Challenge
A chemical manufacturing company in Texas needed a reliable way to manage trace amounts of copper in its cooling tower blowdown. The copper was initially present at low levels, but as the cooling water cycled up, copper concentrations increased. This created discharge compliance concerns when the water was sent to the facility’s fire pond; to meet discharge requirements, copper had to be reduced to meet a limit of 0.03 ppm before release.
The customer contacted Xylem because they were looking for a portable treatment solution with a minimal footprint and Xylem had previously supplied a copper removal system in 2001. Over the years, the system has been successful, so when new cooling towers were brought online, the company wanted to implement a similar treatment approach that had already proven effective at their facility.
Solution
Xylem worked closely with the customer by evaluating the cooling tower blowdown process and conducting engineered wastewater ion exchange treatability studies on the process cooling water. Water samples were analyzed and bench testing was performed to better understand the water chemistry and tailor the treatment design to the application. Xylem also applied their engineering expertise to develop the proper treatment solution and then refined it through sample evaluation and testing.
The initial sample evaluation revealed significant suspended solids in the water stream. This meant the treatment approach had to address not only copper removal, but also the appropriate pre-treatment requirements needed to protect system performance and ensure reliable operation.
Based on this evaluation, Xylem identified a solution using 30 cubic foot vessels loaded with SCU metals-removal media to remove copper prior to discharge. The engineering team also assessed the solids content in the sample and performed a filter study to determine the correct pre-treatment approach. This helped ensure the final design would achieve copper removal targets and appropriate water quality for discharge to the fire pond.
The result was a small footprint, simple to operate, standalone, portable system designed to meet the customer’s treatment needs. Xylem’s AQUA pro service team, supported by its Roseville, MN facility, continues to provide ongoing value through service exchanges, logistics coordination, and waste manifesting, helping keep the system running with minimal downtime.
Results
With Xylem’s solution in place, the customer was able to treat and remove copper to acceptable levels before discharging the cooling tower blowdown to the fire pond. The system provided the compliance support the customer needed while fitting within the site’s operational constraints.
From the customer’s perspective, key benefits included the compact system footprint, ease of operation, and dependable ongoing service support. The ability of the Roseville team to manage future exchanges and service logistics helps to ensure continuity and minimal disruption to production. The Roseville team’s support for future exchanges, logistics, and manifesting also helps to ensure minimal downtime and continuity of production. Overall, the solution provided a practical and proven way to manage copper removal for its cooling tower operation.