How Much Does an Industrial Water Treatment System Cost?

Industrial water treatment is a complex family of technologies and systems, serving a wide range of industries and applications. Whether your needs include water treatment, process purification and separation, wastewater treatment, or a combination of these, you’re probably wondering “How much does an industrial water treatment system cost?”

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As you’ve likely found, estimating the cost of a water treatment system is complicated, in part due to the many factors and variables that play a role in system design. This article helps to tease out some of these factors and show how they apply broadly across a variety of industrial water treatment systems.

What’s included in an industrial water treatment system?

Industrial water treatment encompasses a few main types, including water treatment, process purification and separation, and wastewater treatment. The specific equipment used in your system will depend heavily upon which of these treatment types you need, as well as the unique conditions of your process and plant. The following is a list of equipment commonly deployed across a variety of industrial water treatment systems:

• Clarifiers for removal of suspended solids by sedimentation, flocculation, or coagulation.
• Lime softeners for reduction of total dissolved solids (TDS) in feed and wastewater.
• Oil/water separators and/or dissolved air flotation device for removal of oils.
• Particle filtration for removal of larger particulates and suspended solids.
• Membrane filtration for removal of dissolved particles, biological contaminants, and ionic substances.
• Reverse osmosis or nanofiltration for water purification.
• Filter presses for sludge dewatering.
• IX columns for softening and/or selective removal of ionic substances, including hardness, alkalinity, chloride, mercury, metals and organics, among other substances.
• Reactors and chemical additives for pH adjustment and/or precipitation of metals
• Control panel (depending upon desired level of automation).
• Peripherals, including pumps, tanks, piping, valves, and skids.

The actual components of your industrial water treatment system will depend upon your specific application. There is often flexibility in the use of these and other technologies in fulfilling a given treatment need, and familiarity with factors that drive costs up or down can help you to understand the best treatment system components to meet your needs and budget.

The main cost factors of an industrial water treatment system

There are four main factors that determine the cost of industrial water treatment systems:

• What are the flow-rate requirements of the system? In other words, how fast will you need to process a given volume of water?
• What is the chemistry and quality of your influent stream?
• What is the target level of quality for treated water?
• What construction materials are required?

Answering these questions can help you to pinpoint your needs, and better understand the costs associated with an industrial water treatment system that’s right for your facilit

Flow rates

In general, when it comes to industrial water treatment systems, lower flow rates translate to lower capital costs. While this rule holds true across most systems, flow rate can make a larger difference for some technologies over others. Cost differences between large and small microfiltration (MF) units, for example, are relatively scalable based on flow once you cover the base cost of engineering, control panel, cleaning systems, while the cost of large capacity ion exchange (IX) systems can be slightly more. As an example, increasing the flow by 50% can increase cost by about 20%.

System flow rate is usually measured in gallons per minute (GPM) and/or gallons per day (GPD). When you budget for a new water treatment system, keep in mind that the higher the GPM or GPD capacity, the higher your investment will likely be. Flow rates are always factored into the system cost, so be sure you have an accurate measurement of your process needs when requesting a quote for a new water treatment system.

Water quality

A key factor in the cost of most industrial water treatment systems is the chemistry and content of the stream to be treated. It is important to thoroughly understand the types and concentrations of substances present, as well as any variability in stream makeup. In general, the greater the number of contaminants present, the greater the number of steps in a water treatment train, and the greater the up-front cost. This is particularly evident with IX systems, where a complex stream can increase the up-front cost several times over due to the need for greater numbers of resin varieties, chemicals, and IX beds or columns.

For some technologies, such as RO/NF units, complex streams can greatly inflate costs due to the need for pretreatment. While not always strictly necessary, investment in appropriate pretreatment equipment can help to drastically cut long-term costs by protecting downstream equipment, improving product yields, and reducing waste disposal costs.

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Target purity

It is also important to understand the target output you wish to achieve from an industrial water treatment system. If you are investing in a pharmaceutical water treatment system, for example, you are likely aiming to comply with regulatory standards, which can range substantially depending upon your products manufactured. Fully understanding the contaminant thresholds that are acceptable for your production limits can help to ensure that you choose the right technology to meet your needs, without overspending for water quality that exceeds your target range.

Construction materials

The materials used to construct your water treatment system can have a huge impact on cost. While many industrial applications involve harsh conditions, such as high flow rates, extreme temperatures or pH levels, and/or damaging chemicals, others are less demanding. If this is the case at your facility, you may be able save on up-front costs by using more affordable materials such as PVC piping and FRP tanks, as opposed to more expensive components such as rubber-lined or stainless-steel vessels and/or piping. In many cases, you may also have the flexibility to choose between less-costly manual controls and comparatively more expensive automated PLC panels.

