Case Studies
Bacteria Prevention, 2009
Shortly after start up at a large corporate data center, significant bacteria growth was discovered in the thermal storage tank. Some of the flow sensors were fouled, and biofilm had the potential of impeding heat transfer, which would raise energy costs. US Water Services assessed the problem and was able to find a solution.
Retort Enhancement Program, 2008
A major food processor was experiencing extensive retort shut down due to over pressurization caused by sticking valves from mineralization. The system consisted of ten retort cookers with each having a manual on and off chemical pump and tank requiring extensive monitoring and testing.
Graywater Re-Use, 2008
An ethanol facility discovered it would not have enough freshwater volume to operate partway through construction. However, the city was able to provide enough municipal water for the plant to meet their water needs. US Water Services was asked to construct a pretreatment system utilizing two technologies that had never before been used together in an ethanol plant.
RO Membrane Cleaning, 2008
When an ethanol plant in Texas, serviced by US Water Services, started experiencing problems with their reverse osmosis system, conventional on-site methods of cleaning failed and the reason soon became clear.
Low Phosphorus Cooling Water Chemistry, 2008
A customer in Michigan was recently faced with permit restrictions concerning phosphate in their cooling system discharge water. US Water Services was asked to develop a low phosphorous treatment program in order to meet these new tight discharge limits.
Cold Lime Softening Plant, 2007
When an ethanol plant in Minnesota was built, they made an agreement with the state DNR. They would monitor local wells, and if the aquifer level dropped enough to impact local and owners, they would build a sophisticated water treatment system that would allow them to use multiple water sources.
Bugs Eat Copper, 2007
Do you ever wonder what happens to that water in a closed loop system after the piping is done and you’ve left the job site? Probably not, right? It’s just a closed loop, nothing goes in and nothing comes out, what could possibly go wrong? Well, in some cases, nothing, but in others, it seems like nothing will go right! Let’s talk about some horror stories, and how they could have been avoided.
First Zero Liquid Discharge Ethanol Plant, 2006
In the spring of 2006, Pacific Ethanol Incorporated started their dry grind ethanol plant in Madera, California. One of the most unique features of this start up was that it was the first ethanol plant in the country to be designed and operated with no liquid discharge to the environment. The process that allows for this environmentally friendly system was designed by US Water Services.
Working For A Solution to Iron Discharge Limits, 2006
The National Pollution Discharge Elimination System (NPDES) permit program seeks to reduce the amount of water pollution to surface waters. This is accomplished by regulating point sources such as pipes or man-made ditches that discharge pollutants into public waters.
Water, The Most Overlooked Aspect of Building An Ethanol Plant, 2006
You just committed to building an ethanol plant. You spent thousands to assess gas and electric availability, the cost of running extra rail spurs and even ensuring access to the county blacktop, but did you test the water? You know there is an aquifer a few hundred feet down and the county extension office said there is plant of water, so water WAS the least of your worries.
Total Water Treatment Solution, 2006
One of the most overlooked, yet costly issues facing many plants today is the presence of an ineffective water treatment system. This can often become a financial burden. A mid-western food processing company was experiencing problems with their water system. Facing continued expenditures, the company decided to have US Water Services design a total water treatment solution for their old system.
Temporary Pretreatment on River Water, 2006
Front Range Energy, Windsor, CO went to the well and it was dry. During pre-startup water trials in May 2006, engineers of the 40 million gallon per year ethanol plant discovered the onsite wells didn’t have enough capacity to meet the facility’s needs.
Cooling Tower Toad, 2005
Every year the cooling system for an industrial plant providing comfort cooling was shut down and drained for the winter months. Historically, during this shut down period the cooling water piping and equipment would experience severe corrosion. During startup of the cooling system the next spring, iron flakes would peel off the piping plugging strainers and heat transfer equipment. This would interfere with the efficiency of the production process and cause an increase in maintenance.
Boiler Lizard, 2005
In the past, corrosion of the boilers and deaerator was a severe problem during seasonal shutdown at a Midwestern college. A new boiler and deaerator were recently installed and the chief engineer wanted to protect this new equipment from this type of corrosion. The chief engineer noted that almost all of the boiler corrosion occurred during the idle period when the equipment was drained for their annual inspections and maintenance.