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Integrated Approach Improves Power Plant’s Makeup Water Flow Rate

When a Midwestern power plant began paying credits to a paper mill customer for poor steam quality, they began to search for a solution to their existing reverse osmosis (RO) and electrodeionization (EDI) system.

When a Midwestern power plant began paying credits to a paper mill customer for poor steam quality, they began to search for a solution to their existing reverse osmosis (RO) and electrodeionization (EDI) system.

The system could not keep up with the steam boiler demand and required frequent clean-in-place (CIP) service, resulting in additional chemical and operator costs. During a visit to the plant, U.S. Water recommended an approach to improve their system reliability.

Reverse osmosis system. Photo courtesy: U.S. Water.
Reverse osmosis system. Photo courtesy: U.S. Water.

When the plant began experiencing issues with their equipment, the existing equipment manufacturer did not provide a representative to service the equipment. This left the plant paying $6,000 for an outside service technician visit. U.S. Water introduced the plant to the company’s integrated approach combing chemical, equipment and service, and shortly after, began designing a custom RO to meet their needs.

U.S. Water’s Engineering and Equipment team worked closely with plant management to build a custom solution. An efficient RO system was installed to produce enough makeup to meet the plant’s requirements, as well as a mixed bed demineralizer to further water purification and improve steam quality. A U.S. Water field rep also schedules monthly visits to ensure system reliability.

The equipment program was paired with U.S. Water Reports wireless communications system. U.S. Water Reports allows for daily operator logs and instant alerts if the system is experiencing any irregularities that may need immediate attention.

Since implementing the total solution, the makeup water system has become extremely reliable. During normal operation, the RO is producing 300 gallons per minute (gpm) makeup water to meet the plant expectation. It was also designed to produce 600 gpm in parallel (in case of emergency). Installing the new equipment resulted in no lost time on the RO system allowing for continued steam production, saving the plant $100,000 a year. Due to the high quality steam production, the plant is also able to avoid non-conformance fees, saving approximately $20,000 a year.

RO SYSTEM ACHIEVEMENTS

  • Makeup water flow rate improved to 300 gallons per minute during normal operation
  • Saved plant $10,000 a year in CIP chemicals cost
  • Saved the plant $20,000 a year in outside service technical costs
  • No lost time on the RO system, saving the plant $100,000 a year.

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