Other important factors to consider when pricing an industrial water treatment system

• Up-front planning. The critical first step in securing an industrial water treatment system is planning the concepts, designs, and regulatory requirements for your project. The cost of engineering can typically run 10–15% of the cost of the entire project and is usually phased in over the course of the project, with most of your investment being allocated to the facility’s general arrangement, mechanical, electrical, and civil design.
• Space requirements. When planning for any water treatment system, the size of your system and your plant location will affect cost. If physical space is very expensive at your plant, for example, it may be more cost-effective to invest in technology with a compact footprint. Depending upon your specific water treatment goals and process conditions, you may not have much flexibility in system size, however it pays to take the system footprint into account if you are considering various treatment technologies. 
• Installation rates. Labor costs can vary widely from one location to the next, so be sure to investigate the installation rates specific to your area when planning your project budget. In areas where installation costs are high, prepackaged modular systems may be more affordable than build-in-place facilities. Installation costs typically range between 15–40% of the project cost, depending on the degree of prepackaging and amount of site civil work needed.
• Level of system automation needed.There are two basic approaches to managing your water treatment system. The first is a higher level of automation that requires very little operator intervention. This approach can eliminate human error associated with running the equipment, and can also minimize ongoing labor costs. The downside is that greater automation means a more costly up-front investment in sophisticated PLC controls and instrumentation. The second approach involves a lower level of automation and a greater reliance on operators. While manual controls can save up-front capital costs, they can also mean a greater long term investment in labor. Considering your staffing availability as well as long- and short-term costs can help you decide on the level of automation that’s right for your water treatment system.
• Turnkey and prepackaged systems. Depending upon the scope and complexity of your water treatment needs, you may have the opportunity to choose between a prepackaged and a build-in-place solution. Prepackaged systems typically cost the same or less, and can save up to a few months of construction time. Another benefit to choosing a prepackaged water treatment system is that the production facilities and fabrication shops that offer turnkey systems generally have specialized knowledge and experience in manufacturing the types of equipment used in your solution. This translates to quick and efficient fabrication, as opposed to the delays and added costs that can arise from hiring and onboarding a field crew for a build-in-place system.  
• Shipping the system to your plant. When having your water treatment system shipped to your plant, plant on about 5–10% of the cost of the equipment for freight. This can vary widely depending upon the time of year you are purchasing your system in addition to where your plant is located in relation to the manufacturing facility.
• Operation costs. In water treatment, operational costs are often based on a complex and interconnected set of factors. In planning a water treatment system, you’ll need to weigh the pros and cons of initial versus long-term cost investment, the cost ramifications of adding a pre- or post-treatment system, as well as the availability of staff and space at your plant. For IX resin technologies, you’ll also need to consider whether contracting for off-site regeneration is the better choice. No matter which systems you rely on, commissioning an operating cost analysis can help you to accurately budget for all the chemicals, equipment, labor, and other costs involved in maintaining your system through its life cycle.
• Regulatory costs. It is important to fully understand regulatory requirements for your plant, especially in terms of the cost of compliance for waste disposal. As regulations are increasingly stringent and activity is often subject to oversight, be sure to thoroughly investigate whether you’ll need permits to discharge, and that your facility is approved prior to releasing any waste, as failure to comply with local restrictions can result in heavy fines.
• Waste disposal costs. Also consider that there will be costs to treating the secondary waste produced by your water treatment system(s). With stringent environmental regulations, you will need to either treat the waste for hauling away or solidify with a filter press/evaporator and transport to third party disposal firm.
• Other possible costs and fees.When purchasing a water treatment system, you’ll also want to be sure not to overlook other hidden costs and fees. For example: Will there be any taxes on the system or additional purchasing fees? What effect will the proposed system have on utility costs? Will you need to pay for ongoing analytical, lab, and/or compliance testing?

With these factors in mind, it is often a good strategy to check with your system engineers and/or manufacturer about affordable alternatives. They might be able to shed some light on installation-friendly systems or provide suggestions to help keep your costs to a minimum.

