PTQ Q2 2025 Issue

Application objectives and KPIs

Objective

KPI

Reduce hypochlorite consumption and feeding frequency Improve water quality (by reducing bacteria growth) and

Hypochlorite consumption

Water quality (as measured by total plate

increase consistency of water quality

counts of legionella and e-coli

Reduce corrosion rates (even though a corrosion

Corrosion rates

inhibitor was not being used)

Table 1

make-up water for cooling and other processes. However, they were limited by poor water quality, especially during upsets at the wastewater plant. Traditionally, the plant used a large quantity of hypochlorite for tertiary treatment, which required high concentrations of free chlorine to con- trol bacterial growth in the water. High chloride concentra- tions in the water caused high oxidation reduction potential (ORP), which resulted in high corrosion rates. Despite the large dosage of hypochlorite, this treat- ment could not prevent biofouling, which regularly caused expensive maintenance work. Additionally, any operational problem that occurred in the primary or secondary treat- ment prevented the use of recycled water as make-up water because of its poor quality. Recommendations The refinery partnered with a global producer of specialty chemicals to address the inconsistent water quality and other issues that the wastewater treatment plant was experiencing. The team of chemical specialists completed a comprehensive audit and a walk-through of the refinery’s water treatment system. During this process, laboratory technicians conducted tests to measure the components of the water and determine the best chemical application. The team decided to implement the proprietary ClearPoint Biofilm Detection and Control programme to reduce the growth of bacteria and the rate of corrosion in the wastewater treatment plant. The benefits of using this programme typically include improved microbiological con- trol, reduced corrosion, and reduced operating costs. The biofilm detection and control programme comprises three parts: the proprietary OnGuard 3B analyser, pro- prietary chemistry, and technical expertise. The analyser

employs an advanced ultrasonic probe that provides early detection of biofilm growth in water systems, thus allow - ing for modelling and monitoring of real-time biofilm levels. Early detection enables plant personnel to take corrective action before biofilm harms the system. Proprietary chemistry, which includes a chlorine stabiliser chemistry used to produce a patented, in-situ stabilised active chlorine solution, provides advanced biological con- trol. The resulting solution effectively controls both plank- tonic microorganisms and biofilm and does not cause any of the adverse side effects associated with using strong oxidising biocides. Specialty chemical scientists and engi- neers provide technical expertise to investigate problems, recommend and implement solutions, and deliver results. Given this programme recommendation, the team of spe- cialists set up the analyser and chemical feed to the tertiary system in the wastewater treatment plant. Additionally, they gathered baseline data for hypochlorite consumption, bacteria counts, and corrosion rates. To accomplish their overall goal of implementing circular water usage solutions, they needed to meet several objectives. For this applica- tion, the objectives determined by the plant engineers and specialty chemical team were measured by three key per- formance indicators (KPIs) (see Table 1 ). Results After the refinery engineers and the specialty chemical team implemented the new biofilm detection and control programme, they immediately observed positive results. Any obstructions in the wastewater system due to bio- fouling were eliminated. Whenever an issue occurred in the primary and secondary wastewater treatment plant, the water quality remained consistent. This meant that the

Start ClearPoint

Time (Months)

Figure 1 Hypochlorite consumption decreased after implementation of the proprietary ClearPoint programme

PTQ Q2 2025