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Chemical Manufacturing Company Efficiently Turns Contaminated Well Water into High-Purity Boiler Makeup and Process Water

Project Overview

A chemical manufacturer in Illinois needed to replace its aging softening and demineralization equipment used for generating boiler makeup and process water from a highly contaminated source. SAMCO designed and manufactured a raw water treatment system that helped the client achieve the required water quality while avoiding process downtime.

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Assist the client in meeting stringent process and industrial boiler makeup water quality requirements:

  • Silica < 0.2 mg/L as SiO2
  • Demineralized water < 2 μS/cm

Scope of Service

SAMCO provided services comprising basic and detailed process, mechanical, and electrical design and engineering, system fabrication, controls integration, commissioning, startup, and training support.


  • Very hard raw water (394 mg/L hardness as CaCO3)
  • High TDS
  • Continuous operation required


When a chemical manufacturing plant in Illinois required high-quality water appropriate for feeding its boiler circuit and process streams despite having to draw from local well water—a contaminated source high in TDS—SAMCO designed and manufactured a nanofiltration (NF)system to replace the customer’s aging lime softening process and a demineralization system with single-pass reverse osmosis (RO) system using seawater membranes for high purity to replace their separate-bed and mixed-bed demineralization system.

The design split the water stream to feed equally into two systems so production is uninterrupted during cleaning and maintenance.


SAMCO’s project deliverables and equipment included:

  • Nanofiltration system
  • Single-pass RO system with seawater membranes
  • Chemical feed skids
  • Central clean-in-place skid
  • Integrated PLC controls with central control system