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ProChem recently completed another project that embodies our mission: to advance our customers’ total water management strategies by providing innovative solutions supported by a comprehensive set of services. This project required the coordination of chemistry, equipment, technology, and customer-centered collaboration—all the disciplines on which ProChem was founded and continues to operate.

 

The Customer

Prior to finding ProChem, this wood products manufacturer had been working with their local publicly owned treatment works (POTW) to treat their water. They needed to lighten their heavily pigmented water so that it could be penetrated with a UV light in order to disinfect it before discharging to the POTW.

The company initially hired an engineering firm to find a solution, but because there are so many nuances in waste water treatment that require expertise in multiple disciplines, they were unable to provide one. They would have needed to understand the wastewater, the chemistry, and the unique needs of the customer—a specialized set of services they turned to us to provide.

The plant’s wastewater comes from their wet electrostatic precipitator (WESP) system, which uses water and electricity to scrub fine wood particles from gases before they can be released into the atmosphere according to EPA regulation. Those fine wood particles end up in the wastewater that the ProChem system needed to treat. Our starting point was our CleanWESP water treatment program, designed by ProChem chemists specifically for the wood products industry to protect valuable equipment such as the WESP. Even with this solution in place, this customer had significant problems that would require some creative problem-solving. Fortunately, our team lives by the premise, “The bigger the problem, the bigger the solution.”

While ProChem’s experts were researching the problem, the POTW continued to tighten their restrictions. As a result, the scope of the project pivoted from merely lightening the pigmented water for discharge to treating and reusing 10% of their wastewater inside the plant. This is what we refer to as a “kidney loop”—continuously treating part of the stream, rather than the whole thing, to keep the whole stream cleaner. 

ProChem’s custom-tailored solution to treating wastewater for discharge while also implementing water reuse required a carefully orchestrated combination of chemistry, equipment, and technology.

 

The Chemistry

 

When dealing with wood wastewater, there’s only one proven chemical treatment that works. A coagulant turns dissolved contaminants into solid particles, while the polymer holds those together to make bigger particles, which typically sink to the bottom. But in cases such as this, the wood particles float. The chemistry team at ProChem had to find a combination of polyamene, pH, coagulant, and polymer that had good separation to allow the solids to float in as compact a layer as possible and also produce water as clear as possible. At the plant, the particles on the top get skimmed off and go to the belt press, where the water in the sludge is removed and the sludge is disposed of.

 

The Equipment

 

The system that ProChem designed includes pretreatment, sand filtration, reverse osmosis membrane filtration, and UV lights. The system is based around a specialized chemical treatment program coupled with I-PRO™ and B-PRO™ membrane technologies. Designed to treat up to 60,000 gallons per day at 200 gallons per minute (gpm), the current system handles 125 gpm of reuse water and is integrated with existing clarifiers, dissolved air flotation (DAF), and a belt press.

ProChem fabricators constructed three Conex containers at our facility in Elliston, Virginia, and outfitted them with amenities for 24-hour, year-round operation—lights, heaters, fans, and ventilation.

One container houses three 62-ft3 sand filters operating in parallel with one in service at a time. The sand filters are equipped with automatic switching and backwashing of exhausted columns using permeate water.

Our membrane technology for this project included both I-PRO and B-PRO Conex containers. Both containers consist of an automatic prefilter switching to reduce down time, additional chemistry to prevent scaling and biological growth, and an automatic phase change based on conductivity—keeping discharge within operating parameters. The I-PRO container consists of 10 membrane housings, each with six membranes, while the B-PRO container has eight membrane housings with four membranes in each.

As always, we incorporated the most up-to-date technology that was appropriate for the customer’s particular needs:

  • High-efficiency booster for maximum reuse
  • 125-hp motor and operating pressure, producing approximately 700 psi to 900 psi in the I-PRO
  • 50-hp motor with an operating pressure between 300 psi and 400psi

The initial walkthrough at the customer’s plant revealed tight spaces that would require precise piping work to create the most efficient and sustainable system. For a clean piping sequence, our Project Superintendent made sure there were no “jumping pipes,” meaning no pipes overlap. Overlapping diagonal pipes make the system less serviceable. For example, simply fixing a valve could require cutting pipes. Because of our close attention to detail, that wouldn’t be necessary for this project.

