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THE OPERATIONAL CHALLENGE
In the petrochemical industry, the quality of the water used in the steam injection process is crucial to equipment performance and longevity. Hard water, rich in calcium and magnesium, creates scale deposits inside pipelines, gradually reducing heat transfer efficiency.
This was exactly the scenario faced by an industrial plant located in Mossoró, Rio Grande do Norte, Brazil. The company sourced water directly from the river to feed its steam injection system, but the high concentration of calcium and magnesium salts in that water source turned the operation into a constant challenge.
Scale buildup formed rapidly inside the piping, reducing the process’s energy efficiency and forcing the maintenance team to carry out unplanned shutdowns with increasing frequency. Each shutdown resulted in production losses, overtime costs, and accelerated equipment wear.
The client needed a robust solution capable of continuously and reliably removing water hardness while supporting the high demand of the petrochemical process.
We designed a skid with four softeners operating in alternating pairs. This configuration was engineered to ensure a continuous supply of softened water, with no interruptions even during equipment regeneration cycles.
The system capacity reaches up to 100 m³/h, enough to meet the steam injection demand of the petrochemical plant. The four softeners operate alternately, and during the backwash stage, both pumps are activated simultaneously to ensure the required flow rate is maintained at all times.
The softener vessels were manufactured in carbon steel, selected for its mechanical strength and durability in industrial environments. Each vessel is equipped with a level indicator for visual monitoring, an air release valve for air elimination, and a safety valve to protect the system against overpressure.
The system was fully automated and operates with brine regeneration. This configuration provides greater safety and stability to the steam injection process, ensuring energy efficiency and production continuity.
RESULTS AND OPERATIONAL GAINS
With the implementation of the softening system, the petrochemical industry achieved significant improvements on multiple fronts.
REDUCTION OF SCALING IN PROCESS LINES
LESS NEED FOR CORRECTIVE MAINTENANCE
CONTINUOUS AND RELIABLE OPERATION EVEN UNDER HIGH DEMAND
AUTOMATED AND STABLE REGENERATION CONTROL
