Working in technical partnership with ENGIE, Hydratech combined specialist cooling system engineering through the Hydratech Services Division (HSD), advanced thermal fluid technologies and a comprehensive Fluid Monitoring Programme (FMP) to deliver a consultancy-led approach to cooling system optimisation, improving reliability, operational efficiency and long-term performance.
Biomethane is a renewable gas produced from organic waste through anaerobic digestion. As with many critical industrial processes, maintaining reliable cooling systems is essential to ensuring safe, efficient and continuous operation.
During an initial site visit, Hydratech engineers learned that two biomethane production facilities had previously experienced catastrophic chiller failures caused by freezing within their dryer circuits. Wider discussions with ENGIE's engineering team also identified concerns around cooling system protection, fluid condition and the long-term reliability of critical process cooling assets.
Rather than simply recommending a replacement fluid, Hydratech adopted a consultancy-led approach, working alongside site engineers to investigate the condition and performance of every critical cooling system.
Specialists from the Hydratech Services Division (HSD) carried out comprehensive on-site fluid sampling and laboratory analysis across multiple cooling systems, including:
The findings revealed a consistent pattern.
While the existing chiller glycol systems remained in acceptable condition, every dryer circuit showed little or no inhibitor protection together with evidence of biological contamination.
This detailed assessment enabled Hydratech to move beyond symptom management and develop a structured improvement programme based on measured system condition and long-term cooling system performance.
One of the most significant barriers identified during Hydratech's investigation was that the dryer circuits could not be converted to glycol-based heat transfer fluids.
ENGIE had been advised that, because the sites were operating with conventional heat meters, glycol could not be introduced into the systems. This prevented the implementation of a more robust long-term cooling solution.
Drawing on their specialist knowledge of cooling and heating systems, Hydratech identified a compliant engineering solution. By replacing the existing meters with Multi Fluid Heat Meters, the sites could accurately measure thermal energy using glycol-based heat transfer fluids, removing the technical barrier to system conversion.
Rather than accepting the limitation, Hydratech worked alongside ENGIE to develop a practical engineering solution that enabled the long-term optimisation of the dryer circuits.
Challenge: Conventional heat meters prevented glycol-based heat transfer fluids from being introduced into critical dryer circuits.
Hydratech Solution: Hydratech identified that replacing the existing meters with Multi Fluid Heat Meters provided a compliant engineering route to introducing glycol-based heat transfer fluids.
Outcome: A key technical barrier was removed, enabling the long-term optimisation and protection of cooling systems across multiple biomethane production sites.
With the technical pathway established, Hydratech developed a phased programme of engineering improvements, combining specialist cooling system engineering, advanced thermal fluids and ongoing fluid management.
The programme included:
Every recommendation was supported by engineering expertise, measured system data and laboratory analysis, ensuring the solution addressed both immediate operational issues and long-term system reliability.
Following the planned replacement of heat meters during 2025, ENGIE successfully introduced CoolFlow IGE fully inhibited glycol into the dryer circuits across its biomethane production facilities.
Today, every site operates under Hydratech's quarterly Fluid Monitoring Programme (FMP), providing routine on-site fluid sampling and laboratory analysis, together with expert technical recommendations to help maintain optimum cooling system performance throughout the life of the assets.
Hydratech's consultancy-led approach has helped deliver:
Through the combined expertise of the Hydratech Services Division (HSD), advanced thermal fluid technologies and the Fluid Monitoring Programme (FMP), Hydratech supports operators across the biomethane and anaerobic digestion sector with consultancy-led cooling system optimisation.
From engineering investigations and on-site fluid sampling and laboratory analysis to bespoke Side-Stream Filtration Units, advanced thermal fluids and ongoing technical support, Hydratech helps improve cooling system reliability, maximise operational efficiency and protect critical process assets.
Hydratech Services division provides specialist engineering and maintenance services to customers installing, commissioning, operating or optimising large cooling and heating systems.
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Regular analysis can extend the life of both fluid and system. Hydratech’s Fluid Monitoring Program (FMP) is a very straight forward, effective way to proactively monitor closed-loop system condition.
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