Manufacturing Wastewater Treatment Case Studies
Latex Paint Manufacturing Wastewater Treatment Studies
Latex Paint Manufacturing Wastewater Recycling and Reuse
This
paint manufacturing facility was using 1 MGD
of fresh water in their manufacturing process with
a majority of the water being used for tank and
pipe cleaning. As a cost cutting measure, the
facility wanted to reduce the water consumption
and reuse part, if not all of the wastewater.
They tried several different combinations of
coagulants and flocculants with limited success.
Integrated Engineers introduced the Floccin™ I
as a single treatment alternative (see the jar
tests results above). The water quality was proven
to be sufficient for water reuse saving the facility both fresh water costs and wastewater disposal costs.
An additional cost bonus, they are eligible for
a rebate from the municipality of $50,000 to
be used towards the capital costs for system
modifications for zero discharge.
Over $11,000 Saved a Year in Waste Water Treatment Costs
Another company
was using a traditional chemistry of aluminum
sulfate, lime to adjust the pH, followed by
a flocculant. Switching to Floccin™ 1107 cut
the chemical costs by 30% and decreased the number
of chemicals to one. The facility was also using
large quantities of DE to generate a dry cake
with their bladder press. The Floccin™ 1107 decreased
the usage of the DE by about 50% based on the
visual comparison of the cakes, pictured below.
IE also informed them that they could eliminate
the use of DE completely if they switched to
a plate & frame press.
The city water and labor
required to make up the DE is no longer required,
adding to the savings. The required amount of
labor to operate this facility was reduced by
50%. As shown in the picture, the Floccin™ 1107
generates less solids when compared to their
previous process. The weight of the previous
cake was 0.65 lbs. for a piece and the weight
of an equal sized piece of the cake from our
product treatment was 0.40 lbs., proving a drier
sludge decreasing the sludge haul off costs in
both volume & weight.
The clarity of the treated water was excellent (shown in the picture) and is now reused in the cleaning operations as wash down water.
Estimated Annual Savings:
- Chemicals: $1,300
- Sludge Disposal: $1,500
- Labor: $9,000
- Total Savings: $11,800 Per Year Saved
This conversion to Floccin™ demonstrates that
although the direct savings were not large,
the indirect savings were significant and
easily justified the change.
Waste Water Treatment for 5 cents a Gallon or Less
Integrated Engineers, Inc. did the following treatability on the wastewater produced at a third
Latex Paint manufacturing facility. The treatments required no pH adjustment. The best
product was treated with 0.3 grams of Floccin™ K in a 100 ml sample and required
moderate mixing (1 minute). The dosage equates to a treatment of 25 lbs/1,000 gallons.
At an end consumer price of $2.00/lb., the treatment costs will be about $50/1,000
gallons = 5 cents/gallon if using flocculation alone, less if preozonation steps are taken. The
water can be reused in this industry in the production of concrete admixture.
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