A Success Story
In VOC Monitoring For Wastewater And Cooling Towers
Protecting Texas waterways and achieving Clean Water Act compliance were key milestones in this project. With KECO’s Model 204 analyzers, the company implemented real-time VOC monitoring, delivering long-term compliance, operational efficiency, and financial savings. The advanced system provided automated alerts, ASTM-approved accuracy, and long-term reliability, reducing regulatory risks while enhancing environmental responsibility. This success highlights KECO’s ability to deliver high-performance monitoring solutions that drive compliance, efficiency, and sustainability.
Overview
After a $50 million settlement, a leading plastic resin and petrochemical manufacturer agreed to resolve Clean Water Act violations after allegations of excessive plastic pellet discharge into Texas waterways. To prevent future violations, they needed a VOC monitoring solution for wastewater and cooling tower lines. KECO provided Model 204 analyzers, delivering continuous compliance, cost savings, and operational efficiency. This case study highlights how KECO’s advanced VOC monitoring technology helped the company mitigate risk, improve efficiency, and achieve long-term ROI.
Goals
KECO aimed to help a plastic resin and petrochemical manufacturer achieve compliance in accordance with the Clean Water Act, reduce regulatory risk, and optimize VOC monitoring for cost savings and efficiency.
95%
Reduction in VOC exceedance incidents within the first six months of operation.
10+
Wastewater and cooling-tower lines monitored continuously across the facility.
15+
Years of reliable analyzer uptime backed by KECO’s comprehensive service agreement.
50m
VOC concentration data points collected annually for detailed trend analysis.
The Challenge
Inconsistent, Delayed Data
Prior monitoring relied on manual grab samples and lab analysis, leaving critical gaps without coverage and delaying corrective action. Intermittent sampling could not detect transient VOC spikes in real time, exposing the plant to undetected compliance breaches and regulatory fines.
Labor-Intensive Sampling
Operators had to collect samples from confined spaces and climb cooling-tower platforms several times per week, creating safety hazards and scheduling conflicts. These manual procedures were prone to human error and often delayed by operational demands, threatening to miss critical reporting deadlines.
The Solution
Strategic Deployment of Model 204 Analyzers
Deploying four Model 204 KECO analyzers across both wastewater and cooling-tower lines ensured seamless, real-time monitoring of VOC emissions. Each unit continuously measures aromatic and aliphatic compounds and triggers automated alerts that empower the compliance team to address excursions before they occur. Configured in either general-purpose or explosion-proof enclosures to meet site safety requirements, these analyzers integrate directly into the plant’s network for 24/7 data visibility.
Thanks to PermaStream™, self-calibration, and rugged construction, these analyzers need virtually no upkeep. Certified to ASTM D6348 and backed by TCEQ BAT and Equivalency letters, they ensure reliable compliance, lower service costs, and boost regulatory confidence.
Download Case Study ›The Results
Continuous VOC monitoring with KECO’s Model 204 analyzers delivered measurable outcomes across compliance, efficiency, and cost management. The system not only aligned with environmental regulations but also optimized plant operations while minimizing long-term costs.
Compliance & Risk Reduction
Monitoring aligned operations with environmental standards, reducing violations and strengthening community trust.
Efficiency & Cost Savings
Real-time data improved process control, lowering chemical use and minimizing waste.
Long-Term ROI
Self-calibrating analyzers eliminated the need for regular manual calibration.
Zero Routine Calibrations
Self-calibrating analyzers eliminated the need for regular manual calibration.
Operational Uptime
Rugged construction ensured reliable performance in harsh field conditions.
Audit-Ready Reporting
Built-in data logging simplified documentation for audits and regulatory reviews.
Technology Used
- KECO Membrane Technology
- Proven Sensor Technologies
- Human Machine Interface (HMI)
KECO Membrane Technology
PermaStream™ and Sample Transfer Stripper are KECO’s proprietary membrane separation systems that extract a representative vapor phase from any liquid stream—whether crude oil, fuels, water, or wastewater—without the need for pressure regulators, needle valves, flow meters, or filtration. The durable membrane acts as a physical barrier against mists, particulates, and contaminants, dramatically reducing maintenance compared to traditional head-space stripping columns.
What Our Clients Say
Real stories from real partners. See how we’ve made an impact.
“We are grateful for the chance to evaluate the OxyHound gas detection system at our installation site. The system’s performance and features have made a strong impression on us, as has your dedication to customer service and support. We see the potential value of the OxyHound system for future use in our operations and are very much interested in exploring its possibilities down the road.”
Clint T.
Assets and Systems ManagerExplore Related Case Studies
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Its robust design reduces downtime and maintenance costs, making it the preferred choice for operators who demand precision, consistency, and long-term reliability in critical oxygen monitoring.
Since 1984, Analytical Systems KECO has delivered field-proven online analyzers to the refining, petrochemical, and chemical processing industries worldwide. In this case, a major ethylene plant deployed the KECO Model 204-V-VOC Water Analyzer to monitor hydrocarbon leaks in its cooling towers and heat exchangers. The result: early detection, significant cost savings, and compliance with regulatory standards. This project highlights how KECO’s advanced technology not only protects valuable product but also supports environmental responsibility through precise, real-time VOC monitoring.
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Download Our Case Study
Learn how KECO helped a leading plastic resin and petrochemical manufacturer achieve long-term VOC compliance, reduce risk, and optimize operations. This case study outlines the challenges faced, the technology deployed, and the measurable results delivered by KECO’s Model 204 analyzers.
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