulose Grade 1, 185 mm diameter, 11-micron filter paper is used to separate fine
substances from the effluent after the ECR treatment. This would provide a qualitative
treatment result.

7. The Total Dissolved Solids (TDS) meter used to determine the TDS in the water. pH meter
is used to measure the pH of the water before and after the treatment.

8. 12 cm fully insulated DC power output cable with crocodile clip and banana head. 1 set for
double chamber.

Recommend Additional Components for Conduct of Trials:

1. Beakers/ plastic cups for sampling

2. 2 x pails (optional) – 1 for feed tank and 1 for treated water tank.
3. Pliers – to pull out blades
4. 2 x Universal Adapter
5. Screwdrivers
6. Cloth
7. Funnel
8. Stirrer

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5. Safety Instructions

READ ALL SAFETY WARNINGS BEFORE USING ECR SYSTEM

HAZARD POTENTIAL PREVENTION

CONSEQUENCES
Risk of Electric shock Serious injury could Installation of this unit, including
or Electrocution occur if the ECR system all electrical connections, must
is not connected properly. comply with all local, state and
ECR system is powered national codes.
by electricity and may
cause electric shock or Always be certain the unit is
electrocution if not receiving proper voltage (+/- 5% of
installed properly. the voltage listed on the
nameplate). Before installing
electrical connections, be certain
the power switches are in the
"OFF" position.

Keep all connections dry and off

the ground.

Electrical shock may DO NOT allow metal components

occur if ECR system is of the Electrocoagulation System to
not operated properly. come in contact with live electrical
components.

Serious injury or death Any electrical wiring or repairs

may occur if electrical performed on the test kit should be
repairs are attempted by done by authorized service
unqualified persons. personnel in accordance with
national and local electrical codes.

Before opening the ECR power

box, always shut off the system and

Page 10 of 26
 drain the water. Disconnect the
pump and power box from the
power source. If the control box
cannot be removed from the power
source, lock the On/ Off Switch in
OFF position and tag it to prevent
power usage. Allow the ECR
System components to cool down.

RISK OF Serious injury or death This unit must be placed in an area

EXPLOSION OR could occur from an that is well ventilated, free of
FIRE explosion or fire caused flammable vapours, combustible
by a system electric spark. dust, gases or other combustible
materials.

RISK OF BURNS Serious injury may occur Never allow any part of your body
from touching the to contact the electrical parts until
electrical parts. This area cooled.
can remain hot for some
time after the system is
shutdown.

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 RISK OF BODILY Injury may occur from DO NOT DRINK THE WATER
INJURY test system. IN/ FROM THE ECR SYSTEM.

Raw and Treated water are non-

potable and is not suitable for
consumption.

Know how to stop the test system.

Be thoroughly familiar with
controls.

Before servicing components,

ALWAYS shut off the system.

Consult Material Safety Data

Sheets (MSDS) for safe handling of
system, especially acids and
polymers.

ATTIRE:

Proper attire is essential for your safety. It is advised to utilize whatever means necessary to
protect eyes and skin with appropriate Personal Protective Equipment (PPE).

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6. Variable Parameters

Current density: An important parameter in removal efficiency. A higher current density

would increase the amount of oxidised metal resulting in higher amounts of hydroxide flocs.
On the other hand, a high current density would result in a higher operating cost. The flocs
3+ 2+
would be brownish red rather than green as Fe would be produced instead of Fe . This
would be indicative the current density is too high. When current density is low, no coagulation
occurs. Hence, no clear separation between the floc and the treated water will be observed.

Flow Rate: Depending on the flocs produced, the operator would want to increase or decrease
the flow rate. This would allow the contaminants more time to react and coagulate to form a
better floc. However, a further increase would not improve the removal efficiency as it reduces
the retention time for the process to occur. At times, the higher the flow rate, the shorter the
retention time. The flow rate would depend on the type of flocs produced. If removal efficiency
is greater than needed, the process could be carried out at a lower current density which will
reduce power consumption of the treatment or higher flow rate.

pH: The pH of the wastewater effects the solubility of the Metal Hydroxide generated from the
treatment process which later acts as a coagulant. The ECR works best when the pH is 6 – 7.
If the pH is too high, the formation of iron hydroxide will not be optimum thus producing Fe3+
instead of Fe2+ which decreases the removal efficiency. pH is usually adjusted using
Hydrochloric Acid / Sodium Hydroxide

Conductivity: Conductivity is necessary so current may flow through the water to provide the
necessary reactions. This in turns determines the power consumption required to let the current
flow. High conductivity water would require a higher power and amperage. This affects the
amount of coagulants produced and other reactions taking place in the system. For the ECR to
work, conductivity would have to be 700 μS and above.

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7. Pre-treatment Checklist

Before starting the treatment, the following measures/checks should be carried out:

• Ensure that individual equipment is working well.

• Inlet and outlet hose of the ECR chamber is properly secured.
• There are no loose components in the power box.
• 2 buckets are available. 1 for the raw water and the other for the treated water.
• Ensure that cups/beakers are available to collect the samples.
• Blades are properly inserted into the chamber.
• Refer to Section 9 for when using new blades.
• At least 10 litres of waste water.

