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:
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 EHS Manager and ProChem are currently working on challenges such as:
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:
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.
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.
Reusing or recycling your facility's industrial wastewater means that you:
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.
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.
Our industrial water reuse customers experience immediate ROI on water costs.
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.
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.
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.
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.
Fresh water costs are increasing as the availability becomes less reliable, putting a strain on industrial plant managers who require water for production processes.
The quality of water that is permitted for discharge from industrial manufacturing processes to public treatment facilities is highly regulated and presents a significant environmental liability.
These requirements pose an added strain on operating budgets and plant flexibility. As production requirements grow and processes change, so too will the condition of the wastewater that is generated from the production process. The company's discharge permit, however, is rigid. When a company's wastewater discharge exceeds the permitted limits, fines and other legal consequences may be incurred. One of the most cost-effective ways to reduce such environmental liability is through the implementation of industrial water reuse technologies. These water treatment processes allow for the reuse of industrial process wastewater rather than discharging to the sanitary sewer. Industrial water reuse systems can reduce the need to purchase water for use in production (lowering operating costs) and reduce or even eliminate the need to discharge water from the plant entirely (limiting or eliminating environmental liability). These systems offer a sustainable solution to the industrial water problem using the latest techniques in industrial water technology.