The bottom line

Industrial water treatment systems cover a diverse range of applications, and are used across plants of varying size and process complexity. System costs can range significantly due to these variables, with some simple, low-flow systems running as low as $45,000, to high-end, high-capacity systems with price tags exceeding tens of millions of dollars. While an accurate estimate of system cost is virtually impossible without taking your specific process needs into account, we’ve compiled some ballpark estimates by system type:

Process water treatment

Pretreatment and process water treatment systems are generally used to optimize performance and service life by preventing scaling, fouling, or other damage to downstream equipment. The cost for design, engineering, equipment, installation, and startup for process water treatment systems can vary greatly from one application to the next:

• Boiler feed water treatment systems. Low-pressure boilers require less exacting feed water quality than high-pressure boilers, making their respective treatment systems comparatively less involved and less costly. That said, a 100 to 200 GPM system would likely range between $50,000 and $250,000 for low pressure applications, and $500,000 to $1.5 million for high pressure applications.
• Raw water treatment systems. A standard 200 to GPM capacity raw water treatment system can range from $975,000 to $3 million, depending upon flow rate and water quality.
• Cooling tower water treatment systems. A standard 100 GPM system would run somewhere between $50,000 and $250,000, with more complex needs like desilication and softening pushing the cost toward the upper limit.

Process purification and separation

Process purification and separation systems are used for a variety of applications, such as protecting downstream equipment, treatment or recycling of brine streams, removal of contaminants, concentration of products, recovery of valuable by-products, product purification and potable water generation, among other uses. Estimated costs for various types of process separation units are as follows:

• Microfiltration (MF) and ultrafiltration (UF) systems. While MF/UF are often cited for their cost-effectiveness, their costs can range widely depending upon the materials used and the flow rate needed. A basic 10 to 20 GPM MF/UF system would likely cost less than $100,000, while a larger 100 to 200 GPM unit would run between $150,000 and $450,000 depending upon the quality of materials used.
• Nanofiltration (NF) and reverse osmosis (RO) systems. Costs for RO/NF systems range significantly depending upon the flow rate and level of pretreatment needed. A simple RO/NF system of 5 to 10 GPM capacity might run less than $60,000, while a large 300 GPM system with a complex pretreatment system might run as much as $2 to $4 million.
• Ion exchange (IX) resin systems. IX systems actually represent a large family of separation strategies, with widely variant costs that are closely tied to stream chemistry, as well as flow rate and fabrication materials. At the low end, a simple 20 GPM IX system would likely cost less than $100,000, while a system of similar capacity but greater chemical complexity might double or even quadruple the cost. At the high end, a complex IX system with a capacity of GPM might cost as much as $7 to $10 million.

Wastewater treatment systems

For most industrial applications, a 150,000 GPD capacity WWTS would cost an estimated $500,000 to $1.5 million inclusive of all necessary design, engineering, equipment, installation, and startup. More complex streams, higher flow rates, and higher effluent quality standards will all drive the system cost upward.

Zero liquid discharge (ZLD) systems present a special case where waste treatment is concerned. Since they remove all water from the effluent stream, they include specialized evaporator/crystallizer units which can account for well over half the total system cost. All in all, a fully-installed 1 to 20 GPM ZLD system will run between $250,000 and $2 million, while a  to GPM capacity ZLD system will cost $25 to $50 million.

Can SAMCO help?

SAMCO has over 40 years’ experience custom-designing and manufacturing industrial water treatment systems for a range of industries and solutions, so please feel free to reach out to us with your questions. For more information or to get in touch, contact us here to set up a consultation with an engineer or request a quote. We can walk you through the steps for developing the proper solution and realistic cost for your industrial water treatment system needs.

To learn more about the services and technologies that SAMCO offers, visit our page on water treatment solutions here.

Reverse osmosis (RO) is a widely used method for purifying drinking water in both residential and commercial settings. This advanced filtration process has gained popularity due to its effectiveness in removing a wide range of contaminants. Let's explore the key advantages of RO systems:

• Effective removal of impurities: RO systems can eliminate various contaminants, including dissolved solids, heavy metals, and microorganisms.
• High-quality water production: The result is clean, great-tasting water that's safe for drinking and cooking.
• Easy maintenance: Most modern RO systems require minimal upkeep, making them convenient for homeowners.
• Cost savings: While there's an initial investment, RO systems can save money compared to buying bottled water over time.

However, it's important to consider the potential drawbacks of reverse osmosis:

• Water usage concerns: Some perceive RO systems as wasteful due to the water used during the filtration process.
• Mineral removal: RO filters out beneficial minerals along with contaminants, which some consider a health drawback.
• Energy consumption: Unlike some other filtration methods, RO systems require electricity to operate.

RO Water Waste Debate: Facts vs. Myths

A common question surrounding RO systems is whether they waste water. The answer is nuanced and depends on various factors. Depending on the type, quality, and age of a system, RO units can produce 3 - 25 gallons of waste water per one gallon of purified water.

