Burt Process Equipment designed and delivered a fully integrated containerized pH Adjustment System paired with a Duplex Pump Lift Station for a state-of-the-art bioprocessing facility. This project supported process wastewater neutralization at a facility manufacturing aseptic sampling and fluid management products. The modular design, advanced instrumentation, and automated control system were engineered to ensure safe discharge, compliance, and operational efficiency.
Industry
Bioprocessing Manufacturing
Challenge
Variable pH Effluent
Solution
Customer Profile
The customer, a global provider of biopharmaceutical fluid management solutions, required a high-performance wastewater treatment system to neutralize variable pH effluent generated by manufacturing processes. The system needed to meet environmental discharge standards and fit within a pre-engineered modular footprint suitable for installation at a Massachusetts-based facility.
Challenge
The facility generated batch discharges of low and high pH wastewater requiring real-time neutralization and flow control. The customer needed a turnkey system that could be installed quickly, operate autonomously, and integrate with existing infrastructure while minimizing on-site labor. Additionally, the system needed to be enclosed, weather-protected, and climate-controlled for year-round operation.
Solution: Containerized pH Neutralization and Lift Station System
pH Adjustment System (BPDN-300):
- Two 300-gallon AVS baffled polypropylene treatment tanks with mixers and pH probes
- Dual chemical injection systems with Pulsatron acid and caustic metering pumps
- Two 70-gallon double-wall HDPE reagent tanks
- Effluent monitoring U-trap with sample ports, magnetic flow meter, and automated shutoff valve
- Siemens-based PLC control panel with touch HMI, Nanodac data recorder, and integrated motor starters for pumps and mixers
- 500-gallon equalization tank with guided wave radar level sensor and high-level alarms
- Two 30 GPM Finish Thompson transfer pumps with isolation valves and automated butterfly valve
Lift Station (PPS-2007-34-D):
- 200-gallon welded polypropylene tank with twin Hayward T7 vertical centrifugal pumps (40 GPM @ 20′ TDH)
- Float switch level control with 4-point logic: high-level alarm, lag/lead pump-on, and pump-off settings
- Duplex control panel with pump control, alarm system, and automatic lead/lag cycling
Containerization:
- Entire system constructed inside an 8’ x 40’ x 9’6” steel container
- Double personnel doors, floor drain, operable cargo doors, R-21 insulation, and 3-ton HVAC unit with electric heat
- Pre-wired lighting, power distribution, and fully modular layout for rapid installation
Key System Components:
- pH treatment tanks with mixers and instrumentation.
- Dual reagent dosing system with secondary containment.
- Equalization tank with guided wave radar level sensor.
- Duplex lift station with centrifugal pumps and leak detection.
- Siemens PLC and HMI for automated control and monitoring.
- Containerized enclosure with HVAC, insulation, and floor drain.
Outcome:
- Continuous pH monitoring and automated neutralization for safe effluent discharge.
- Modular, factory-tested system delivered in a plug-and-play container.
- Simplified installation with minimal on-site plumbing and wiring.
- Operator-friendly HMI interface with integrated alarms and data logging.
- Long-term reliability through durable materials and secure enclosures.
Conclusion
Burt Process Equipment successfully delivered a fully containerized pH neutralization and lift station system tailored to the needs of a cutting-edge bioprocessing manufacturer. Through advanced automation, rugged construction, and thoughtful modularization, Burt Process ensured compliance, ease of operation, and long-term performance for wastewater management.
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