Understanding Chemical Failures in Industrial Wastewater Treatment

Ask any industrial wastewater treatment plant operator how often their plant experiences upsets and the answer is rarely “never”. In plants that rely on chemistry (and where the mechanical equipment is functioning correctly), the most common cause of poor performance is an unstable or ineffective chemical program. Some form of chemical treatment in industrial wastewater applications is often essential, but it is inherently sensitive to pH, solids loading, temperature, and a wide range of other substances and conditions. Even the best-designed balancing systems cannot eliminate the variability typical of industrial wastewater.

The Cost of Feed Variability

When feed conditions change, conventional coagulant and flocculant programs can destabilise quickly, leading to poor solids removal, sludge blowouts, inconsistent effluent quality, and rising operating costs. A common misconception is to dose chemicals based on a “worst-case scenario”. In practice, this usually results in chronic over-dosing, which can be just as detrimental to plant performance as under-dosing while costing significantly more.

Why Better Chemistry Matters

The real solution lies in chemistry that is less susceptible to feed variability and engineered to perform across a wider operating window. Achieving this requires deep industry experience, an understanding of what drives instability, and how to design a chemical program that remains as consistent as possible under real-world conditions. Many operators may be satisfied when their plant achieves 95 percent performance reliability, but shouldn’t we all be striving for performance that is as close as possible to 100 percent?

Hydroflux Utilities: Not a Chemical Supplier, but a Problem Solver

Although Hydroflux Utilities has developed and offers a comprehensive range of coagulants, flocculants, and specialty reagents, our long-term customers—and we ourselves—do not view us as a chemical supplier. Far from it. When someone asks us for a particular chemical, our first question is why. What challenge are they trying to solve? What outcome do they need? Our focus is on solving process issues, stabilising performance, and reducing operating costs by applying the right chemistry—not simply supplying more of it.

Turning Chemistry into Stable Performance and Lower OPEX

By combining decades of operational experience with detailed analysis of influent variability, Hydroflux Utilities selects and implements the optimal chemistry for each site. This results in stronger, more stable treatment processes and delivers:

• More consistent and reliable plant performance
• Lower sludge volumes and improved dewatering
• Reduced chemical consumption
• Improved equipment efficiency
• Lower overall operating costs

Plants often achieve equal or better performance while operating equipment at lower loadings and experiencing fewer interruptions.

Ongoing Support to Maintain Long-Term Savings

Hydroflux Utilities specialists work closely with site teams to refine chemical programs, conduct performance trials, and support ongoing optimisation. We can even provide remote monitoring services that help anticipate problems before they occur. This ensures that improvements are not temporary but sustained over time. The outcome is a more reliable, lower-cost treatment process that strengthens the long-term operational resilience of the entire facility.

To learn more about Hydroflux Utilities’ specialised chemical programs, call 1300 417 697 or visit www.hydrofluxutilities.au.

About the Hydroflux Group

The Hydroflux Group aims to deliver the highest level of engineering and scientific know-how to the emerging issues of sustainability, climate adaptation and environmental protection with a specific focus on water and wastewater.

As part of its vision and mission, Hydroflux has always taken its climate responsibility seriously. In 2022, Hydroflux became Australia’s first water treatment and technology company to achieve Climate Active carbon neutral certification for its organisation and products. It knows that partnering with customers and clients is the most significant impact it can have in its journey. The Group employs over 100 staff and operates throughout Australia, New Zealand and the Pacific Islands, with office locations in Sydney, Melbourne, Brisbane, Perth, Auckland, Suva and Portsmouth.