The Sunflower Electric Power Corporation operates a 349-MW coal-fired power plant with a zero liquid discharge policy.  As part of the cooling tower makeup water treatment, a polymer is used along with ferric sulfate in the lime/soda ash softening process in a reactor-type clarifier.  Understanding fluid dynamics and polymer chemistry is critical in designing effective mixing equipment to maximize the value of high molecular weight polymer.  The high efficiency polymer make-down system has provided Sunflower Electric Power Plant with consistent operation and greater performance of the clarifier and reduced the potential of a hazardous work environment.