 

The Technology

 

This system is automated and continuously transmits data to ProChem’s AutoRun™ software. To accomplish this, our Controls & Instrumentation Engineer used the P&ID to determine how many PLC (programmable logic controller) inputs and outputs would be needed. The PLC is at the center of the control system, continuously monitoring the state of input devices and making decisions based upon a custom program to control the state of output devices as much as 100 times a second.

Our Controls & Instrumentation Engineer writes custom programs using algorithms to monitor flow, dose chemicals, adjust pH, control agitator speed, and much more. Any signal that can be measured can also be manipulated.

ProChem upgraded the customer’s wastewater treatment system to provide operators the means to enhance their process for meeting the plant’s water quality needs. As part of the upgrades, ProChem modernized the control system utilizing a Remote I/O solution. This technology reduced wiring costs while improving operational readiness and reliability.

The Remote I/O system provides a reliable method to transfer monitoring and control signals to and from the PLC-based control system. In this configuration, two Remote I/O stations are situated along the Ethernet network in different areas of the system. Each station contains five to 10 I/O modules. For monitoring applications, the system collects signals from analog transmitters or discrete devices. It concentrates the signals and, when polled by the network master, sends them over the Ethernet network directly to the main PLC control panel. For control, process commands from the host are transmitted over the network and converted to analog or discrete form to control valves, pumps, motors, and other types of proportional and on/off control elements.

 

The Takeaway

This wood products manufacturer has a large and complex treatment system with multiple moving parts. The challenge for us was to make all those parts work together in balance. It was the most complicated control system our engineers have ever designed.

As always, we maintain an ongoing relationship with this customer and continue supporting them both remotely and on-site. In fact, one of our Environmental Technicians is responsible for the day-to-day optimization of the system.

ProChem’s team took a customer who was discouraged and gave them the solution they needed to protect their costly (about $1 million/year) WESP equipment by treating and reusing their wastewater. The remaining wastewater is discharged to the POTW, guaranteed to maintain compliance.


Looking for a solution to your industrial water problems? Contact our experts today!

 

Fresh from Hurricane Harvey, Houston has suffered through the consequences of their inadequate flood mitigation strategies. The flood conditions could be even worse this season—starting June 1—and preparations made by local and state governments will be under the microscope. Will they set aside the money for mitigation efforts, or will they roll the dice?

The social, economic, environmental, and structural effects of flooding vary depending on the location and severity of the flooding. Moreover, flood mitigation strategies themselves can expose the vulnerabilities of communities. Implementing successful mitigation requires cross-district and state policy regulations—storm water, for example, doesn’t obey municipal lines. To implement flood abatement and prevent catastrophic events from potentially raining down on their citizens, cities and townships should decide how to allocate funding: education, city infrastructure, or public services. Government officials and local professionals must draw upon current flooding data in their geographical range to justify appropriate funds and move forward with plans that can preserve not only economic dignity but also the lives of those at risk.  

Educating citizens about how to prepare and having emergency plans for every department are crucial in developing a more resilient city. Local communities are responsible for mitigating repetitive flood problems by implementing educational measures, including information about emergency routes and actions to take in the case of a flood event—such as not crossing a flooded area, not re-entering homes prematurely, or not drinking tap water that could potentially be contaminated. Education, however, is only a small part of this equation and should act as a catalyst that spurs citizens to push their government to allocate the funding to support the physical components of the mitigation strategy.

Both built and natural infrastructure affect the extent of flooding consequences from storm surges. Natural structures include channels and natural floodplains, while built structures are comprised of damns, levees, and flood walls. Investment in city resilience planning reduces the flood time within a city, decreases property loss, and lessens the mortality risk while also keeping a city economically afloat during a tragedy—because businesses remain open.

Strong organizational commitment to flood protection is not a one-time deal. It requires long-term adjustment of policy. Analyzing what worked, what didn’t, and the changing conditions of the built environment inform smart policy. These factors should be adaptive instruments used to respond to various ecological and human-made systems.

