volvo group north america, llc reuse of wastewater - a manufacturer’s experience steve pierett,...
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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
Brian Kidd, Principal
ProChem, Inc.
540-268-9884