Chemical-physical wastewater system, CP system

An industrial chemical-physical wastewater system is used for the chemical-physical (CP) treatment of wastewater produced in an industrial plant in order to meet the regulatory requirements for the discharge of wastewater into a body of water or a municipal wastewater treatment plant.

Any commercial or industrial use of water, even on a small scale, also generates wastewater, the discharge of which must be approved by the authorities. Approval for wastewater disposal is generally only granted if the water is pre-treated in accordance with the generally recognized rules of technology (e.g. DWA-M 765) or the state of the art (§ 3 No. 11 WHG in conjunction with Annex 1 No. 13 in conjunction with BAT data sheets). This requires a chemical-physical wastewater system for pre-treatment, which treats the wastewater in the respectively required wastewater partial streams (e.g. chromium(VI) reduction or cyan oxidation) and then finally transfers it to a common treatment, usually in a hydroxide precipitation with an auxiliary additive in the batch or, if necessary, as a continuous flow system. The resulting hydroxide sludge is separated via a chamber filter press or a belt filter and the wastewater is passed through a multi-layer filter. Final cleaning is often carried out using a selective exchanger to remove residual metals, possibly with pH adjustment before and after the selective exchanger. Sampling for self-monitoring and plant-related government monitoring is carried out in the final pH control.

Industrial companies are generally assigned to one of the industrial sectors listed in an annex of the Wastewater Ordinance (e.g. Annex 40 for metal processing companies) and must treat the wastewater with regard to various parameters depending on the type of discharge, direct into a body of water or indirect into the municipal wastewater treatment plant. For direct dischargers, Part C of the respective Annex applies; for indirect dischargers, the statutes of the municipal wastewater treatment plant apply instead.
With regard to the approved parameters, the chemical-physical wastewater system iis operated. For example, a chromium(VI) batch is detoxified separately by reducing the batch to chromium(III) at < pH 2.5 (temperature-compensated) using the reducing agent sodium bisulphite, whereby the pH value is stabilized. The chromium(III) is then transferred in a batch treatment, if necessary together with other partial streams containing metal salts, in a hydroxide precipitation with the addition of e.g. flocculation polymer and bentonites into a sedimentation-capable precipitation product and, if necessary, concentrated in a sludge thickener. The solid/liquid separation takes place in the batch via a chamber filter press or a belt filter after the clear water has been removed if necessary. The aqueous phase is pumped through a multi-layer filter to a (possibly externally as service regeneration of ion exchanger ) selective exchanger to be regenerated, so-called police filter, with an IDE ion exchanger resin such as Lewatit TP 207 in order to comply with the discharge monitoring values of the regulatory requirements. Equipment for pH adjustment may be installed upstream and/or downstream of the selective exchanger.

The CP wastewater system can be modularly supplemented with additional filter stages, such as activated carbon, selective exchangers with e.g. Lewatit TP 207 or an additional iron oxide/hydroxide filter stage or a further anionic selective exchanger to remove any organics, complexes or PFC/PFAS. The wastewater system can also be expanded to include disinfection steps, oxidation steps or rinsing steps. Depending on the size of the system, the selective exchangers are equipped with devices for regeneration/conditioning on site or are recycled in the central regeneration station in 92348 Berg using the ion exchanger regeneration service. If there are non-treatable partial flows in wastewater systems, these can be selectively fed to an evaporation process.

The sensor design can be analog or digital, e.g. using Memosens sensors.

In addition to the technical requirements for the design of the wastewater system from the annexes of the Wastewater Ordinance or the statutes of municipal wastewater treatment plants/sewage treatment plants, other preconditions may also apply to the operation of the wastewater system or the operating personnel that must be taken into account (e.g. DWA-M 1000 with regard to the monitoring of external personnel and training courses of the own staff).

Products

An industrial chemical-physical wastewater system iis always subject to approval; this also applies to parts of these systems, e.g. only a selective exchanger with very low discharge quantities and low loads. The operation of the chemical-physical wastewater system always requires specialist personnel.

Customer-specific adaptation of a chemical-physical wastewater system:

  • Customer-specific design to suit the upstream production processes and the budget, starting from a semi-automated, functional basic version through to an automated and remotely monitored digital version with evaluation options.
  • Adaptation to any existing control technology and connection to a process control system and the existing structural conditions at the site or the entry to the site
  • Siemens PLC circuit with/without touch display, computer control also with the option of external access
  • Energy-optimized design according to § 3 para. 2a Wastewater Ordinance
  • PP plastic construction for batch containers with sloping bottom for complete emptying, PE for storage tanks, PP or PVC piping.
  • Decoupled agitators optional.
  • Consideration of energy efficiency requirements for wastewater systems
  • Fastenings subject to specialist company regulations in WHG areas with WHG anchors optional.
  • Piping and fittings in PVC or PP from the manufacturers GF, GEMÜ (pneumatic or electrical) or according to customer requirements; otherwise design with standard industrial components without special elements where possible.
  • System design optimised for occupational safety
  • System design for operation in compliance with occupational safety requirements, even in the event of typical misuse
  • Disinfection option
  • Possibility of pre-acceptance and trial operation in our own workshop, assembly on site by our own personnel
  • Training on your own system or on the in-house wastewater system
  • Modular, maintenance-friendly design according to customer requirements with various optional expansion options, e.g. storage tanks for the separate collection of acidic/alkaline wastewater, chemical storage tanks as dosing stations or as AwSV LAU systems, collecting trays, selective exchanger, if necessary fully automatic or for external ion exchanger regeneration, simple feeding to redundant FU duplex pressure booster stations, pressure difference displays on multi-layer filters, actual consumption and production data acquisition, system access control, valve position feedback, redundant pH/redox probes, analog or digital Memosens MSR technology.

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