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CLIENT: Large Manufacturer of Automotive Fabricated Components
LOCATION: Northern Illinois
HIGHLIGHTS: Wastewater Treatment Evaluation and Upgrade, Analytical Monitoring, System Expansion Design
Water Treatment
A major manufacturer of fabricated metal seals contracted with Environmental Services, Inc. (ESI) to evaluate their wastewater pre-treatment system design and operating procedures. Even though the wastewater treatment system was relatively new, they were experiencing a large number of regulatory violations. ESI determined that the system design was fundamentally sound. However, several operational problems and operator inexperience were hindering optimal system performance.
ESI was hired to operate the system with trained operators on a 24-hour per day basis. The violations were eliminated. Improving performance and reducing operating cost were the next goals.
Chemical Cost and Usage
ESI reviewed past chemical procurement procedures and negotiated a significantly lower cost for the chemicals (annual savings of $245,000).The packaging method was also changed, minimizing safety concerns. The chemicals were being provided in drum packaging requiring drum to feed tank transfer. Having the chemicals supplied in totes, which feed directly into the system, creates a much safer operator environment and saves spillage. Metering pumps were provided, replacing high maintenance diaphragm pumps.
Flow Modification
The original waste stream fed into a sump pit that was undersized. The physical limitations of the pit prevented steady flow operation, thereby limiting the effectiveness of the chemical / physical treatment process. ESI modified the system diverting the flow to an existing emergency holding tank. The wastewater settling time has been increased and the flow to the neutralization tank is steady. Metals precipitation is maintained with a reduction in chemical volume.
DI Regenerative System
ESI designed and installed a new pH control and neutralization system for the wastewater discharged during the regeneration of the water de-ionizing system. This new system will stabilize conditions in the pre-treatment system.
ESI continues to provide wastewater treatment system operation and to suggest environmental recommendations for the production water system and the wastewater system.
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