A zero-liquid discharge facility faced critical operational challenges relying solely on mobile DI trailers for all water production. Limited trailer throughput, seasonal operation restrictions, and severe weather threatened continuous plant operation. During peak demand, as many as 60 trailers were required, and sudden water shortages created costly logistical strain.
These challenges often led to increased downtime risks and significant financial consequences when production was interrupted. The dependency on so many trailers required constant coordination and frequent scheduling adjustments, placing heavy demands on plant personnel
Solution:
MPW introduced the Gas Transfer Module (GTM) to increase DI trailer throughput by more than 25% while extending the useful life of mobile DI units, creating significant cost savings. The system added 250,000–300,000 gallons of storage, boosting total capacity by up to 40% and providing a buffer during peak demand or logistical delays.
Tested for several months to confirm ROI, the GTM’s value led to the construction of a dedicated building for year-round operation, ensuring winter readiness.
Additionally, MPW structured agreements to eliminate derage fees when GTM was on-site, maximizing client value. The GTM also supports NOx emission reduction, ensuring EPA compliance and seamless integration with modified trailers to optimize water processing.
Results:
Trailer needs have dropped from approximately 60 to 30–40, with some delivering up to 300,000 gallons/trailer on well water with conductivity well over 900 μS/ cm. Main tank levels now remain between 28 and 30 feet, avoiding the critical lows previously experienced.
The added storage capacity and year-round readiness have prevented disruptions during winter storms, extreme heat, and emergency events. The GTM maintained uninterrupted operation during both a 2018 tornado and a 2021 transformer failure, transforming the client’s water production from a seasonal, high-risk process into a reliable, resilient, and cost-efficient system in cooperation with MPW’s mobile DI fleet—the largest in the industry.