Chemical plant approaches zero discharge

The Gulf Coast facility was faced with an unreliable demineralizer system to meet a proposed expansion of boiler feedwater requirements with a wastewater goal of zero liquid discharge. High TDS in a proposed new well-water source threatened to increase regeneration frequency, greatly increasing acid and caustic usage. This also meant more wastewater to treat, a condition that ran counter to a zero discharge system. The turnkey solution came from USFilter...

WARRENDALE, PA, Jan. 5, 2006 -- A Gulf Coast chemical plant was faced with an unreliable demineralizer system to meet a proposed expansion of boiler feedwater requirements. In addition, the plant had a wastewater goal of zero liquid discharge.

High TDS in a proposed new well-water source threatened to increase demineralizer regeneration frequency, greatly increasing acid and caustic usage. Increasing regenerations also meant more wastewater to treat, a condition that ran counter to a zero discharge system.

Solution
The chemical plant selected an outsourcing alternative and opted to shutdown its old demineralizer. USFilter's consulting engineering team designed and installed a system to expand capacity and reduce wastewater discharge.

The turnkey solution consisted of an expandable 300-gpm reverse osmosis (RO) system with mobile cation softening to pretreat the RO.

USFilter drilled a 1,200-foot well, poured the concrete pad, constructed a building and installed the system as part of its build/own/operate service. Under this program, USFilter owns and operates the system to supply water for a fixed price and at an agreed upon quantity and quality of water for the length of the contract.

All pretreatment chemicals were eliminated due to the use of mobile softening and off-site regeneration.

To conserve plant water and minimize waste, the RO concentrate stream is used for cooling tower makeup.

A remote monitoring system supplements USFilter's regular maintenance and operational service.

Results
The following results were realized by the customer:
• Reduced wastewater by 22 million gallons annually
• Eliminated $300,000 emergency mobile demineralizer expense
• Assures predictable boiler feedwater costs
• Advances zero discharge goal by mobile softening and reuse of 2.2 million gallons per month of RO concentrate
• Eliminates hazardous chemical storage providing a safer workplace and environment
• Redirects plant capital and labor to core business
• No unexpected costs from operational upsets
• No unscheduled downtime due to purified water shortages

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Siemens Water Technologies (www.siemens.com/water), delivers cost-effective, reliable water and wastewater treatment systems and services to municipal, industrial, commercial and institutional customers worldwide. The division -- which includes USFilter (www.usfilter.com), of Warrendale, Pa. -- is part of Siemens' Industrial Solutions and Services Group (I&S). Siemens I&S (www.industry.siemens.com) is an integrator of systems and solutions for industrial and infrastructure facilities and a global service provider for the plant and projects business covering planning, installation, operation and the entire life cycle. In fiscal 2004, I&S employed a total of 30,000 people worldwide and achieved total sales of EUR 4.290 billion [US$5.21 billion].

[US$1=EUR0.823]

Also see:
-- "Hydro-Clear filter rehabilitation keeps Libertyville, Ill., plant running like new"
-- "Australian power station saves money with water reclamation"

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