Cooling systems play a critical role in a majority of industrial operations all around the world. Due to the vast amount of water resources cooling systems require to cool down machinery and process equipment, engineers are always looking for new and better solutions to make these systems more efficient, consuming less water and less energy. Chemical manufacturing is an example of an industry that is essential to our economy, but is also among the most water-intensive. With the global water crisis spurring increasing pressure to reduce environmental impact, making sustainable solutions within the industry is an economic necessity.
Although water is also used for steam generation and to be blended directly in the manufactured products, the majority of the sector’s water usage comes from cooling systems. While cost-effective, traditional phosphate-based cooling water additives often lead to operational inefficiencies and environmental concerns that today’s manufacturers can no longer ignore. Especially for facilities using high-hardness make-up water, these challenges manifest in equipment scaling, reduced run-length and high maintenance costs. For every other, it can still translate into excessive water consumption, algae growth and microbiological fouling, as well as growing regulatory pressures around phosphate discharge.
A chemical plant in the Southern US turned to Veolia for help because its hot process heat exchangers suffered from persistent calcium phosphate deposition despite careful pH control through acid addition. Maintaining operations required a costly trade-off: Either accept frequent cleaning cycles and equipment damage or significantly increase water consumption through conservative cycling rates. Both options drained resources and hindered efficiency. The facility needed a better solution — one that would protect its systems while reducing its environmental footprint.
Veolia’s history of developing sustainable water treatment solutions positioned us well to tackle this challenge. Through years of research into non-phosphorus chemistries, our team developed E.C.O.Film technology — a breakthrough in engineered carboxylate oxide chemistry. This innovation provides comprehensive scale and corrosion protection without phosphorus or EPA-priority pollutants, creating an ultra-thin protective barrier using only carbon, hydrogen, and oxygen (C-H-O) molecules. The specialized C-H-O polymer technology eliminates the risk of calcium phosphate deposition and reduces the nutrient load that can fuel biological and algae growth.
Optimizing water usage
Veolia experts began with a thorough system audit, employing a proprietary digital cooling water modeling software to simulate the scaling conditions. This detailed analysis revealed an opportunity: By implementing E.C.O.Film technology, the facility could increase both cycles of concentration and pH while eliminating phosphate from the treatment program entirely. The solution promised to eliminate acid feed and reduce water consumption greatly while controlling deposition and corrosion in the system.
The implementation delivered transformative results. The facility eliminated 50,000 gallons of acid annually and reduced water consumption by 20 million gallons per year. These improvements generated operational savings exceeding $100,000 annually and prevented approximately 6,800 pounds of phosphate discharge per year. Beyond the numbers, the simplified treatment program enhanced workplace safety through reduced chemical handling while maintaining superior system protection.
Veolia’s expertise in chemical manufacturing
E.C.O.Film technology is just one of Veolia’s many innovative solutions that can help chemical manufacturers enhance operational efficiency while meeting environmental goals. With years of industry and region-specific experience, Veolia experts work in lockstep with customers to tailor the right solution to meet their operational requirements. Our comprehensive approach integrates advanced monitoring systems, predictive analytics, and expert support to optimize treatment programs for each facility's unique requirements.
Contact our specialists today to learn how our innovative solutions can transform your chemical processing facilities while advancing your sustainability goals.
By Kevin Thompson, Product Application Expert - Cooling Product Line, Veolia's water technology activities
