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Month: September 2019

Wastewater Treatment System: Balter Brewery

Balter Brewery approached RWTS with the need for an upgraded trade wastewater treatment system to handle their steadily increasing daily load.

The Issue | An overrun wastewater treatment system

The wastewater treatment system procured originally was designed adequately for the daily load of 3000 litres and was sufficient for the brewery’s early beginnings. However, due to Balter’s growing popularity, production has both increased and improved. This lead to daily site hydraulic loads of the wastewater treatment solution exceeding its designed capacity.

As such, the system design was essentially overrun, creating operational and reliability issues. This resulted in a system that could not perform correctly and meet the hydraulic demands the site was experiencing. In addition, we saw the potential to add significant value and functionality to the brewery’s waste treatment system design.

The RWTS Solution

We proposed, designed and developed an enhanced system to not only ensure reliable operation, but to allow the comfortable treatment of 20,000 litres per day (that’s a lot of beer!).

By integrating advanced wastewater treatment technology, the new design allows for remote monitoring of the entire system operation, minimising the need for operator intervention and unnecessary maintenance. In short – more insight, less work. The HMI will provide a flow log and pH log each time the system discharges to trade waste on a daily basis. Data from the system can be stored for a minimum 30-day log and potentially up to 60 days.

If your brewery is looking for a wastewater treatment solution that provides detailed insight in real time but requires minimal operator intervention, we would love to discuss a tailored solution with you.

EcoFarmer Sewage Treatment System: Wallumbilla Remote Camp

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RWTS supplied two EcoFarmer 100 wastewater treatment systems to the Santos’ Wallumbilla remote camp.

These WWTPs were acquired from RWTS’s rental fleet. For more information on the systems we offer for lease, click here.

RWTS installed and commissioned a potable water system and wastewater treatment system to the site.

Treated effluent from the EcoFarmer was re-purposed for use by local farmers to irrigate grass areas for livestock.

Wastewater Biological Treatment and Ultrafiltration System

RWTS custom-built a wastewater treatment back-end biological polishing unit designed within an ultrafiltration system. The system treated Class C effluent to that of a true Class A final release standard. 

The system was complete with front end glass media filtration, before water was filtered through the ultrafiltration membrane elements.

The membranes of choice for the wastewater biological treatment were the RWTS UF-PVDF-1060 hollow fibre filter housings with an effective filtration area of 78 m2. The membranes were configured to an outside-inside, with air sparge backwashing, forward flush, top and bottom backflush, and an independent enhanced backflush EBF cycle also coded within the PLC. The PVDF fibre allows for greater tensile strength when filters are exhausted and feed pressures rise, due to uncontrolled front end treatment. The ability to rejuvenate the fibre element is second to none; with an aggressive alkali and acid cleaning process the filters will bounce back yielding their intended designed flux. Other membranes constructed of improved PVC and simple PVC cannot withstand such harsh environments and are susceptible to fibre breakage, resulting in cross contamination of raw and treated water streams.

The system was constructed on a purpose-built, 316 stainless steel frame. All pumps utilised for filtration, backwash and chemical injection were Grundfos pumps to ensure durability and reliability.  The feed pumps being controlled by VSD which allowed for variable flow treatment through the day. Process control pneumatic valves used in this system were air torque actuators with separate limit switches and Ritork cast wafer valves were integrated. Burkert instruments were chosen by the client. Additionally, control automation was completed through an Allen Bradly 800 Series PLC and Panel view plus 7 – 9 inch HMI screen with a Ewon modem for remote telemetry access.

The membranes have been installed with individual isolation valves on all 3 streams allowing for the disconnection and replacement of the individual membranes units without isolating the system. Clear tubing has additionally been added to allow the operator to view the turbid backwash reject water exiting the system.

All in all, RWTS has encompassed the very best in equipment supply and design to deliver a high-performance, durable system which will see many years of trouble-free filtering.

The equipment was installed and successfully commissioned onsite by the RWTS electrical and programming division.

EcoFarmer Sewage Treatment System: Santos Cooper Basin Remote Camp (Tarbat)

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RWTS Eco Farmer 50

RWTS were awarded the contract by client Santos cooper basin projects to deliver a treatment system catering for their remote camps waste water needs out at Tarbat operations, Queensland.

Due to the ever flocculating camp numbers (as low as 15 to 50 ep), the process of  converting the BOD and Nitrogen loadings placed on the plant was a challenge.

The RWTS process team overcame the issue by utilising a biological additive yielding 900mg/ kilo of mass dosed through our dosing system set up. The results allow for a constant and stable mixed liquor within the aeration chambers vital to the growth of essential bacteria.

The system was completed within the confines of an international shipping container, making for seamless road transportation. Built from the ground up and structurally certified, the treatment system was the perfect fit for the environment. The hand rails and ladder system were compliant to code, thus allowing for safe height access. Furthermore, the turnkey design minimised the commissioning process so allowed the camp to continue business-as-usual operations while the plant was installed for remote camp tenants by 6 pm. The treated effluent was then dispersed on the lease via sprinkler system and compliant to the overarching ERA as set out by the Department of Health.

Specialised Recovery Reverse Osmosis System: Manufacturing Industry
Reverse Osmosis System

RWTS where engaged to engineer a solution in providing a recovery reverse osmosis system allowing for our client to maximise their wastewater reclamation potential on their production water streams.

