IndustryFood and Drink
Project StatusOngoing Project
Our Client, an international beverage manufacturer was looking to expand one of its production facilities. The existing WwTP on the site was already underperforming, with various process-related issues and resultant capacity limitations while meeting the existing discharge limits. Consequently, it was determined that a significant capacity increase, including change of process and plant configuration coupled with alternative separation technologies, was necessary to meet the new capacity requirements and comply with new discharge limits pending following a License review. The existing WwTP was configured as an Activated Sludge (AS) Plant with a Membrane Bio-Reactor (MBR) separation stage which while capable of providing high-quality effluent was very much capacity limiting due to persistent fouling, resulting in high energy, cleaning, and replacement costs.
The existing Plant incorporated the following unit operations:
- Inlet Screening
- pH Correction
- Balancing and Equalisation
- 2 Stage Aeration System (interstage clarification)
- Chemical Phosphorous Reduction
- MBR Reactor Separation System
- RAS/EAS sludge Pumping
- Sludge Thickening and Dewatering
Plant monitoring and control was/is provided by a PLC/SCADA system, enabling the necessary close Operator involvement in meeting the required performance.
- Discharge Licence Application and negotiation
- Duties of the PSDP
- Process Design
- Mechanical Design
- EICA Design
- Civil Design (via local Civil Consultants, BJS)
- Preparation of Tender Documents
- Evaluation of Tenders
- Site Supervision
- Supervision of Testing and Commissioning
The Plant Upgrade consisted of:
- New Balance Tank complete with concrete roof and access platforms
- New High-Level pH correction system and associated support structure
- Revised mode of operation for the Aeration System
- New Chemical DAF unit complete with coagulant dosing, polymer dosing, flocculation
- Associated sludge tank and sludge pumps
- Associated PLC/SCADA upgrade to cater for the revised user requirements
- The MBR System was retained as a backup
Provision of a study and report to determine the projected loading and required capacity increase, including options and alternatives for upgrades to the plant in order to meet the new capacity and discharge limits. An intensive report and analysis was conducted of the existing plant, including recommended upgrades, which were progressed by the Client as a DB Contract, based on the detailed design and engineering services provided by WEW Engineering.
Following completion and optimisation of the Plant, it is now meeting the new capacity requirements, while obtaining the more onerous discharge License Limits. The plant is now running more efficiently and more economically, as in the plant is less costly to run, in terms of energy and operational costs.
WEW Engineering continues to have an ongoing working relationship with the client and is actively involved on some of their other sites, both nationally and internationally.