To understand this better, let's break down the RO process:

1. Water enters the system and passes through pre-filters to remove larger particles.
2. The water then undergoes cross-flow filtration through a semi-permeable membrane.
3. Purified water (called the permeate stream) flows to the storage tank.
4. The waste stream (concentrate stream or brine) containing contaminants and dissolved inorganics is directed to the drain.

It's this last step that leads to the perception of water waste. However, it's crucial to understand that this process is necessary for maintaining the efficiency and longevity of the RO membrane.

Reframing the Waste Water Perspective

While the term "waste" is commonly used, it can be misleading. A more accurate description is that reverse osmosis systems use water as part of their purification process. This usage is similar to how we use water for other essential household tasks.

Consider these comparisons:

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• Hand washing: All water used goes down the drain, yet it's crucial for hygiene.
• Showering: Uses significant amounts of water, but is essential for personal cleanliness.
• Laundry: Washing machines use large volumes of water, which is necessary for clean clothes.

In each of these cases, we don't typically consider the water as "wasted" because we recognize the benefits of the process. Similarly, the water used in reverse osmosis contributes to the production of clean, safe drinking water.

That said, it's important to acknowledge that some RO systems do use more water than necessary, particularly if they are not properly maintained or are of low quality. This excessive usage can indeed be considered wasteful and highlights the importance of choosing a high-quality system and maintaining it properly.

Water Consumption in RO Systems: Breaking Down the Numbers

The amount of water used by an RO system isn't fixed and can vary based on several factors:

• Water quality: Higher levels of contaminants require more water to flush them away.
• Total Dissolved Solids (TDS): Water with high TDS levels may require more flushing.
• Water temperature: Colder water is more difficult to push through the membrane, potentially increasing water usage.
• Membrane recovery ratio: This indicates how efficiently the system converts feed water to purified water.
• System condition: Older or poorly maintained systems may use more water.
• System size and pressure: Larger systems or those operating at higher pressures may use water differently.
• Membrane type: Different membranes have varying efficiency levels.

As a system ages, it typically uses more water due to the membrane accumulating contaminants over time. Regular maintenance and timely replacement of components can help mitigate this issue.

Membrane Recovery Ratio: Key to RO Efficiency Explained

The membrane recovery ratio is a crucial factor in determining an RO system's efficiency. It indicates how much water is "recovered" as purified RO water compared to the total amount of water that enters the system.

For example, a recovery ratio of 25% means that for every 100 gallons of water that enter the system, 25 gallons are purified, and 75 gallons go to drain. A higher recovery ratio results in less drain water, which is generally more efficient.

However, it's important to note that some RO designs cannot handle high recovery rates as they may lead to membrane scaling and premature fouling. This is why it's crucial to choose a system that balances efficiency with long-term performance.

Most residential RO systems have an actual recovery rate of 10-25%, even if manufacturers claim higher rates. When choosing a system, always ask about the waste water ratio before purchasing. Be wary of claims that seem too good to be true, as they often are.

Zero Waste RO Systems: Revolutionary Solution or Clever Marketing?

In response to water usage concerns, some manufacturers have developed "zero waste" RO systems. But what does this really mean?

"Zero waste" RO systems use the same purification process as traditional systems, but they handle the waste water differently. Instead of sending it down the drain, these systems recycle the waste water within your home. Here's how it typically works:

1. The system purifies water as normal, producing both clean water and a waste stream.
2. Instead of draining the waste water, it's redirected to other household uses.
3. Most commonly, under-sink zero waste RO systems send the reject water to your hot water supply.

While this approach does eliminate water "waste" in the traditional sense, it's important to consider the implications:

• The recycled water contains the contaminants removed from your drinking water.
• You'll be using this water for tasks like washing hands, cooking, and cleaning.
• Depending on your water quality, this could potentially introduce contaminants into these processes.

Therefore, while zero waste systems can be a more water-efficient option, they may not be suitable for all households, particularly those with high levels of certain contaminants in their water supply.

How Reverse Osmosis Works: Demystifying the Purification Process

To truly understand the water usage in RO systems, it's helpful to know how the process works. Reverse osmosis is a water purification process that uses a semi-permeable membrane to remove ions, molecules, and larger particles from drinking water.

Here's a step-by-step breakdown of the process:

1. Pre-filtration: Water first passes through a sediment filter to remove larger particles like dust and rust.
2. Carbon filtration: Next, it goes through an activated carbon filter to remove chlorine and organic compounds.
3. Reverse osmosis: The pre-filtered water is then forced through a semi-permeable membrane under high pressure. The membrane has tiny pores (about 0. micron) that allow water molecules to pass through but block larger molecules like dissolved salts, bacteria, and other impurities.
4. Storage: The purified water is stored in a tank until it's needed.
5. Post-filtration: When you turn on your RO faucet, the water passes through a final carbon filter to improve taste before reaching your glass.

