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Food Plant in Southern California, USA

Double Pass Reverse Osmosis System for Maximizing System Recovery (Food Plant in Southern California, USA):

Pure Aqua, Inc. has been working with a Steam Boiler company known for their energy efficiency since 2009. This company has had major success in proving that their Fuel-to-Steam efficient boiler design (85% fuel-to-steam) saved money for the end-users in cost of operations. However, just like any other steam boiler company in the industry, they also have some challenges with regards to water usage efficiency, which is mostly dependent on the water quality of the source in each of their customer’s locations.

Our customer has a client in the food manufacturing industry based in Santa Fe Springs, CA that specializes in packaged meat products. Their plant has 6-units of 50 HP (300 HP total) Steam Boilers and were initially fed with just softened Santa Fe Springs city water, which is high in TDS. This would be acceptable if the client’s manufacturing process generated a good amount of steam condensate which can then be mixed with softened city water to eventually lower the total TDS of the feed water into the Steam Boilers. However, they mostly have a direct-steam injection process that has 0% return condensate into the steam system. The challenge to both the Steam Boiler Company and the client is to minimize, or eradicate, the wet steam plaguing the plant due to high TDS and corrosion issues on steam lines from the boiler water carry-over. Also, the client had to deal with a high-cost of boiler chemicals, energy lost on blow-downs and water wastage.

These challenges called for a study to install an RO system that would lower down the feed water TDS to the steam boiler drastically and be able to:

  • Increase boiler cycles-of-concentration, which will result in less blow down
  • Decrease energy lost on boiler water during blow down
  • Decrease volume of water wastage on during blow down
  • Eradicate wet-steam issues and steam line corrosion

The Steam Boiler Company asked for the assistance of Pure Aqua Inc. to design a Double Pass RO system, which can maximize water recovery instead of just proposing a Single Pass RO system that is quite limited on system recovery by design. A Double Pass RO System would provide more advantages to the overall plan, such as savings on water usage and sewage fees. More importantly, a DPRO would lower the environmental impact on California, as well as the rest of the US.

The whole world is facing water scarcity concerns. That is why we, here at Pure Aqua, are trying to save one of our precious resources.

The manufacturing plant invested and installed a Pure Aqua Double Pass RO System, TW-27K-9240 (1st Pass) and TW-12K-840 (2nd Pass). They have been able to increase the system recovery rate from 68% (based on 1-pass RO system) to 89% with the Double Pass RO system. Pure Aqua’s DPRO system increased the recovery rate by 21%. 

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