volvo group north america, llc reuse of wastewater - a manufacturer’s experience steve pierett,...

Volvo Group North America, LLCVolvo Group North America, LLC

Reuse of Wastewater -Reuse of Wastewater -A Manufacturer’s ExperienceA Manufacturer’s Experience

Steve Pierett, Env.Mgr.Steve Pierett, Env.Mgr.CEM, CRM, CP EnMS-IndustrialCEM, CRM, CP EnMS-Industrial

Volvo NRV Plant – Dublin, Virginia

Area’s Largest Manufacturing FacilityArea’s Largest Manufacturing FacilityLargest Mfg. Facility in Volvo FamilyLargest Mfg. Facility in Volvo Family

New River Valley Plant, Dublin, VA

Volvo NRV Plant – Dublin, Virginia

OutlineOutline

Drivers and IncentivesDrivers and Incentives

WWTP Discharge EvaluationWWTP Discharge Evaluation

Selected Treatment Method Selected Treatment Method

Wastewater Reuse PointsWastewater Reuse Points

Pros and Cons of Process Use PointPros and Cons of Process Use Point

Continual Improvement Continual Improvement Overall BenefitsOverall Benefits

Volvo NRV Plant – Dublin, Virginia

Wastewater Reuse DriversWastewater Reuse Drivers

Surfactant issues at the regional authority / foaming

Molybdenum contamination of land-applied sludge

Volvo is proactive to identify its contribution to a potential issue

Environmental IssuesEnvironmental Issues

Volvo Environmental RequirementsVolvo Environmental Requirements Wanted Position: To install water recycling processes

with low water usage and preferably with chemical recycling in closed loop processes

Volvo NRV Plant – Dublin, Virginia

Wastewater Reuse IncentivesWastewater Reuse Incentives

Volvo is reusing up to 8.4M gal/yr of process water

Annual reuse rate is 60 to 80% for process water

Environmental Sustainability Environmental Sustainability

Plantwide use of 62 Mgal in 2003 to 26 Mgal in 2012 Since 2003, 57.6% Reduction in plant water use Volvo is saving a projected $90,000 in the purchase

of water and the disposal of water.

Reduction in Purchase of WaterReduction in Purchase of Water

Volvo NRV Plant – Dublin, Virginia

Reduction of Plant-wide Water Use Reduction of Plant-wide Water Use

Volvo NRV Plant – Dublin, Virginia

Wastewater Reuse IncentivesWastewater Reuse Incentives

Quality of feed water to industrial processes will reduce the need for chemical treatment and increase cooling efficiency and equipment life.

Process ImprovementsProcess Improvements

Direct capital funds to recycle water instead of meeting increasingly stringent environmental regulations.

Environmental Liability / Risk Mgmt.Environmental Liability / Risk Mgmt.

Volvo NRV Plant – Dublin, Virginia

WWTP Discharge Evaluation CriteriaWWTP Discharge Evaluation Criteria

1. Average daily flow from WWTP

36,307 gallons per day

2. Maximum treated flow (WWT) = 500 gpm

3. Storage capacity of untreated wastewater

240,000 Gallons

4. Conventional precipitation system.

Treats Nickel and Zinc (0.099 mg/L limit for Ni and 0.6 mg/l limit for Zn)

5. Details presented at AWMA conference in June 2006

Tracking Number: 06-A-28-AWMA

Volvo NRV Plant – Dublin, Virginia

Technologies Evaluated

Distillation / Evaporation

Ion Exchange

Membrane Filtration with Ultra-Filtration and High

Pressure Reverse Osmosis System

Volvo NRV Plant – Dublin, Virginia

Selected Treatment Technology

Membrane Filtration (UF with HPRO)

-- Produces acceptable process water with little organic,

microbiological or inorganic contamination.

- Minimal operating labor required (automatic operation did not

require additional labor)

- Waste is simple to treat (concentrate streams treatable with

conventional precipitation system)

- Low Capital Cost of system and low overall operational cost

Volvo NRV Plant – Dublin, Virginia

Treatment MethodTreatment MethodThe reuse system consists of the following components:The reuse system consists of the following components:

To PlantProcesses

Cartridge Filter

UV LightUF FeedStorage

Ultra-Filtration

High Pressure Reverse Osmosis

ReuseWater

StorageUV Light

WWT

WasteWater

Storage

HPRO Feed

Storage

UntreatedWastewater

UV Light

Volvo NRV Plant – Dublin, Virginia

Design Specifications and Installation

Ultraviolet Light (254nm)Ultraviolet Light (254nm) Cartridge FiltrationCartridge Filtration

Volvo NRV Plant – Dublin, Virginia

Design Specifications and Installation

Ultra-FiltrationUltra-Filtration High Pressure ROHigh Pressure RO

Volvo NRV Plant – Dublin, Virginia

Initial Usage Points – Initial Usage Points – Focus on Non Process OpportunitiesFocus on Non Process Opportunities

Paint Booth Water: 15,000 gpd

Humidification: 12,000 to 18,000 gpd

Parts Wash: 12,000 gpd

Cooling Tower: 4,000 to 6,000 gpd

Volvo NRV Plant – Dublin, Virginia

Current Usage Points – New Focus on Process Opportunity

E-coat high-purity water (HPW) system required replacement

Ran 3-4 months of water testing to baseline system to verify performance before incorporating process needs

Advantage:

Avoid capital expense and incorporated e-coat into reuse system instead

Disadvantages:

Drives reuse water requirement to lower conductivity

More frequent discharge events due to higher water quality requirements.

Volvo NRV Plant – Dublin, Virginia

PROCESS

E-coat System: 15,000 to 20,000 gpd

NON-PROCESS

Humidification: 500 to 1,000 gpd

Parts Wash: 12,000 gpd

Cooling Tower: 4,000 to 6,000 gpd

Current Use Points Current Use Points

Volvo NRV Plant – Dublin, Virginia

Pros and Cons with Process Use Advantages

– Improved consistency and demand of reuse

System easier to manage

– Eliminated auxiliary RO system for E-coat

Less cost / salt / energy / capital investment / labor

– With e-coat demand, less water loss during shutdown

Disadvantages

– Lower conductivity required to support E-coat process

– Increased frequency of discharges to regional authority

– At lower end of reuse performance over time

– Increased need for more storage capacity

Volvo NRV Plant – Dublin, Virginia

Process Improvement - 2014 Install solids removal methods for E-coat discharge to reduce

impact of process on conductivity/TDS & TSS.

Volvo NRV Plant – Dublin, Virginia

Process Improvement - 2014

Expand the storage capacity for reuse water to address losses associated with shutdown periods by addition of two 17,000 gallon pure water storage tanks.

Eliminate Stormwater influent to WWTP causing reduced WW reuse efficiency

Volvo NRV Plant – Dublin, Virginia

Process Improvement - 2014 High pressure RO system will address lower conductivity

requirement for E-coat, but allow improved system reuse (provide greater than 90% recovery of process waters)

Volvo NRV Plant – Dublin, Virginia

Overall BenefitsOverall Benefits Low operating costs

Improved feed water quality

Reduce environmental liability and risk

Reduced chemical usage

Decrease in water purchase and disposal costs

Major step towards fulfilling Volvo Wanted

Environmental Position

Volvo NRV Plant – Dublin, Virginia

Thank You Thank You

Steve Pierett, C.E.M., Environmental Manager

Volvo Group North America, LLC

540-674-7730

stephen.pierett@volvo.com

Brian Kidd, Principal

ProChem, Inc.

540-268-9884

bkidd@prochemwater.com