A leading tech company needed a robust solution to manage chemical wastewater across multiple sites. To meet stringent environmental and operational requirements, Burt Process designed and supplied four identical Wastewater pH Neutralization Systems. These systems were engineered to handle large volumes of wastewater from the company’s chemical waste production network, ensuring treated water was suitable for safe discharge.
Industry
Wastewater Treatment
Challenge
Strict environmental & operational standards
Solution
4 identical pH Neutralization Systems
The project encompassed the delivery of the following key components:
- (4) Feed Pump Skid Assemblies
- (4) Dual Stage Treatment Trains
- (2) Final Combined Effluent Regulatory Monitoring Skid Assemblies
Each of these systems was designed to operate autonomously, providing continuous treatment to ensure regulatory compliance for discharge water.
System Design and Operation
The pH Neutralization System accepts chemical wastewater on a continuous basis from the facility’s production network, ensuring reliable treatment under varying load conditions. The system treats wastewater with a flow rate of 250 gallons per minute (gpm) per treatment train under normal conditions, with a maximum flow rate of 450 gpm.
The treatment process begins with wastewater flowing through a simplex basket strainer to remove debris that could damage sensitive system components. From there, the water is pumped into the first of two stages of treatment, each designed for independent and fine-tuned pH adjustment.
Key features of each stage include:
- Primary Stage Treatment Tank: This tank is equipped with a top-mounted mechanical agitator for thorough mixing, a pH sensor for real-time monitoring, and chemical dosing equipment to introduce sulfuric acid or other reagents as needed for pH neutralization.
- Secondary Stage Treatment Tank: After the primary treatment, wastewater overflows into this second tank, where additional adjustments are made to bring the water to the desired pH range.
Both tanks are constructed from double-walled copolymer-polypropylene, ensuring structural strength and secondary containment for spill prevention.
Final Effluent Monitoring
Following the dual-stage treatment process, wastewater flows into a Discharge Collection Tank where it is tested for both pH and temperature before being discharged or recirculated for additional treatment. The system employs a sophisticated monitoring setup, including:
- Temperature and pH Sensors
- Electromagnetic Flowmeters
- Automated Control Valves
Wastewater meeting the stringent discharge criteria is routed through In-Spec Valves to the final effluent monitoring skids, which include redundant flowmeters for reliability.
Performance and Benefits
This pH neutralization system not only ensures that the facility complies with environmental regulations but also maximizes operational efficiency by minimizing retreatment. The parallel operation of the four systems allows for continuous treatment and monitoring, even during peak demand periods. Key benefits include:
- Continuous Operation: Each system operates independently, ensuring no downtime even if one treatment train is offline for maintenance.
- Automated Control: The use of Variable Frequency Drives (VFDs) and real-time monitoring enables precise control over wastewater flow rates and chemical dosing.
- Redundancy: Dual-stage treatment with monitoring at multiple points ensures that any off-spec wastewater is recirculated for further treatment, guaranteeing compliance before discharge.
Conclusion
Burt Process Equipment successfully delivered a custom solution to this leading technology company, providing a high-capacity pH neutralization system capable of handling varying wastewater loads with precision. By implementing four identical systems, the company ensured operational reliability, regulatory compliance, and environmental safety. With a total project value of $3,000,000, this project highlights Burt Process Equipment’s ability to design, fabricate, and implement advanced wastewater treatment solutions for industrial applications.
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