Watreco AB in Malmö has so far been a research and innovation company, developing prototypes and products according to the principle of "from nature to industry".
Primarily, the company develops products in water treatment, based on the technology platform VPT - Vortex Process Technology - and the patented vortex generator. The company is now placing a stronger focus on the market and thus also on the production of high-quality products for its customers.
Learning from Nature
Curt Hallberg, who serves as the Research and Development Manager at Watreco, has long been interested in nature's way of solving problems and how flora and fauna have evolved. This area is called Biomimicry.
"Nature's techniques have much to teach us, but it requires an open mind and interdisciplinary understanding to translate it into technology that we humans can use," he says.
When his employer within the defense conglomerate Celsius shut down operations in Skåne, Curt found that he suddenly had time to develop his thoughts on vortex technology. He and some like-minded individuals began to tackle problems and opportunities, inspired by, among others, Viktor Schauberger, an Austrian forest ranger, philosopher, and inventor who, in the early 1900s, became interested in natural vortex generators in fish, for example. Another source of inspiration was the tornado, a natural vortex movement with extreme energy.
Business Area Realice
When ice is laid from scratch with vortex-treated water, you achieve the greatest energy savings. The water is then maximally de-aerated from insulating air bubbles, resulting in less energy-demanding heat transport through the ice. Ice became its own business area under the name Realice. A system for an ice rink costs about 150,000 SEK, but the cost is typically recouped within a year. Of Sweden's approximately 350 ice rinks, about 40 have so far installed the Realice system. The system has also been tested on toboggan runs with good results.
Kalkens fiende
What was also noted at Rosengård's ice rink was that the deposits of lime in the scraper collection area decreased, as did the clogging of the nozzles of the ice machines. This further led to another application area – prevention of scaling in waterborne systems, such as cooling towers. The water used for cooling the towers' coils is heavily affected by lime deposits. It is a time-consuming process involving both chemicals and physical treatment to remove the lime. In tests with vortex-treated water, it was found that the deposits ceased, and it even dissolved old lime.
"There are many interesting application areas for the future," says Curt. "Just think about all the dishwashers, washing machines, and toilets, everywhere where there are issues with lime deposits."
From Principle to Product
The period from the 1990s to around 2010 was dedicated to the development of both technology and applications.
"When we finally succeeded in designing and refining our vortex generator, it was a bit of 'technology seeking applications'," recalls Curt. "And the patent was secured!"
In the vortex generator, a vortex of water—or any other liquid—is created at high speed. The vortex is formed using specifically designed channels and the generator's carefully crafted geometries. Water moves along the walls, while other particles and air collect in the center of the vortex and can be separated.
"We were not completely in the dark regarding application areas, of course, but the path to commercialization is not always straightforward," adds Anders Lindskog, CEO of Watreco.
Energy Savings in Ice Rinks
What has been observed in tests with water treated in a vortex generator includes, for example, better crop growth and higher yields, faster water freezing into ice, and efficient water decalcification.
"The idea to venture into the field of ice led us to Rosengård Ice Rink in Malmö," Anders explains, "and here we began a collaboration with some very dedicated ice technicians."
A vortex generator was installed on an ice machine, and they experimented. What they eventually found was that:
the ice freezes faster the ice freezes at a lower water temperature the ice becomes stronger and more resilient the ice becomes clearer (lines and advertisements are more visible) it requires less energy to preserve the ice
"Vortex-treated water is different and crystallizes more easily when freezing into ice," Curt explains.
When the small bubbles are gone, the viscosity of the water changes so that it flows out more easily, allowing the ice to be laid at a much lower water temperature than before. The optimal temperature for laying the water is about +18ºC, compared to about +50°C traditionally.
Watreco and GTP
Curt had worked with GTP on several projects during his time at Celsius, and the collaboration was resumed when the first vortex generators were manufactured. GTP developed "moulds for moulds" using SLA technology, a somewhat cumbersome method. The later, sleeker models posed a manufacturing problem from the start. It involves a very complex geometric structure that cannot be injection molded or cast.
When Curt and Anders visited GTP's booth at a trade show, they saw a tool for the slaughterhouse industry that GTP mass-produces and that can only be manufactured using additive manufacturing - there simply is no other way. The similarities in manufacturing challenges were obvious - now Watreco had found the manufacturing method that could handle the vortex generator!
Vortex generator for mixing
If you reverse the principle in the generator, instead of separation and deaeration, you get a highly efficient mixer. This can be used to mix liquids or to mix liquids and gases. An example is oxygenation of water in ponds and other bodies of water, such as wastewater treatment plants.
"Anders explains that manufacturing the FlowMixer, as we now call it, also has to be done in one piece. So, it's a task that only GTP can handle!"
