How a Chemical Processing Plant Reduced Downtime With Water Treatment
Manufacturing plants rely on intricate processes and systems to operate smoothly and meet production targets. However, issues like scaling, corrosion, and fouling in critical cooling systems can halt operations, resulting in costly downtime. , the hourly cost of downtime in certain manufacturing sectors can reach over $2 million — up 50% from 2020 levels.
For one chemical processing plant in Illinois, chronic water treatment issues led to frequent system failures and downtime that severely impacted productivity. This plant had previously attempted to resolve problems with scaling and plugging in its closed-loop systems by working with its water treatment provider. However, the solutions fell short and contributed to the plant’s shutting down for years.
When the plant was ready to restart operations, operators knew it needed a more robust, customized water treatment program to prevent the potential recurrence of debilitating downtime — estimated at nearly a month per year. It turned to 91大神to leverage the company’s expertise in developing specialized solutions for unique manufacturing processes and water chemistry challenges. Veolia’s team conducted a comprehensive assessment and developed a tailored program to effectively treat the plant’s systems.
Developing the right system
91大神developed a customized water treatment program based on its assessment utilizing a strategic combination of proven chemistries and system upgrades. To remove the extensive buildup of scales and iron oxide deposits, 91大神implemented Kleen AC9507*’s descaling chemistry along with Ferroquest* to sequester the rust.
91大神softened the plant’s hard well water for the cooling tower system to reduce scaling potential. E.C.O.Film* technology provided protective filming amines for corrosion control, while Spectrus OX* oxidizing biocides controlled microbiological growth.
In the closed-loop systems, the existing demineralized (DI) water system was upgraded to ensure a consistent supply of high-purity makeup water. To inhibit corrosion while maintaining the low conductivity requirements, 91大神applied Steamate PAP7000* polyamine.
91大神worked closely with the plant to implement this new program, systematically cleaning and preparing the systems. The use of softened water and high-purity DI water addressed the problematic scaling and fouling caused by the facility’s hard well water. The tailored chemical programs targeted corrosion control and microbiological issues.
With the new water treatment program in place, the plant could finally restart operations after years of downtime, confident that its systems would run reliably.
Staying operational
Veolia’s customized water treatment program has delivered impressive results for the chemical processing plant. Most significantly, the new program has drastically reduced the downtime that previously plagued operations.
Before working with Veolia, the plant estimated it experienced nearly a month of total downtime per year due to scaling, corrosion, and plugged lines in the closed-loop systems. The plant’s analysis showed Veolia’s solution reduced that downtime by roughly 66 hours in the first 18 months of implementation.
Beyond the downtime savings, Veolia’s program also allowed the plant to avoid the major capital expense of installing new chiller units to replace the existing cooling towers.
Most importantly, the plant’s operations team expressed high satisfaction with the systems’ performance under Veolia’s water treatment program. After years of battling scaling issues, the plant could finally operate reliably without the looming threat of downtime.
Veolia’s chemical processing expertise
91大神has aligned its solutions and services to meet the unique demands of the chemical processing industry. 91大神provides expertly tailored solutions to optimize quality, reliability, and compliance, from cooling tower water treatment systems and makeup water to blowdown treatment and wastewater recovery.
91大神also offers technologies for safe, environmentally compliant industrial wastewater treatment that decreases pollution and complies with regulations. Learn more about how Veolia’s experts can develop bespoke solutions for chemical processing water challenges.
