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.

Summary

The plant saved 200 million gallons of water a year, with scale and corrosion inhibitor use down 75.5%. That is the largest water saving on this site, and it came from letting the tower run at higher cycles rather than from any change to the tower itself. For operators held at low cycles by scaling risk, the result shows water and chemical savings arriving together without any loss of cooling reliability. The client is anonymised at their request; the figures are theirs.

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