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8. Recording of Test Parameters

Test parameters can be recorded using the template shown:

Run: Date:
Sample From:
Sample Type:
Sample Volume: Remarks:

Electrode Connection: Single / Double Chamber

pH Adjustment: Yes / No
If Yes, HCl/NaOH
HCL/NaOH Concentration: __________%
HCL/NaOH Volume: ____ ml / 100ml raw water
Settings Voltage:
Current:
Pump Speed:

Raw pH
Parameters Raw Water Adjusted ECR Treated Water
pH
TDS (mg/l)
COD (mg/l)
TSS (mg/l)
Colour (Pt/Co)
Other Parameters
(if necessary)

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9. Equipment setup

9.1) Preparing the blades in the ECR chamber

Ensure that the finishing, edges and coating of blades are of good condition. Each blade is to
be placed parallel to each other through the blade guides. The longer blades which acts as the
anode and cathode and are placed at each end of the chamber. Ensure that the blades can slide
through the guides easily without any knocking or excessive force. Knocking or excessive force
will damage the guides.

*Aluminium blades are used in the illustration above.

Single chamber connection: Single chamber connection is for normal operation. Connect ECR
power cables to first and last power electrodes of the chamber.

_
+

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Double chamber connection: After trying the single chamber setup, if no treatment is achieved,
consider using a double chamber setup. Double chamber is effective when the water is not
conductive enough. Connect one ECR power cable one end and the other one to middle power
electrode. Connect jumper cable to both first and last power electrodes.

_
+
+

+ +

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9.2) Pump Head

Ensure that the silicon tubing sits nicely in the pump head. Secure the tubing by clamping the
lever downwards.

9.3) Power Supply box

Check that the supply box is working. The On/off switch will light up once it’s being switched
on. Turn the power knob in the clockwise direction to increase the voltage. Current will only
increase once there is water in the chamber. After checking that the box is functioning, ensure
that the readings on the volt and ammeter are set to zero by turning the power knob anti-
clockwise. Once done, switch the box off.

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 Voltmeter On/Off
switch

Power
Ammeter knob

Negative Positive

9.4) Overall treatment Setup

The treatment setup will look as such:

*Items seen in overall treatment setup are for illustration purposes only. Colour, model of the equipment used
etc. may vary depending on availability.

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10. Conditioning of New Electrodes

New electrodes are often coated with protective layer. This layer inhibits the release of ions
from the blades ECR treatment. The electrodes need to be conditioned before the conduct of
trials. Below details the conditioning procedure (note that the coating on Aluminium blades
take a longer time to be removed):

Safety Note: A mask should be worn when carrying out this procedure. Gases will be released
during this coating removal process.

Items needed:
- 1 x beaker/pail
- table salt
- tap water

1. Fill the pail with water.

2. Add salt to the water while constantly measuring the TDS levels of the water. Stop
once TDS level reaches around 800 ppm. Salt is used to induce TDS to the water.
3. Set up the lab unit as detailed in Section 9.
4. The suction and discharge hose will be to the same beaker/pail.
5. Set pump speed knob to 3.
6. Turn on the pump. Let salt solution flow. Once the chamber is filled, turn on the
power (ensure that knob is at zero or turned all the way to the left). Gradually increase
current until it reaches the maximum position (ensure current does not exceed fuse
current rating).
7. Leave the process running for 30 minutes. If too much sludge is generated. Swap the
pail with a fresh batch of salt solution.

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11. Standard Treatment Procedures

11.1) Set pump knob to 6 (1 LPM). If raw water is limited, run at a lower speed (knob
3, 0.5 LPM). Turn on the pump. The influent will be introduced at the bottom of the chamber
and will be dispersed evenly as it moves upward through the blades. Once the chamber is full,
only then can the power supply box be turned on.

Safety note: - Ensure that the power knob is being turned to zero once the box is
turned on.
- Do not stand too close to the chamber as there might be sparks when power
is turned on.

11.2) Vary the power knob. Observe the reaction in the chamber. Each time the power
knob is being varied, give it a few seconds to allow reaction to happen. Once coagulation is
observed in the chamber, stop varying the current. Let it run for at least 1 min. Collect water
sample.

11.3) There are two variables that can be adjusted once treatment begins. Adjust one
variable at a time (flow rate/current).

11.4) Give it some time for the treatment process to stabilise after adjusting each
variable. If sample is overtreated, either increase the flowrate gradually until it has reached 1
L/min. If it is still overtreated, reduce the current.

11.5) If sample is undertreated, increase the current gradually until coagulation occurs.
If there is still no treatment, reduce the flow rate gradually. Look to reduce the pH of the raw
water or go for double chamber if there is still no coagulation.

11.6) Once the right settings are achieved, record the required parameters and power
settings.

11.7) Use the 11 Micron filter paper and filter the treated water sample. This filter paper
simulates the effect of a clarifier.

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After filtration:

• Once the right settings are achieved, filter the sample with the 11-micron filter
paper. If the filtered sample is clear and does not turn yellow when left to sit
overtime, a good treatment was carried out.
• If filtered sample turns yellow overtime, look to reduce the current settings as
the sample is overtreated.

