A Midwest chemical factory was dependent on a traditional soft water system to support its boiler operations. Eventually, this approach led to high water conductivity, frequent scale build-up inside boilers, and a heavy reliance on chemical cleaning. Operators were required to constantly monitor and adjust the system, increasing labor costs. The salt usage alone carried a significant monthly expense while the hidden costs of reduced boiler efficiency and recurring chemical treatments accumulated. It was time for a more advanced, reliable, and sustainable solution.
Solution:
Company leadership observed MPW’s reverse osmosis (RO) skids in operation at a chemical plant near the Ohio River. Impressed by the system’s performance, and on the recommendation of the MPW customer, the team arranged a site visit to MPW’s Hebron headquarters. The visit confirmed the strength of MPW’s technology and service, leading to an agreement to implement a Build, Own, Operate, and Maintain (BOOM) RO system tailored to the facility’s needs. The BOOM model shifted operational and maintenance risk from the customer to MPW, ensuring consistent performance and allowing the facility to focus on production.
The installation included a holding tank, suggested by MPW, for uninterrupted operation during cleanings, ensuring reliability even during maintenance. With MPW’s responsive service and collaborative approach, the facility simplified operator responsibilities, eliminated onsite salt storage, and produced high-quality water. Operators praised MPW’s quick response, open communication, and proactive monitoring.
Results:
The RO system has been in operation for more than a year and a half, delivering measurable improvements. Boiler scale and chemical cleanings have been eliminated, while water quality remains consistently high. Operators now focus on performance measurements.
Improved boiler performance, reduced chemical usage, and decreased water consumption are creating long-term value.
Water turnover rates have climbed from five or six cycles to twenty to twenty-five cycles, reflecting efficiency gains. RO water in bleach production has eliminated the salt formation that previously compromised quality, resulting in a cleaner, more consistent product.
Although costs shifted from salt purchases to a service fee, reduced chemical use, fewer cleanings, and labor savings more than justified the investment. The BOOM arrangement assured consistent results backed by 24/7 monitoring, with MPW’s service and accountability defining the partnership.