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Santos Cooper Basin Remote Camp | Wastewater Treatment

Slide Slide Slide EcoFarmer Santos Cooper Basin Internal

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

Client: Santos

Location: Tarbat Queensland.

Technology implemented: EcoFarmer 50

Industry: Mining

BACKGROUND

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 SOLUTION

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 wastewater treatment 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 wastewater 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.

RESULTS

The treated effluent was then dispersed on the lease via sprinkler system and compliant to the overarching Environmentally Relevant Activity (ERA) as set out by the Queensland 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 Waste Water Treatment Plant: Miles Airport

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RWTS was tasked with implementing a waste water treatment plant for the Miles Airport in Queensland. 

This project involved the design and construction of a waste water 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 Wastewater Treatment System: Gold Ridge Mining

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RWTS was awarded the contract to build an arsenic and cyanide wastewater treatment 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.

Chemical Dosing System & Plant Monitoring: Bungaroo FIFO Camp

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Accommodation villages for workers in remote locations rely on a secure water source as their drinking water supply. In many instances, where water is transported in and stored, additional chemistry is required to maintain effective chlorine residual.

The RWTS water treatment plant has provided a turnkey means of disinfecting the water supply in the Bungaroo FIFO camp to allow for safe consumption. For added convenience, a state-of-the-art monitoring system has been integrated to allow for full remote telemetry communication with the plant operator. This provides the plant operator with the ability to consistently check on the status of the plant and tank level from the convenience of their office.

The RWTS containerised water treatment solution caters to the needs of small rigger camps through to large stay-over camps. Our systems include the highest quality analysers and pumping equipment to deliver effective pH correction and chlorine dosing.

Wastewater Storage vs. Onsite Wastewater Treatment For Mining

Are you curious as to whether it’s worth investing in onsite wastewater treatment for your project or simply storing wastewater before pumping offsite? We’ve been asked this question time and time again, so we’ve weighed up the pros and cons of each management method to help you decide.

Water management plays an integral role in the seamless day-to-day operations of any remote site, particularly an accommodation camp within the mining sector.

Water is an essential resource when it comes to:

 

  • cooking,
  • cleaning,
  • operating amenities such as showers, taps and toilets,
  • vehicle wash bays,
  • and most importantly, providing safe drinking water.

It’s no mystery then, that wastewater is an inevitable by-product of the extensive water usage on remote sites. In the early stages of planning any accommodation village, the pressing question of how this wastewater will be dealt with arises.

There are two primary options on the table:

1. Integrating an onsite sewage treatment plant

2. Storing wastewater for offsite treatment

There is no hard and fast rule when it comes to choosing which option is best suited to your site, but we’ve discussed a few key factors to consider. The table below very generally captures the best option based on these factors.

 

Water Storage vs. Water Treatment Matrix

1. TIME

How long is your site realistically going to be in operation?

Short-term

A short-term site with a lifespan of just 1-8 months will likely see greater benefit in water storage.

Why?

 

  • Reduced capital investment – Any water treatment plant will likely not in operation for long enough to offset the greater investment of such a system.
  • Rapid deployment – Water storage options such as tanks or the WaterBox, offer the advantage of rapid deployment. These are pre-packaged products that can be transported to site on short notice.
  • Environmental approval takes time – A tailored wastewater treatment system requires environmental approval from the state’s environmental regulatory body in order to discharge effluent onsite. This is often a time-intensive process and, depending on the terrain of your site, may not be feasible for your site or project timeline.

Long-term

If your site will be in operation for longer than 8-12 months, looking to an onsite wastewater treatment plant will likely be worth your while.

Why?

 

  • Pump-out fees will be too expensive – Although a more costly investment upfront, by integrating a wastewater treatment system you will be forgoing the costly pump-out fees of transporting your wastewater to an approved discharge location. This may be justified on a short-term project, but over time this will chew through the budget significantly.
  • Treated wastewater can be reused – Depending on your site, the treated wastewater can be used for local irrigation, reducing the demand on potable water.

 

2. Environmental Regulation

Environmental bodies have rigid regulations when it comes to discharging treated wastewater to the land. This can make the process of having a wastewater treatment plant approved a difficult endeavour, and even impossible when the terrain is not permissive of irrigation (e.g. close proximity to a bore, watercourse, wetland or spring).

Should your plans not comply with regulation, wastewater storage may be your only option.

REFERENCE / FURTHER INFORMATION:

 

3. MOBILITY

Mobile

Is your camp likely to be relocating on a regular basis? If so, a wastewater storage solution will be the better option. The WaterBox has been optimised for such circumstances and can be relocated with a 12-tonne forklift or crane. It’s shipping container design also lends it to easy compatibility with any truck/train transport.

Fixed

Wastewater treatment systems tend to be far more difficult to relocate, and commission and decommission. Taking all other factors into consideration, these are far better suited to camps that will be in a fixed location for a prolonged period.

If you are looking for a turnkey wastewater treatment system that can move with your camp, discover the EcoFarmer.

 

4. CAMP SIZE

Similar to the factor of time, the size of your remote camp will impact the volume of wastewater produced.

Small

For a small camp consisting of up to 100 people, less wastewater will generally be produced and therefore, wastewater storage may be more feasible.

Large

For a larger camp accommodating over 100 people, the volume of wastewater produced would likely be in excess of what mere storage could handle. This increased load would lend itself to a wastewater treatment solution being integrated.

 

5. COST

At this point, you’ll understand that many factors will impact the cost of a wastewater management system, but generally:

 

  • for a short-term or mobile project, wastewater storage will be more cost-effective.
  • for a long-term, fixed project, onsite wastewater treatment will be more cost-effective.

Below we’ve outlined the primary costs (other than the cost of the system itself) associated with each option:

Wastewater Storage

 

  • Wastewater pump out – Only licensed liquid waste transport operators can legally transfer wastewater to an external facility. Due to the environmental, public health and workplace safety risks of transporting such high volumes of sewage, the cost of liquid waste removal services can be extremely high.

Wastewater Treatment System 

 

  • System maintenance – A wastewater treatment plant will require regular maintenance to ensure the ongoing efficiency of the system. Neglected plants with built up residue will eventually break down and require expensive repairs or replacement. We recommend a cleaning-in-place (CIP) system to ensure the long-term health of your plant.
  • Chemicals and consumables – In order to treat the wastewater, chemical dosing is generally required. Therefore, there is an ongoing cost of ensuring there is sufficient inventory to keep the system in operation.

 

We’re here to support you

The experienced team at RWTS is always available to guide and support you in developing the best wastewater management system for your project. For a truly tailored approach, get in touch with us today. We’ll handle the complexities of system design, leaving you with a streamlined, user-centred solution.

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