Case Study: Carbon Black Manufacturing Plant – Franklin, Louisiana
Expanding RO Capacity Without a Full System Replacement
Carbon Black plant in Franklin, Louisiana facility relies on high-purity water to support its boiler feed operations. Their existing reverse osmosis (RO) system had performed well for years, but as production demands increased, the system could no longer deliver the permeate volume the plant required. The plant needed an additional 60 gallons per minute of RO-quality water—but the solution proposed by their previous supplier created a major obstacle.
The Challenge
The supplier recommended replacing the entire water treatment system with a new, larger RO unit and accompanying filtration train—a capital project that they could not secure funding for. Budget constraints made a full system replacement impossible, yet the plant still required a significant and immediate increase in permeate output to maintain operations.
The plant needed a solution that was cost-effective, operationally efficient, and capable of using the equipment they already owned.
Sepratech’s Approach
Sepratech evaluated the performance history, current loading, membrane condition, and hydraulic limitations of the existing RO system. Instead of defaulting to a costly replacement, Sepratech approached the challenge the way the company always has—with an engineering-driven focus on optimization before replacement.
After assessment, Sepratech determined that no additional pretreatment or filtration equipment was required for their water quality. The primary limitation was RO capacity, not upstream loading or water chemistry.
This allowed Sepratech to propose an unconventional solution: increase output using the system they already had.
Key Takeaways
Three added flow tubes expanded RO output by 60 gpm at a fraction of new-system cost.
No new filters or pretreatment equipment were required—only enhancement of the RO skid.
A budget-friendly upgrade avoided lengthy CAPEX approvals and kept the project moving.
Sepratech solved the problem by improving current assets, aligning with customer needs and long-term operating goals.
The Solution: RO Capacity Upgrade Using Three Additional Flow Tubes
Rather than replacing the existing RO, Sepratech upgraded it by adding three new flow tubes to increase permeate output by the required 60 gpm. This approach expanded the hydraulic and membrane surface area capacity of the system without altering the main skid, controls, or pretreatment stages.
The advantages were immediate:
A fraction of the cost of new equipment
Minimal disruption to plant operations
No need for facility-wide approvals tied to major capital expenditure
Faster turnaround and installation
Sepratech’s engineering team completed the design, integration, and commissioning, ensuring the upgraded RO performed reliably within the plant’s operational demands.
Results
The plant approved the upgrade because it fit comfortably within available budget limits—an approval that had been impossible with the previous vendor’s proposal.
Once installed, the upgraded RO system:
Delivered the additional 60 gpm of permeate flow
Operated within acceptable pressure, recovery, and water quality parameters
Eliminated the need for a full system replacement
Reduced long-term cost by optimizing rather than replacing existing equipment
The plant now has a treatment system that meets production demands while avoiding unnecessary capital investment—demonstrating how Sepratech’s philosophy of customization and practicality directly benefits industrial operators.