During this process, the system continuously flushes the membrane to prevent clogging and maintain efficiency. This flushing action is what produces the "waste" water in traditional RO systems.

The result of this thorough process is water that's free from a wide range of contaminants, including:

• Dissolved salts and minerals
• Bacteria and viruses
• Chemical contaminants like lead, arsenic, and fluoride
• Organic compounds

This comprehensive purification is why RO water is often described as "tasteless" - it's free from the minerals and compounds that typically give water its taste.

Expert Tips to Optimize Your RO System's Water Efficiency

To minimize water usage and maximize efficiency, consider these tips when selecting and maintaining your RO system:

1. Assess your needs: Determine if you truly need an RO system or if other filtration methods could meet your needs. For example, if your main concern is chlorine taste, a simple carbon filter might suffice.
2. Research thoroughly: Before purchasing, investigate different systems' efficiency and recovery rates. Look for independent reviews and certifications.
3. Invest in quality: Remember the adage "buy cheap, buy twice." A high-quality system may cost more upfront but can save money and water in the long run.
4. Regular maintenance: Replace membranes and filters as recommended by the manufacturer. This keeps your system running efficiently and can significantly reduce water usage.
5. Consider water pressure: Ensure your home has adequate water pressure for efficient RO operation. Low pressure can lead to increased water usage.
6. Monitor performance: Keep an eye on your water bills and the taste of your water. Sudden changes could indicate maintenance is needed.

By following these guidelines, you can ensure your RO system operates at peak efficiency, minimizing water usage while providing high-quality drinking water.

Reverse Osmosis System for Pure, Safe Drinking Water in

When looking for an efficient RO system, consider options like the HydroGuard HDGT-45 series. This system offers excellent filtration capabilities with fewer filters to replace, making it cost-effective. Key features include:

• Compact design: Fits easily under most sinks.
• Easy installation: Can be set up without professional help in most cases.
• Sanitary quick-change filters: Makes maintenance fast and hygienic.
• Leak detector shut-off valve (FLOWLOK™): Provides peace of mind against potential water damage.
• Water pressure regulator: Protects the system from water hammer and pressure spikes.

This system effectively reduces levels of contaminants like lead, nitrates, cysts (such as cryptosporidium and giardia), arsenic, and sodium, among others.

Ultrafiltration: The Eco-Friendly Alternative to Reverse Osmosis

While reverse osmosis is highly effective, it's not the only option for high-quality water filtration. Ultrafiltration (UF) offers several advantages over traditional RO systems:

• Zero wastewater production: UF systems don't produce a waste stream.
• Low-pressure operation: Works effectively even in low water pressure conditions.
• No energy required: Operates without electricity.
• No storage tank needed: Produces filtered water on demand.
• Retention of beneficial minerals: Unlike RO, UF doesn't remove dissolved minerals from water.

One example of an efficient UF system is the Premiere PS-PURUF. This multi-stage drinking water system features:

• A 0.02 micron ultrafiltration membrane
• Two high-performance 0.5 micron carbon filters
• Over 99.9% bacteria and pathogen removal
• Reduction of heavy metals and chemicals including chlorine, chloramines, pharmaceuticals, pesticides, lead, and VOCs
• On-demand water production (up to 1.5 gallons per minute)
• No storage tank required, reducing the risk of bacterial growth

The PS-PURUF system can be an excellent alternative to traditional RO systems, especially for those concerned about water usage or mineral retention.

Conclusion: Making an Informed Decision

Choosing the right water filtration system for your home involves weighing various factors, including water quality, usage patterns, environmental concerns, and personal preferences. While reverse osmosis systems are highly effective at producing clean, safe drinking water, they do come with considerations regarding water usage and mineral removal.

By understanding how RO systems work, their benefits and drawbacks, and the factors that affect their efficiency, you can make an informed decision about whether an RO system is right for your home. If water usage is a primary concern, consider exploring alternatives like ultrafiltration or high-efficiency RO systems.

Remember, the goal is to find a solution that provides you with safe, great-tasting water while aligning with your values regarding resource conservation. Whether you choose reverse osmosis, ultrafiltration, or another filtration method, regular maintenance and proper use will ensure you get the best performance and longevity from your system.

Ultimately, investing in a quality water filtration system is an investment in your health and wellbeing. Take the time to research and choose wisely, and you'll enjoy the benefits of clean, purified water for years to come.

Are you interested in learning more about pharmaceutical water system? Contact us today to secure an expert consultation!