What Happens During Treatment?

As Direct Current (DC) is introduced into the chamber; the liquid becomes a conductor,
allowing the DC current to pass. The metal blades react with the current by releasing charged
metal ions into the influent. The flooding of electrons in the wastewater neutralizes charged
particles, causing them to be pulled out of suspension. The metal ions tend to form metal oxides
that electromechanically becomes attracted to the contaminants that have been destabilized.
The released ions neutralise the charges of these particles and thereby initiate coagulation.

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12. Observations
The picture below illustrates possible treatment outcomes:

Note: Different waste water reacts differently with the treatment. Not every outcome is as
described as per the pictures illustrated below.

Floc rises to the top

instantaneously.

Clear separation between treated

water and floc layer is observed.

From left to right:

1) Raw water.
2) Post ECR treated water. Clear separation can be observed. Flocs rise to the top
instantaneously. However, the treated water is still cloudy which means it is undertreated.
3) Current is increased slightly. Observation is the same as Sample 2. However, the treated
water is much clearer. This is an example of a good treatment.
4) As the current is increased further, the floc gets thicker and denser. It is unable to float or
separate instantaneously. The treated water colour is yellowish. These are signs of
overtreatment.
5) There is no clear separation and the treated water colour does not look good.

Note: While colour and turbidity are indications of treatment performance, it is important to
remember that visual results do not necessarily translate to actual contaminant removal rates.

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13. Troubleshooting

No. Common Issues Solutions

1 Control box switch turned on, but • Is main power turned ON?
nothing happens. • Are there any blown fuses?
• Are the cable connections inserted
properly?
• Are there any loose connections in the
power box?
2 System operates but there is no • Check the current to the power electrodes.
floc. • Ensure there are electrodes in the chamber
• Adjust pH.
• Ensure there is no excessive solids formed
on electrodes.
• Increase current.
• Reduce flow rate.
3 Water quality deteriorates • Increase/decrease the flow rate.
(Over/Under treatment) • Increase/Decrease the current density.
4 Feed pump runs, but low/no • Reduce the flow from pump
water discharge • Ensure there is no obstruction/kink on the
pipe.
• Ensure there is water in the tank.
• Ensure that the suction tube is placed at a
good position for suction.
• Ensure tubing is fixed properly on the
pump head.
• Check the power supplied to the box.
5 Too much foam or bubbles. Too • Increase the flow rate.
much gas being released. Sign of • Decrease the power settings
overtreating.

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14. Shut Down Procedure

14.1) Once treatment is completed, turn power off at the control box. Once power
has been turned off, remove the crocodile clips from the electrodes.

14.2) Raise pump head lever. This would ensure that the ECR chamber has been
cleared of any fluids. Disconnect silicon hose from the chamber.

15. Maintenance/ Equipment Cleaning

15.1) Remove the electrodes from the chamber using a pair of pliers. Rinse the
electrodes under slow running water. Scrub the blades using a wire scrubber to remove any
stubborn residues. There is no need for any chemicals.

15.2) Rinse ECR chamber with water and regular soap. If required, leave the unit to
soak over a period to remove any bad smell or flocculants. Do the same for the hoses.

15.3) Use a dry cloth and dap dry the electrodes and ECR test unit. Subsequently, it can
be air dried. Rust observed on the electrodes after drying is normal.

15.4) Electrodes replacement is only carried out if the blades are worn out.

15.5) If the condition of the chamber & electrodes deteriorates, soak them in Diluted
Hydrochloric Acid (HCl) for half an hour and then rinse with water. Observe proper safety
practices when handling HCl.

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16. Warranty

The products are warranted to be free of defects in material & workmanship for a period of 12
months from the date of shipment. This warranty does not cover defects arising from the
incompatibility of third-party equipment (I.e.: water pumps, etc.) damage or deterioration due
to improper use, misuse, abuse, negligence, accident, wear and tear due to exposure, and covers
only such products as have not been altered or modified.

TWS exclusive liability and Customers exclusive remedy under this warranty shall be limited
to the installation/ commissioning Company repair or replacement F.O.B. at the point of
manufacture, of the defective part or component, upon proof of defect satisfactory to TWS.
TWS shall have no further liability under any circumstances for damages of any kind, including
lost profits, or exemplary damages, and whether in tort or contract, to Customer or Customer’s
employees, agents, subcontractors, invites, or any third parties, including but not limited to
personal injuries and property damage resulting from use or handling of products. This
warranty is expressed in lieu of all other warranties expressed or implied, including but not
limited to any sample warranty or any implied warranty of merchantability or fitness for any
particular purpose.

No warranties, whether expressed or implied, including the warranties of merchantability or

fitness for a particular purpose, are made by any distributor or dealer of the product herein
warranted, nor shall such dealer or distributor be liable for payment of any direct, consequential
or incidental damages. TWS does not take claim to any waters, before or after ECR treatment,
and does not assume responsibility for clarification, sedimentation or any other process
parameters of an existing or new wastewater treatment plant; unless otherwise contracted to do
so.

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