Thermal Chemical Engineering
Optimizing the Cycle, Preserving the Flow.
The Critical Role of Water in Chemical Processing
In the thermal chemical and petrochemical sectors, water is the primary vehicle for heat transfer and a fundamental component of molecular synthesis. However, raw water contaminants pose a constant threat to plant integrity. We address the core pain points of chemical plant operators:
Thermal Inefficiency
Even a thin layer of scale in a high-pressure boiler or heat exchanger acts as an insulator, requiring significantly more energy to achieve the same thermal output.
Corrosion in Aggressive Environments
High temperatures accelerate chemical reactions. Dissolved gases and ionic impurities can lead to pitting, stress corrosion cracking, and catastrophic equipment failure.
Wastewater Complexity
Chemical effluent often contains phenols, hydrocarbons, and heavy metals that are resistant to standard biological treatment.
Regulatory & Resource Pressure
With tightening environmental standards, plants must transition from “treatment for discharge” to “treatment for reuse.”
Advanced Technologies for Extreme Conditions
We provide ruggedized water treatment systems designed to handle the high-load, continuous operations of chemical complexes.
For high-pressure boiler feed and sensitive chemical reactions, we provide integrated membrane systems.
Key Parameter: Our systems consistently produce water with Resistivity >16 MΩ·cm and Silica <10 ppb, protecting turbine blades and catalyst beds.
Unlike traditional vacuum deaerators, our membrane contactors provide a compact, chemical-free solution.
Key Parameter: Reduces Dissolved Oxygen (DO) levels to <5 ppb, significantly extending the lifespan of carbon steel piping and heat exchangers.
For petrochemical applications, we utilize specialized media and membrane barriers.
Key Parameter: Effective removal of oil and grease to <1 mg/L, enabling the reuse of process water in cooling towers.
For treating “hard” COD in chemical wastewater.
Key Parameter: Utilizes ozone or UV/H2O2 to break down complex organic chains, achieving a 40-60% reduction in non-biodegradable COD.
Specialized Application Scenarios
We provide our solutions to handle all phases of the chemical water cycle in our divided solution segments.
- 1. High-Pressure Boiler Feedwater supplies ultra-low conductivity water which stops scale-induced hotspots and steam contamination from occurring.
- 2. Cooling Water Make-up & Blowdown uses “Smart Softening” technology to boost concentration cycles which decreases raw water consumption and chemical anti-scalant expenses.
- 3. Process Water for Synthesis tailors specific ionic profiles which enable particular chemical reactions that would otherwise result in catalyst poisoning from minerals.
- 4. Zero Liquid Discharge (ZLD) uses brine concentrators and crystallizers to run operations without liquid waste while recovering distilled water for operational reuse.
Why Choose Molewater?
Quantifiable Value & Operational Impact
We don’t just provide hardware, we provide measurable economic performance:
- 15% Energy Savings: By maintaining scale-free surfaces on heat exchangers our customers report an average reduction of 15% in the use of electricity or fuel for thermal processes.
- Lower Chemical Dependency: The membrane-based demineralization process eliminates the requirement to regenerate bulk acid or Caustic which can save up to $30,000 per year in the purchase of chemicals and neutralizing costs.
- Extension of Turnaround Time: The improved water chemistry can extend the time between cleanings of equipment by 25-40% and keeps your plant running longer.
- 95% Water Recovery: In ZLD-configured facilities, we allow the recovery of approximately 95% of the influent water and future-proofing the plant against water shortages in the local area and the rising cost of utility services.
Engineered Solutions & Product Portfolio
Built to provide 24/7 durability for industrial use, our systems are equipped with PLC-based automation as well as corrosion-resistant materials (SS316L/Duplex).
- Modular Demineralization Skids: RO/EDI units that have been tested by the factory to allow for quick on-site integration.
- Macro-Porous Ion Exchange: Specialized resins that remove organics as well as specific Ions from chemical process streams.
- Separators of Oil-Water and DAF Units: A robust primary treatment system for the effluent of petrochemicals.
- Thermal evaporation systems: High-efficiency brine concentrators to manage wastewater with high TDS.
Request More Information
Contact Molewater for more information on available solutions.