CASE STUDY: REDUCING CHEMICAL COST THROUGH PRODUCT OPTIMIZATION

A leading industrial client in Pakistan was facing rising water treatment costs and complex chemical dosing operations. Their previous supplier’s program required two separate chemicals — one for oxygen scavenging and another for scale inhibition.

This setup not only increased chemical consumption and storage requirements but also resulted in higher labor and maintenance costs due to dosing management and frequent adjustments

1. High chemical cost per cubic meter of treated water.
    
2. Two-chemical dosing leads to doubled handling and equipment usage.
    
3. Operational inefficiency and risk of dosing errors.
    
4. Inconsistent performance, requiring frequent recalibration.

HNJ Hydro Chem analyzed the existing program and proposed its special multifunctional oxygen scavenger & antiscalant, which replaces both previous chemicals with a single formulation.

This advanced product is designed to:

• Scavenge dissolved oxygen effectively to prevent corrosion.
   
• Inhibit scaling and deposit formation.
   
• Maintain stability under variable temperature and pressure conditions.
   
• Reduce dosing frequency and chemical consumption.

• Replaced both existing chemicals with one multifunctional HNJ Hydro Chem product.
   
• Optimized dosing parameters to suit the client’s system design.
   
• Trained on-site operators for simplified handling and monitoring.
   
• Monitored results over multiple operating cycles.

Following HNJ Hydro Chem’s modification, the system showed remarkable overall improvement. The feed water TDS, which had been high and unstable, became controlled and significantly reduced, resulting in stable and consistent operation. The permeate TDS improved from being above the acceptable limit to within the desired range, producing better-quality water. 

Additionally, system recovery increased from 65–70% to 80–85%, allowing the plant to generate more treated water with the same input. The cleaning frequency was also optimized — instead of cleaning every 2–3 weeks, it was extended to every 2–3 months, effectively prolonging membrane life and reducing downtime. Overall, the operational cost decreased by 20–25%, resulting in a more efficient, economical, and reliable RO system.

By adopting HNJ Hydro Chem’s multifunctional product, the client achieved:

• Cost reduction of approximately 25–30%.
   
• Simplified dosing, cutting equipment and labor needs in half.
   
• Consistent system protection from corrosion and scaling.
   
• Improved operational safety and reliability. 

Lower cost, less complexity, and better performance — all from one optimized chemical solution.