- Industry: Automotive
- Application:Chilled loop for cooling automotive parts
- Problem: Challenging quality river water source resulted in frequent fouling of RO membranes yielding an additional $80,000 annual operating expense increase
- Solution: Corrosion issues in the water line affecting quality of end product. Unplanned cleaning of the line disrupting production.
- Results: 10% increase in production efficiency due to more effective cooling + Disruptive weekly cleans of the water line were eliminated, resulting in manpower , water and treatment savings.
Client
The customer is a prominent global manufacturer of innovative lightweight spring components and similar products for the automotive industry. They are devoted to delivering outstanding product quality whilst utilising environmentally friendly and sustainable processes throughout their various sites around the globe.
Condition
The production of automotive springs and stabilisers is reliant upon excellent system water quality. The customer has reported poor water quality and unstable parameters, with visible signs of corrosion occurring within the system. This has resulted in production line shutdowns for cleaning, disrupting the manufacturing process and causing the loss of earnings.
Chem-Aqua’ s Solution
- To tackle the problem, Chem-Aqua introduced a range of equipment and chemical solutions. For example, the Aquapass bypass feeder allows both mechanical filtration for removing particles and impurities, as well as chemical dosing of the system.
- Appropriate amounts of HP888STX and Corrend corrosion inhibitors were added to eliminate corrosion issues on metal surfaces.
- Regular service, and application of the optimal water treatment program contributed to reduce manual burden on operators and to ensure good quality preventative measures.
Before
After
Enhanced water quality and stabilised parameters thanks to Chem-Aqua’s bespoke water treatment program
Quenching system water exhibited significant improvements in quality and appearance after the introduction of Chem-Aqua’s cleaning and treatment solution.
The Get Clean, Keep Clean Approach rectified water quality problems
Corrosion by-products were eliminated by a combination of on line cleaning via filtration and chemical treatment. Metallic surfaces showed fewer signs of corrosion.
Results
- Improvement of water quality has eliminated the requirement for weekly cleans, leading to less frequent breaks and caused a production increase of 10% and a decrease in ITG cooling line costs
- Regular service, water analysis and appropriate dosing with Chem-Aqua’s chemistry removed the need for regular checks from the customer — more convenient for operators.
- Thanks to Chem-Aqua’s program, a complete system water renewal is no longer required. This is now conducted only once a year, saving water treatment costs.