Great Lakes Plant: 200M Gallons and $350K Saved a Year

Home 9 Case Studies and Results 9 Great Lakes Plant: 200M Gallons and $350K Saved a Year
Key results
200 million gallons saved a year
75.5% less inhibitor
$350K estimated annual saving

Case Study from HydroFLOW USA

The Challenge

  • Cooling tower inhibitor reduction was needed alongside lower water use, without losing cooling reliability
  • The 10-cell recirculating cooling tower used large volumes of water
  • Chemical treatment created high operating cost
  • Scaling risk forced the plant to run at low concentration cycles
  • Cooling reliability had to be maintained throughout

The Solution

Two HydroFLOW® Multihead 60 inch units plus a Custom 24 inch were installed on the large cooling tower pipework of a 700MW plant with a 10-cell recirculating cooling tower, over a typical eight to twelve week site evaluation. The plant was able to run at higher conductivity without additional scaling, which cut blowdown water demand by 60%. Scale and corrosion inhibitor use fell 75.5%, biocides and dechlorinator by over 70%, and cooling differential and condenser vacuum stayed stable.

Testimonial

“I would recommend evaluating HydroFLOW® for cooling tower water management applications.” — Plant Manager

Key Outcomes

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Annual water savings reached 200 million gallons

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Biocides and dechlorinator reduced by over 70%

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Scale and corrosion inhibitor use reduced by 75.5%

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Cooling differential and condenser vacuum remained stable throughout

Independent Verification

All results in this study were measured and verified by third-party facilities managers and technical staff.

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