Case Study: Safely Removing Biofilm While Reducing Hazardous Chemicals at a Major Virginia Medical Center

Industry: Healthcare
Location: Mid-Atlantic U.S.
Application: Cooling Tower Water Treatment
Challenge: Persistent biofilm growth and emergency shutdowns during peak season

Table of Contents

• Challenges
• Investigation & Root Cause
• Chemstar WATER’s Breakthrough Solution
• The Power of MIOX Technology
• Long-Term Outcome & Results

Challenges: Recurring Biofilm and Emergency Shutdowns

Every summer, a major medical center in Virginia faced a critical water treatment challenge: rising approach temperatures, reduced cooling efficiency, and emergency shutdowns in one of its buildings. Upon inspection, gray biofilm deposits were discovered coating the condenser tubes—a condition not observed at the facility’s other three buildings, despite nearly identical systems.

The onsite team along with the guide of a water treatment company, aggressively dosed the system with sodium hypochlorite, alternating biocides, and biodispersants in an effort to contain the microbial contamination. However, these efforts proved ineffective during the hot summer months, leading to costly shutdowns for inline disinfection due to the presence of positive Legionella.

Given the mission-critical nature of hospital cooling systems—especially during high ambient temperatures—an urgent and more sustainable solution was required.

Investigation & Root Cause Analysis

After multiple failed attempts to eliminate the issue using conventional chemical treatments, Chemstar WATER was brought in to perform a comprehensive assessment. Our technical team noticed a critical difference between the impacted cooling tower and the others: a helicopter landing pad located in close proximity to the troubled system.

Through site analysis and water chemistry reviews, the team hypothesized that airborne hydrocarbons from helicopter exhaust were entering the cooling tower basin, serving as a nutrient source for microbial growth, feeding a specific gray colored visible biofilm. This external contamination was fueling rapid biofilm development and rendering traditional biocides ineffective.

---

“Every summer, we were scrambling to manage rising temperatures and unexpected shutdowns in one of our critical buildings. No matter how much chemical we fed, the biofilm kept coming back. It wasn’t just frustrating—it was risking patient comfort and operational integrity.

Bringing in Chemstar WATER was a turning point. Their team quickly diagnosed the root cause—something we hadn’t even considered—and proposed a solution that didn’t involve more hazardous chemicals. Since implementing the MIOX system, we’ve had no shutdowns, better system performance, and safer operations for our staff. It’s made a huge difference, and they’ve truly earned our trust as a long-term partner.”

– Facility Manager, Major Medical Center in Virginia

---

Chemstar WATER’s Breakthrough Solution

As a vertically integrated and technology-agnostic water treatment provider, Chemstar WATER selected the most suitable treatment platform for this unique challenge. The team identified MIOX® on-site mixed oxidant generation as the optimal solution.

Unlike traditional biocides, MIOX generates a powerful oxidant blend of hypochlorite and hydrogen peroxide directly on-site using only water, electricity, and salt. This approach ensured consistent control over biofilm formation, even in the presence of organic contaminants from the helicopter exhaust.

The Power of MIOX Technology

MIOX AE-4 System Specifications:

• Daily Oxidant Production: 4 lbs/day Mixed Oxidant Solution (MOS)
• Free Available Chlorine (FAC) Concentration: ~3,800 mg/L (±1,000)
• Salt Conversion: 3 lbs salt per lb FAC
• Energy Conversion: 3.5 kWh per lb FAC
• Dimensions (W x D x H): 40” x 12.5” x 44.1” (101.6 cm x 31.75 cm x 112.01 cm)

Safety and Sustainability Benefits:

• Eliminates the need for bulk chemical deliveries
• Removes risks associated with storing and handling hazardous biocides
• Improves workplace safety through use of food-grade salt as a feedstock
• Reduces the facility’s environmental footprint

Compared to traditional sodium hypochlorite and commercial biocides, MIOX offers superior oxidizing power and reduced chemical risk, making it ideal for sensitive healthcare environments.

Long-Term Outcome & Results

Following MIOX implementation, the facility has experienced:

• Complete elimination of emergency shutdowns due to biofilm
• Improved heat exchange efficiency and lower approach temperatures
• Significant reduction in chemical handling risks
• Lower total cost of treatment over time

Furthermore, the facility has embraced the technology’s sustainability benefits and appreciates its alignment with internal ESG goals.

For facilities dealing with persistent biofilm or unexplained microbial fouling, especially in mission-critical cooling systems, Chemstar WATER’s innovative and agnostic approach ensures every problem receives the best-fit solution.