Overview

A leading ethanol production facility was experiencing persistent algae growth in its cooling tower despite operating a comprehensive water treatment program comprising multiple treatment chemicals. Excessive biological fouling on the cooling tower basin and walls was affecting system cleanliness and posed a potential risk to heat transfer efficiency and overall plant performance.
To overcome these challenges, The Catalysts Group implemented ALGYCIN, a specialized algae control solution, as part of a simplified treatment program. The objective was to effectively control algae growth, improve cooling tower hygiene, and maintain stable cooling tower performance without disrupting normal plant operations.

Plant Profile

Parameter Details
Industry Ethanol Production
Application Cooling Tower Water Treatment
Trial Duration 20 Days
Existing Treatment Program Three Biocides, One Antiscalant, One Corrosion Inhibitor & One Dispersant
Product Evaluated ALGYCIN

The Challenge

  • Persistent algae growth throughout the cooling tower basin and side walls despite the use of a multi-chemical water treatment program
  • Heavy biological fouling posed a risk to cooling efficiency, heat transfer performance, and overall system hygiene
  • Existing treatment required multiple specialty chemicals but failed to provide effective algae control
  • The plant required a reliable algae management solution that could simplify the treatment program while ensuring uninterrupted plant operation

The Catalysts Solution

Following a comprehensive on-site assessment, The Catalysts Group implemented ALGYCIN, an advanced algae control solution designed to effectively inhibit algae growth and minimize biological fouling in industrial cooling water systems. The existing multi-chemical treatment program was discontinued, and the cooling tower was treated using only ALGYCIN and Hypochlorite. Throughout the 20-day evaluation period, the Catalysts technical team continuously monitored cooling tower cleanliness, algae reduction, cooling efficiency, and critical operating parameters to ensure consistent system performance.

Performance Highlights

  • Successfully controlled excessive algae growth across the cooling tower within the 20-day trial period
  • Significantly reduced biological fouling on the cooling tower basin and walls, resulting in visibly cleaner surfaces
  • Simplified the cooling water treatment program by replacing a multi-chemical regime with only ALGYCIN and Hypochlorite
  • Maintained stable cooling tower efficiency throughout the evaluation period

Before vs After Performance

Before Application After Application
Heavy algae growth throughout the cooling tower basin and walls Significant reduction in algae growth across the cooling tower
Existing treatment using three biocides, one antiscalant, one corrosion inhibitor, and one dispersant was unable to effectively control alga Effective algae control achieved using only ALGYCIN and Hypochlorite
Extensive biological fouling affected cooling tower cleanliness Cooling tower surfaces became visibly cleaner with significantly reduced biological deposits
Continuous risk of reduced cooling efficiency due to algae accumulation Cooling tower efficiency remained stable throughout the trial
Multiple treatment chemicals required for routine operation Simplified treatment program while maintaining stable operational performance
Ongoing concerns regarding biological fouling Smooth, uninterrupted plant operation with stable distillation vacuum

Key Outcomes

  • Effective Algae Control: Achieved significant algae and biological fouling reduction during the 20-day commercial evaluation
  • Simplified Treatment Program: Reduced dependency on multiple specialty chemicals while improving overall cooling tower cleanliness
  • Stable Plant Performance: Maintained cooling tower efficiency, stable distillation vacuum and uninterrupted plant operation throughout the trial
  • Reliable Solution: Validated ALGYCIN as an effective and dependable solution for industrial cooling tower algae management

Conclusion

Effective Cooling Tower Control: ALGYCIN, combined with hypochlorite, effectively controlled algae and biological fouling, maintaining cleaner surfaces, stable cooling efficiency and reliable plant operation without affecting distillation performance.

Simplified & Reliable Treatment: The trial validated ALGYCIN as an efficient solution for simplifying cooling water treatment, improving cooling tower hygiene and supporting long-term operational stability in ethanol production facilities.