By Jon Cleveland water costs
As a general rule, industrial processes use water, sometimes a lot of water. If you’re brewing beer or making other beverages, water is often the primary ingredient. If you are using tap water in your industrial pre-treatment wastewater system, it’s important to know what impacts that’s having on your results, and how to optimize its use.
TTX Environmental was recently asked to help a new customer out who had a problem. Their core business practice was making a slurry of clays, fibers, and other material which was cast into large forms for later use. The slurry needed to be cleaned out of the production area after every shift so a clean and traceable batch could be started with the new shift. water costs
During the TTX Site Survey, it was noted how many hoses were used to clean out gutters which ran throughout the facility. These gutters moved discarded overflows of slurry to a sump, from which it was pumped to a frac tank, and the solids allowed to settle out for later removal and dewatering before being sent to the local landfill. Working with the facilities manager, monthly clean water flows were calculated, and the results showed several more gallons of water were used for cleaning than were used for slurry production! All that water wound up in the Frac tank where an operator had to keep track and pump out the clearer liquid when possible. Overflows were common, and the cost of shipping the Frac tank “solids” to the landfill were considerable as they needed to be dewatered before finally being disposed.
The TTX Sales engineers designed a system which removed the frac tank and allowed the waste slurry to be dewatered via a large plate press. Clean water from the plate press was not sent down the drain however, it was stored in a large tank, and then pumped throughout the gutter system in place of tap water.
The savings were several fold:
1) far less clean water was consumed each day.
2) filter cake from the plate press was dry enough that it could be sent to the landfill directly, without the need for dewatering.
3) the often-problematic pump that sent waste from the sump to the frac tank was replaced with a specially designed macerating pump to break up large chunks sometimes found in the slurry, resulting in minimized downtime for the line.
The project optimized each dollar spent on freshwater and yielded considerable financial benefit to the customer. water costs
If you’d like to investigate your water usage and how revising your wastewater treatment system can bring similar benefits, call TTX Environmental, we’re happy to consult with you to achieve your payback goals.
Jon Cleveland currently works at Therma-Tron-X, Inc. as Sales Engineer for the Environmental division, and brings nearly 30 years of experience in instrumentation and control, highlighting his expertise in municipal and industrial water treatment. Process optimization has been a passion of his from the start. Jon looks forward to working with you to get the most out of your water treatment systems.
FURTHER READING: Optimizing your OpEx with a small investment in CapEx