CASE STUDY: CHILLER SYSTEM STABILIZATION & OPTIMIZATION

 A large industrial complex operating multiple HVAC chillers faced serious water-side issues that threatened equipment reliability and cooling efficiency.

The previous chemical program failed to provide adequate corrosion and scale control, resulting in reduced cooling capacity, microbiological growth, and frequent maintenance. 

• Heavy scaling on chiller condenser tubes reduces heat exchange efficiency.
   
• Corrosion in pipelines and condenser water circuits.
   
• Algae and slime growth, due to poor biocide performance.
   
• High operational cost, with frequent manual cleaning and high power consumption.
   
• Inconsistent chemical results and unbalanced pH control.

HNJ Hydro Chem’s water treatment experts redesigned the entire chiller treatment program with:

• HNJ’s advanced chiller treatment chemical, a combination of scale inhibitor, corrosion inhibitor, and biocide.
   
• Shock dosing and system cleaning, to remove deposits and biological fouling.
   
• Dosing automation and control for accurate chemical feed.
   
• Regular monitoring of pH, conductivity, and microbiological activity.
   

This comprehensive program targeted both mechanical and chemical optimization, ensuring long-term reliability of the chiller system.

Before HNJ Hydro Chem’s intervention, the client’s chiller system suffered from heavy scaling on condenser tubes, moderate to high corrosion rates, and frequent algae and slime growth, which led to reduced heat transfer and system inefficiency. The plant also faced high power consumption, as the chillers had to work harder to maintain cooling performance, and monthly manual cleaning was required to remove deposits and biological fouling. 

Additionally, the chemical program was costly and inconsistent, offering unstable results. After implementing HNJ Hydro Chem’s advanced chiller treatment program, the system’s condition improved dramatically — scaling was completely removed, corrosion became negligible, and biological fouling was fully controlled, keeping the system clean and efficient. 

As a result, power consumption dropped by 10–12%, maintenance frequency decreased to once per season, and the chemical cost became optimized and stable, ensuring reliable performance, longer equipment life, and significant operational savings. 

After implementing HNJ Hydro Chem’s chiller treatment program, the client achieved:

• Complete elimination of scaling and corrosion.
   
• Stable and clean chiller operation, with balanced chemistry.
   
• Improved cooling efficiency and lower energy use.
   
• Extended maintenance intervals and reduced labor costs.

The plant’s chillers now operate at peak performance, consuming less energy and requiring minimal intervention — thanks to HNJ Hydro Chem’s customized chemical solution.