The treated water stream extracted from the process was further used in the production facility, reducing costs associated with water and waste handling. The system design was configured as a reverse osmosis filtration process, mechanically filtering and separating the waste from the treated permeate water. The challenges with the wastewater from the manufacturing facility were:

 

  • the higher than anticipated inlet water temperature of 65 degrees celsius;
  • conductivity between 2000 – 9000 Ms (depending on the process being disposed of); and
  • extremely high levels of COD.

To overcome this, RWTS completed the design with 316 stainless steel 8040 filter membrane vessels, full stainless high pressure piping and C PVC manifold pipework on the permeate stream. The membrane selection was the key to the plant design and success with RWTS consulting a membrane manufacturing specialist in the United States solely focusing on membrane technology. Instrumentation of choice to keep in tying with the remainder of the factory was Krohne with the use of a front end Brix analyser, mag flow totalising and instant flow meters the valving being branded keystone spring return close.

System integration was tied in together with a Allan Bradly PLC 800 series and HMI panel view plus 7 screen allowing for the ability of remote telemetry access through a Ewon modem allowing off site operator to dial in and see visually see the plant operation. The integration also allowed for a full automated chemical cleaning ‘CIP’ process minimising the risk of chemical handling by onsite plant operators.

The entire build and engineering was completed in house with the RWTS team providing a complete solution.

EcoFarmer Wastewater Treatment Plant: Miles Airport

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RWTS was tasked with implementing a wastewater treatment system for the Miles Airport in Queensland. 

This project involved the design and construction of a wastewater treatment plant as well as its installation and commissioning. The design integrated a wastewater disposal system to the surrounding gardens to re-purpose treated effluent.

Based on the unique requirements of the airport, RWTS chose employ an EcoFarmer 50 – Class B.

Wastewater Treatment Plant and Servicing: Kimberley College

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A customised treatment process for a growing school community in Carbrook, Queensland. 

RWTS were engaged by Kimberley College to rectify their waste water treatment facility. A key consideration for the development plan was the expansion of the school from 600 to 1,200 students.

Due environmental sensitivities, RWTS worked in conjunction with environmental engineers to develop a sustainable solution. All submissions were passed and approved by the local governing authority and the Department of Environmental Resources Management.

Due to the nature of the waste stream, RWTS process engineers needed to combat the higher than anticipated Nitrogen/ Ammonia loading that would be placed on the plant. This was done through various treatment processes, resulting in a Class B final effluent waste stream before further treatment by a customised ultrafiltration plant yielding Class A water fit for site release. The ultra-filtered water with a turbidity of less than 1 NTU is used as irrigation for the site through various methods as to not make contact with the students.  A 100 m3 panel tank forms part of the irrigation design accommodating for days’ worth of final storage capacity as to not irrigate through rain events an automated rain gauge sensor diverts the treated waste stream from the day irrigation storage tank to the holding tank for further irrigation when weather permitting. The system was then placed through an extensive commissioning phase with daily sampling and weekly nutrient and biological testing completed by the Redland City Laboratory and accepted and signed off on by all relevant governing personnel.

RWTS 3 years on still maintain the service contract for the school and assist in making sure the water is within release limits.

Sewage and Potable Water Treatment, and Water Reclamation: Horizon Shores Marina
Horizon Shores Marina

RWTS facilitates the servicing and ongoing growth of Horizon Shores Marina.

To date, RWTS has upgraded the sewage treatment facility, potable water system and water reclamation plant to ensure Horizon Shores Marina’s site complies with the Gold Coast City Council regulations.

Arsenic & Cyanide Treatment Plant: Gold Ridge Mining

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RWTS was awarded the contract to build an arsenic and cyanide removal system for Gold Ridge Mining Ltd’s St Barbara site in the Solomon Islands.

The site was a tailing storage facility used in a gold production process. The facility was contaminated with levels of cyanide arsenic and other heavy metals.

RWTS build a treatment system in Australia before shipping it to the Solomon Islands for installation. The system included a lime dosing system for pH control, a ferric chlorite injection system to bind particles and a Chlorine dioxide generator for oxidisation and cyanide destruction.

A part of the contract RWTS facilitated the rectification of the storage facility to include rebuilding access and roads, rebuild a chemical storage facility and installation and commissioning of a water treatment system.

RWTS successfully completed the project and the system is currently in full operation.

Ultrafiltration: Darling Downs Eggs

RWTS, in conjunction with client Integrated water management, delivered a complete water solution to the Darling Downs Eggs precinct.

This project was aimed at supporting the improved health of the birds, ultimately minimising mortality, yielding higher gross margins overall for the farmers. Water treatment a key ingredient to the survival of the birds found that we would treat the sites bore water through a  nanofiltration process with media filtration front end and calcium for hardness absorption on the permeate stream.

The additional water make up source came from the farms turkeys nest where raw surface water was treated through glass media filtration, disinfected with sufficient oxidant before entering the ultrafiltration system for further treatment. The RWTS design included our Improved PVC inside – outside  hollow fibre canister membranes complete on 316 industrial grade stainless steel equipment skid. The system was powered through a Mitsubishi PLC and HMI with Ewom modem for remote telemetry access to allow for plant manipulation and performance trending from the office with remote SMS alarm capability.

The ultrafiltration engineered package is designed to treat up to 10 kl / hr of permeate with redundancy @ a 98% efficient recovery rate. Both treated water sources make up the 120 KL panel holding tank which is then further recirculated and treated with a specific formulation of Chlorine dioxide maintaining bacterial loading within the water stream, keeping a residual oxidant throughout the water network.

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