Within the past 20 years, we have begun to see dramatic shifts in rain patterns, which lead to extreme weather events. The swings in air and ocean currents are changing global weather patterns at a high rate (some research on that can be found here). Every community has flooding risk, but deviations show increased likelihood of flooding in places with little to no experience with extreme flooding, as Houston discovered last summer.

As our weather shifts, our priorities should follow suit. Commitment to preemptive flood abatement measures needs to be demonstrated in community budgets. Among the noise surrounding climate change and weather shifts are many helpful and potentially life-saving pieces of wisdom. At the very least, we ought to be concerned about the economic benefits of taking preemptive action—a precautionary strike may be the only way to protect ourselves and our communities from the potentially ruinous effects of storm water.

 

For Further Reading:

Flood Ready

Natural Hazards

Clean air, safe drinking water, and sufficient food supply are all increasingly at risk from extreme weather events as we advance into the 21st century. In the absence of government mandates, it’s incumbent upon U.S. industry to take precautionary actions like those outlined in the Paris Climate Agreements. Doing so will prevent the pervasive, irreversible consequences of climate change by allowing for adaptive management to changes over several decades. By implementing cost-effective measures, environmental and health degradation can be mitigated.

After a long struggle to contain a global rise in temperature, the largest international climate conference in history, the 2015 United Nations Climate Change Conference (COP21), made commitments aimed to keep global warming below 2°C by developing The Paris Agreement. The multilateral agreement between 197 parties who came together to create a sustainable and dynamic action agenda seeks to prevent the escalation of climate change, but what about the impacts of deviations in weather patterns already in effect?

A common misconception regarding climate change is that it simply means the earth will get warmer, but the true definition reveals that the change is in the distribution of weather patterns around the world. Quite simply, wet areas will get wetter and dry areas will get drier. Climatologists are already seeing this pattern and predict more extreme weather events, sea levels rising, and warming oceans in the coming decades.

Policymakers typically structure environmental policies to stop worsening climate change, but the burden on water resources has already started being intensified. For every fraction of a degree the atmosphere is warmed, the hydrologic cycle is altering the intensity of precipitation—impacting both water quality and the safety of water sources.

We may soon see impacts on drinking water and ecosystems that will lead to ripple effects on our food supply as water quality and supply are jeopardized by climate change. Water quality is already diminishing due to increased sediment from heavy downpours. In some areas where competition for water is increasing, quantity is decreasing as short- and long-term droughts are gradually intensifying.

Skeptics often cite lack of scientific certainty as a reason for postponing action on climate change, but accumulating evidence is adding weight to the “better safe than sorry” argument. Early warnings of climate change ring the alarm bell for doing the bare minimum—just in case—as the economic consequences of doing nothing continue to mount. The U.S. weaning itself off fossil fuels is a clear first step in abating those consequences. The 97% chance that climate change is caused by human involvement is evidence decisions about energy profiles need to look differently from this point forward.

Our country has been one step behind Europe in creating energy efficient products and reducing greenhouse gas emissions through policy techniques such as carbon pricing and “cap and trade” agreements. If corporations were to get in front of potentially strict cap and trade agreements before they’re on the table, for example, they would be able to act gradually and economically, rather than abruptly with potential penalties for violations.

The removal of the U.S. from the Paris Climate deal came after President Trump talked skeptically of climate change—calling it a “con job” and a “myth.” But what are the costs of waiting for a permanent display of its authenticity? The U.S. is not tied to any international climate legislation since the withdraw from the Paris Climate Agreement in 2017, a decision that came with strong criticism both internationally and domestically and resulted in estrangement from our closest allies. States have taken up the Paris targets on their individual agendas, but not taking the opportunity to mitigate climate change at a national level could cost America.

Critics of climate change attest that legislation will negatively affect our strongest economic sources based in fossil fuels, but not leaning into the precautionary principle could lead to costs that could be mitigated in the inevitable fight for water resources.

Climate change: How do we know?

Water Supply

U.S. withdrawal from the Paris Agreement: Reasons, impacts, and China's response