Feed Mill Facility Increases Efficiency and Reduces Chemical Usage with EnergyOUT™

A Midwest Feed Mill was treating its incoming well water for high levels of alkalinity with amine chemical. Unfortunately, amine is one of the most expensive chemicals used in water treatment. If the facility chose not to treat the well water for alkalinity, it could result in failure of the condensate return lines, a costly plant shutdown and capital equipment replacement expenses. U.S. Water’s EnergyOUT system presented an integrated solution to address the alkalinity issue and improve plant efficiency, that the facility’s current water treatment provider could not match.

U.S. Water representatives completed a plant audit with on-site wet testing to identify an opportunity that could improve the makeup water to reduce chemical consumption and boiler blowdown. By introducing a Reverse Osmosis (RO) unit into the system 90% of alkalinity could be removed, thereby reducing 90% of the chemical required to treat the system. Based on the cost savings this solution provided on chemical use alone, the facility chose to implement the EnergyOUT solution.

A new reverse osmosis system can be a significant capital expense that a facility may not have available in its budget. U.S. Water’s EnergyOUT reverse osmosis unit is an alternative solution to this capital expense. Available through an operating lease, the EnergyOUT integrates equipment, service and chemicals to enhance a facility’s sustainability by reducing fuel demand, carbon emissions, chemical use and water discharge.

Built with a VFD controlled pump and low energy membranes to reduce electric consumption, the EnergyOUT boiler pre-treatment solution provided the facility with:

  • A complete RO with carbon filtration and prefilters to protect the membranes
  • RO product water storage tank with level controls and water forwarding pump
  • Planned maintenance and warranty repairs
  • pH adjustment of RO permeate to prevent corrosion
After the EnergyOUT unit was installed, the reduction of the boiler blowdown provided a significant energy savings, as the water can be reused in the boiler for a longer period of time. The facility is also using 90% less chemical overall, saving $34,000 in chemical costs in the first year of implementation. With the U.S. Water service agreement, the facility also experienced a reduction in the system’s maintenance costs and operator time.

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