Case Study: Electric Utility Facility – Eunice, Louisiana
Reducing Iron Fouling and RO Maintenance Through Sepratech’s Microfiltration Upgrade
An electric utility facility in Eunice, Louisiana, relied on water drawn directly from the Chicot aquifer – a groundwater source historically known for high concentrations of soluble iron. For years, the plant treated its well water using a conventional sequence of multimedia filtration, cartridge filtration, reverse osmosis (RO), and mixed-bed polishing. While this process worked on paper, it struggled in real operating conditions. The soluble iron in the raw water continued to cause recurring performance issues that disrupted operations, increased maintenance labor, and elevated costs far beyond expectations.
The Challenge
As the well water passed through the treatment train, the soluble iron gradually oxidized. This caused two major problems:
Frequent Cartridge Filter Change-Outs
Once oxidized, the iron precipitated into fine particulates, overwhelming the cartridge filters. Cartridge housings were continually loading with iron solids, forcing the maintenance team to perform frequent change-outs just to keep downstream equipment online.RO Membrane Fouling and Premature Wear
Any iron that remained in soluble form—and therefore passed through the cartridge filters—fouled the RO membranes. The membranes required ongoing off-site cleanings, and the rate of degradation accelerated significantly. Replacement frequency increased, adding cost and downtime no plant manager wants to see.
The situation had become unsustainable. The cartridge consumption rate was too high, membrane performance was declining too quickly, and maintenance costs were tightening operational margins. A long-term, engineering-driven solution was required.
Sepratech’s Approach
With more than 35 years of supporting power generation facilities across North America, Sepratech understood the chemistry and operational mechanics behind the problem immediately. Soluble iron needed to be reliably oxidized—and more importantly, removed—before reaching any fine filtration or membrane equipment.
Sepratech worked closely with their operations team to evaluate real-time water quality, existing system behavior, and performance logs. The goal wasn’t just to fix a symptom but to redesign the front end of the treatment process so that the entire system—from filtration to polishing—could operate efficiently and reliably.
Key Takeaways
Microfiltration eliminated oxidized iron upfront, reducing strain on cartridge filters and improving overall treatment reliability.
Cleaner feedwater extended membrane life, lowering the frequency of cleanings and replacements.
Reduced cartridge use and fewer membrane swaps resulted in rapid cost recovery—payback achieved in under 1.5 years.
The upgraded process now handles the iron-heavy Chicot aquifer consistently, providing the facility with predictable, stable operations.
The Solution: Hollow Fiber Microfiltration
Sepratech implemented a 0.1-micron hollow fiber microfiltration system, engineered specifically to remove iron after oxidation. The system provided a consistent mechanical barrier between the oxidized iron particulates and the downstream treatment stages.
This solution delivered several key benefits:
• Complete removal of oxidized iron prior to cartridge filtration
• Dramatic reduction in cartridge load, extending filter life and reducing labor
• Significant decrease in RO membrane fouling
• Longer membrane life and fewer off-site cleanings
• Greater operational stability across the entire treatment process
Sepratech also supported the facility with operational guidance, ensuring the oxidation step was controlled and consistent so the microfiltration system could capture the iron in its particulate form with maximum efficiency.
Results
The results were immediate and measurable:
• Cartridge filter life extended dramatically
What once required constant attention became a routine maintenance item.
• RO membrane fouling decreased sharply
The membranes remained cleaner, performance remained stable, and chemical cleanings were far less frequent.
• Membrane replacement intervals extended
Reducing both capital cost and system downtime.
• The microfiltration system paid for itself in under 1.5 years
Savings from reduced cartridge consumption, fewer membrane cleanings, and extended membrane lifespan offset the investment in a remarkably short timeframe.
The facility gained a more predictable, efficient, and cost-effective water treatment process—with long-term benefits that will protect equipment and improve reliability for years to come.
This project demonstrates Sepratech’s core philosophy: solving water treatment challenges isn’t just about supplying equipment—it’s about understanding the chemistry, hydraulics, and operational pressures that industrial facilities face every day.
By combining field experience, engineering expertise, and hands-on operational support, Sepratech delivered a solution that strengthened their water treatment infrastructure and eliminated persistent inefficiencies that had plagued the plant for years.
The facility now benefits from a robust pretreatment system tailored to the realities of the Chicot aquifer. And as the plant continues to grow and evolve, Sepratech remains a long-term partner—committed to reliability, performance, and customer-focused solutions in power generation and beyond.
