Tip Sheets

Saving Water and Energy in Industry

Build a Water Efficiency Program

  1. Create a water efficiency team and designate a water efficiency coordinator.
  2. Identify and introduce a proper measurement system.
    • Develop a baseline and metrics
    • Benchmark progress internally and externally.
  3. Carry out facility assessments.
    • Identify potential water-efficiency improvement at the target facility.
    • Calculate the expected water savings and the estimated costs associated with the implementation of water -efficiency projects.
  4. Establish a program of maintenance, inspection and evaluation of
    production practices.
  5. Increase management and employee awareness of the need to use water efficiently. Involve employees in water efficiency efforts.
    • Develop best practices training.
    • Check with peers to verify technological results of similar projects and to get advice.

Optimize the water distribution system

  1. Check for leaks.
    • Inspect for leaks in pipes, fittings, pumps and gauges in mechanical rooms and headers throughout the building. Repair will prevent collateral damage to wood surfaces and furnishings, ceiling tiles and electrical equipment. The savings will occur in the water bill and through a lower sewer disposal fees as well.
    • Leaks occurring in closed systems can be even more expensive. Water circulating in the chiller, the condenser and the steam loops is usually chemically treated for corrosion and high hardness. Here the total loss covers water as well as very costly chemicals and some of the energy needed to heat or cool the circulating fluid.
    • Inspect and repair damaged insulation systems. Sagging or missing sections of insulation indicate possible leaks.
  2. Cooling systems and cooling towers
    • Meter and record water use.
    • Never use once-through water cooling. If there is no other choice, reuse the water elsewhere in the facility.
    • Use air cooling, as opposed to water cooling, where feasible, as opposed to water cooling.
    • Establish performance-based specifications when contracting with a cooling tower vendor.
    • Investigate side-stream treatment.
    • Investigate the potential of wet-dry cooling towers.
    • Reuse treated wastewater or other sources of water for cooling tower make-up.
  3. Boilers and hot water
    • Insulate boilers, storage tank(s), and pipes.
    • Use instantaneous heaters at remote locations.
    • Establish performance-based specifications when contracting with a boiler vendor-operator.
    • Check stream traps regularly - faulty steam traps waste water and heat.
    • Reuse steam condensate water and boiler blow-down water where feasible.
    • Feed used water back into systems where possible.
    • Record water use and check for leaks.
  4. Other water using equipment and operations
    • Use automatic valves that shut off the water when equipment is off.
    • Consider minimizing water use when purchasing new equipment.
    • Use mechanical/oil seals instead of water packing glands on pumps where possible.
    • Capture reject water from reverse osmosis units and reuse it where feasible.
    • Use automated computer control technology to regulate water use.
  5. Reuse Wastewater
    • Try to close the manufacturing loop by reusing water.
    • Treat used water only if necessary.
    • Identify discharges that can be reused and implement reuse practices.