Poor water quality at a Nevada printing company, with very high silica levels (67 PPM), limited the plant to running its boilers at a maximum of 10 cycles of concentration. Because it was difficult to control the high conductivity required, the system experienced frequent foaming and carryover, and energy costs were escalating.
Garratt-Callahan recommended the installation of a reverse osmosis unit. Outputting nearly pure water, this system allowed the plant to run its boilers at up to 300 cycles of concentration – and at much lower conductivity, virtually eliminating foaming and carryover problems. To deal with the high silica levels and keep the R/O membranes from becoming fouled (and shortening their useful life), Garratt-Callahan also introduced the use of G-C Formula 6040 scale inhibitor.
After implementing Garratt-Callahan’s solution, the printing company saved $78,000 in energy, water, and treatment chemical costs.