As industrial facilities grow, water demand often grows with them. Unfortunately, many plants find themselves limited by equipment that was originally sized for lower production volumes. When that happens, the typical solution is installing a larger reverse osmosis (RO) system This can require significant capital investment and extended downtime.
Recently, Watertech worked with a customer facing exactly this challenge. Their facility’s industrial RO system had become undersized for their current production needs, and the plant was struggling to keep up with daily water demand. Instead of pursuing a full system replacement, Watertech worked closely with the customer to find an innovative solution that met performance objectives while accommodating time, production, and budget considerations.
A Different Approach: Upgrading the Membranes
After evaluating system performance, operating pressures, and flow limitations, the team determined that upgrading the RO membranes would significantly improve system efficiency without requiring mechanical modifications.
Watertech installed next-generation 3D-printed RO membranes within the existing pressure vessels. These advanced membranes are designed with optimized feed channel geometry, which provides several performance advantages compared to traditional membrane spacers.
Key benefits of the 3D-printed membrane design include:
- Reduced pressure drop across the membrane elements
- Lower overall energy consumption
- Improved flow distribution within the membrane element
- Higher permeate production from the same system footprint
Because the upgrade involved replacing only the membrane elements, installation was straightforward and required no changes to the piping, pumps, or controls of the existing RO system.
Immediate Performance Improvements
Following the membrane upgrade, the facility began seeing measurable improvements in system performance. On average, the plant experienced a 9% increase in permeate flow, helping the facility better keep pace with rising water demand without requiring any additional equipment.
The new membranes also allowed the system to operate more efficiently, resulting in a 15% increase in runtime between clean-in-place (CIP) cycles, which reduced maintenance requirements and improved overall system uptime.
Additional Optimization Through CIP
Best PracticesBeyond the membrane upgrade, Watertech worked closely with the plant team to further optimize system performance. During a site visit, we walked the operators through an optimized clean-in-place (CIP) procedure, reviewing proper cleaning chemistry, circulation practices, and operating parameters to ensure the membranes were being cleaned as effectively as possible.By refining the CIP process and improving cleaning efficiency, the facility was able to recover additional membrane performance and gain approximately 3% more permeate flow on top of the 9% increase already achieved through the membrane upgrade.
Maximizing Existing Infrastructure
One of the biggest advantages of this solution was the ability to maximize the performance of the existing RO system rather than replacing it entirely. By focusing on targeted upgrades and operational improvements, the customer was able to significantly increase water production while keeping costs under control.
For many facilities facing similar capacity challenges, advancements in membrane technology, combined with proper system operation and maintenance, can unlock additional performance from existing infrastructure.
A Collaborative Solution
Projects like this highlight the importance of collaboration between facility teams and water treatment specialists. By carefully evaluating system performance, implementing innovative membrane technology, and optimizing cleaning procedures, Watertech helped the customer improve water production without a large capital investment.
As industrial water demands continue to grow, solutions that improve efficiency, reduce energy consumption, and extend equipment life will play a critical role in helping facilities meet their operational goals.
Jake Russell
Territory Manager
Jake has been with Watertech of America since 2020 providing industrial water treatment solutions for boiler, cooling and wastewater applications. Jake frequently leads educational training events and seminars to promote better water management and improve safety. He holds a BA in Engineering from UW-Madison.