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Congratulations to the ProChem team on a successful system start-up for Alcoa!

This wastewater treatment system was designed and engineered specifically to target and treat the contaminants found in the wastewater at their facility.

Features

The system is fully automated and features web-based remote monitoring software, allowing the system to run 24/7 with only 2 operators.

Services

Alcoa also chose ProChem as their contracted operations service. Both of the operators needed to run the system work for ProChem, so Alcoa doesn't have any added overhead for their new system—but all the benefits of it.

Results

We are proud to report that the system is producing 100% compliant effluent. This system is one huge step towards the facility’s goal to reach a 95% wastewater reuse rate. The second phase of the project will include implementing ProChem’s high-pressure reverse osmosis technology, which will allow them to reuse their wastewater. Great job, team!

One of the largest facilities in its area and one of the largest in that company, a heavy duty truck engine and cab manufacturing facility chooses to recycle their industrial wastewater.

Corporate mandate to reach zero discharge may have been a large motivating factor, but the success of the industrial wastewater recycling program and the cost savings prove to be the wins for this facility. They are now reusing up to 8.4 million gallons of their industrial process water per year, which translates to a 60% - 80% reuse rate. And they have plans to improve that rate to 100%. With ProChem's help, that is a real possibility.

The EHS Manager in this facility faced several challenges with the wastewater they previously discharged. Surfactant issues and foaming at the regional water authority, where the wastewater was received, and also molybdenum contamination of land-applied sludge were reported. The EHS Manager was proactive in identifying the facility's contribution to these issues and in finding a solution. ProChem and the EHS Manager worked together to find the solution that was best for the facility. Multiple technologies were evaluated, including vacuum distillation, ion-exchange, and membrane filtration with nanofilter/reverse osmosis system. The membrane filtration with nanofilter/RO technology would ultimately become the best option for meeting the corporate goal of zero discharge through a closed loop industrial water reuse system.

The proposal to the facility's management included incentives such as directing capital funds to recycling industrial wastewater instead of meeting increasingly stringent and recurring environmental regulations. The recycled water could be routed to the cooling towers because it would actually be of higher quality than what is purchased from the city, reducing the need for chemical pretreatment, increasing cooling efficiency, and extending the equipment's life. More specifically, the membrane filtration (with nanofiltration/RO system) technology offers the following benefits:

  • Produces acceptable process water with little organic, microbiological, or inorganic contamination
  • Requires minimal operating labor (because ProChem water reuse systems are automated)
  • Produces minimal concentrate (waste), which is simple to treat through a conventional precipitation system
  • Comes with a reasonable price tag and overall low operational costs

Additionally, adopting industrial water recycling in the facility would eliminate the need to store untreated wastewater due to the flow restrictions from the water authority. Their permit restricts them to 36,307 gallons per day, causing the facility to store an excess of 240,000 gallons.

After implementing the industrial water reuse system, the plant-wide use of water has been reduced from 62 million gallons per year to 26 million gallons per year. Over a 9 year period, plant water use has been reduced by 57.6%. The facility is saving a projected $90,000 on the purchase and disposal of wastewater alone.

The facility uses recycled industrial water in several different applications:

  • The e-coating system within the manufacturing process (15,000 to 20,000 gallons per day)
  • Humidification (500 to 1,000 gallons per day)
  • Parts wash system (12,000 gallons per day)
  • Cooling tower (4,000 to 6,000 gallons per day)

The EHS Manager and ProChem are currently working on challenges such as:

  • Installing solids removal methods for e-coat discharge to reduce the impact on conductivity/TDS and TSS
  • Expanding the storage capacity for reuse water to address losses associated with shutdown periods
  • Eliminating stormwater influent to the wastewater treatment process that reduces the water reuse efficiency.
  • Adding a high-pressure reverse osmosis system to address the lower conductivity requirement for the e-coat process but also allowing improved reuse rate (>90%)

This facility's EHS Manager is a proponent of industrial water reuse/recycling and despite the remaining challenges still in front of them before reaching their ultimate goal, they are experiencing great benefit from the system:

  • Lower operating costs
  • Improved feed water quality
  • Reduced environmental liability and risk
  • Reduced chemical usage
  • Decrease in water purchases and disposal costs
  • Major step towards fulfilling the company's desired environmental position

Conserve resources

Only 3% of Earth's total water supply is fresh water.

Of that 3%, only 0.008% is available for us to purify and use. The rest is contained in soil moisture and frozen in ice.

  FreshWater Graph AvailableFreshWatergraph

Reducing the daily and hourly strain on that water means there will be more to go around at a given time. Industrial water recycling and reuse practices now are sustainable solutions with long term benefits.

Reduce operating costs

Reusing or recycling your facility's industrial wastewater means that you:

  • Won't have to purchase water as often or ever again, avoiding the ever-increasing water rates.
  • Won't need to pay to discharge to the sewer, avoiding surcharges and penalties.
  • Can have better quality influent via your recycled water than the city water you purchase now, so you can save on pretreatment efforts, equipment, maintenance, and product fouling.
  • Can use the recycled water for for any other process that uses water: utilities, cooling/heating water, process feed waters, and so on.

Eliminate discharge permits

You can reduce or eliminate your current and future wastewater permit challenges and liabilities. Because the amount of water you'll discharge will be significantly reduced, if not eliminated, you will be able to lower the discharge permit limits and never deal with flow restrictions again.

Brag about it

You'll earn the positive environmental image and the right to market yourselves as water stewards. Once you implement one sustainable practice and remove the worry associated with your wastewater, it is much easier to envision environmentally sound solutions and sustainable practices in other areas of the business.

Does your industrial process use a significant amount of water or have high costs associated with water or wastewater?

Our industrial water reuse customers experience immediate ROI on water costs.

Are you currently treating the purchased water before using it?

Our industrial water reuse customers report that the quality of recycled water is the best they've had for their process and have eliminated their pretreatment system as a result. Eliminating pretreatment means fewer chemicals to purchase and less equipment to maintain.

Do you know of a process or plant activity that could use recycled water?

The recycled water can be purified to the highest quality or to contain essential minerals that help the process to which the water will be fed. The industrial water reuse system is designed to meet your unique needs, not to meet the needs of the majority in an off-the-shelf solution.

Are your operating costs a prohibitive factor in wastewater treatment?

Our industrial water reuse systems are automated and offer web-based remote monitoring, so our reuse customers get more from their current operators without having to increase operating costs. We also offer outsourced industrial water reuse system operations, where we employ the operator so you don't have to.

Is there space available in your facility or outside of it to add an industrial water reuse system?

Our industrial water reuse systems are designed to be integrated into existing wastewater treatment systems and can even be installed outdoors in the open or in an external enclosure. We fabricate the systems in house, allowing us to design the system according to your footprint.

Congratulations to the ProChem, Inc. Water Systems team for a successful system start-up for a leading manufacturing of fiber cement siding and backboard. This system treats and reclaims effluent from the facility's existing wastewater treatment system for reuse in their manufacturing process. It features automation and web-based remote monitoring and utilizes ProChem, Inc. microbiocide, anti-scalant, and pH adjustment products.

This wastewater reuse system allows the customer to reuse 300k gallons of wastewater per day, instead of discharging it from the plant.

ProChem, Inc. industrial wastewater reuse system in conex containers ProChem Inc HPRO for Wastewater Reuse ProChem, Inc. HMI in PLC cabinet for the automation control system with web-based remote monitoring