Cleveland Ohio, USA

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Complete Zero Discharge Waste Treatment System

Customer:

Fortune 500 manufacturer of heavy equipment

Problem:

The object of this project is to use wastewater treatment and water recycling technologies to achieve near zero discharge of waste water from the surface finishing process.  This was a brand new building, new line and new waste water treatment system.

Although the Waste Water Treatment System is not intended to discharge to a municipal sewer system, the system had to be designed to meet the federal pre-treatment standards for standard wastewater discharge for heavy metals, toxic organics, total suspended solids and a discharge pH between 6.0 and 9.0.  It was also essential that the filter cake solids be between 20-50%.

Size requirements were that the entire system must be installed in area 120’ x 35’ building addition.

With this proposal, we needed to supply

  • Preventive maintenance schedule and training
  • Critical spare parts recommendations
  • Field testing, start-up and installation
  • Equipment warranties
  • OSHA  safety standards
  • Fresh RO System
  • Wastewater collection
  • Wastewater treatment equipment
  • Sludge precipitation and dewatering equipment
  • Water reuse
  • Process RO water supply
  • Engineering information

Process:

We began with a general discussion of the system requirements and expectations including how automated the system needed to be.  There were several proposals that were modified as discussions continued regarding the type of treatment that would be best for this brand new application.  We sent our engineering staff and project manager to the facility in order to go through the project and site details that needed to be considered. 

Prior to the installation of the system, Met-Chem submitted drawings to a certified engineer in order to have them sign off, indicating that the proposed system was in compliance with that state’s wastewater treatment and discharge requirements.  Once the system was approved, we began manufacturing the equipment.
We were working with tight time constraints to get this system built, installed and running.

Solution:

We started with the basic water treatment equipment which included wastewater collection, pH adjust, solids settling and dewatering.  The key pieces of equipment installed included collection and treatment tanks, sludge thickening tank, clarifier, filter press water softeners, reverse osmosis system, cationic and anionic polymer feed, pumps, meters, level controls and alarms.

After standard chemical precipitation, the clarifier water had to be cleaned up to be reused on the process line.  Following the clarifier, the water went through sand filters, carbon filters, cartridge filters, bag filters and then through an ultra filtration system and finally to a reverse osmosis system to provide clean water that could be used on the process line.  The contaminants from the filters and the ultra filtration and reverse osmosis went to a waste reverse osmosis system to squeeze out as much water out of the waste for reuse while the remaining waste water was sent to holding tanks for haul off.  The plan was to add evaporation equipment to these waste holding tanks to reduce this haul off water by 90% when the end user had more capital money available in the next budget year.  This system allowed the customer to send no water to sewer, reuse 98% of the waste water on the process line and only haul off 2% of their water as waste (which can be reduced to .2% if evaporation equipment was added on the waste haul off tanks.) 

Met-Chem handled the entire project in house from start to finish.  We manufactured the equipment, installed the system, and personally handled the on-site trouble shooting and training of waste treatment personnel at the facility. 

All requirements were met within the allotted timeframe, including installation and start up.  The system continues to function as originally designed.