Tailored ProChem System Replaces Multiple Add-On Systems - Achieved 100% Discharge Permit Compliance

The Customer
An automotive assembly plant whose manufacturing process required a high volume of water and introduced nickel, zinc, and other metals into their wastewater.

The Problem
The facility was experiencing discharge permit compliance issues and production interruption due to operation and maintenance issues. The facility’s existing wastewater treatment system consisted of multiple smaller treatment systems that were added on as production expanded over time. These systems were being operated by internal production and maintenance technicians.

The ProChem Solution
After completing the water analysis and assessing the facility’s production goals, ProChem offered a Design, Build, Operate solution that included a new wastewater treatment system and ongoing system operation and maintenance services.

The wastewater treatment system is a twin 300 gpm dual-train continuous-flow system that removes nickel, zinc, and other metals from the facility’s wastewater using physical/chemical treatment. It is equipped with local monitoring and automation controls and ProChem’s web-based remote monitoring service, which reduces required operator interaction with the system. This advanced automation allows ProChem to operate the system with significantly reduced manpower than was needed with the original multi-system configuration.

A ProChem employee operates the wastewater treatment system on-site daily. These responsibilities include treatment process monitoring to ensure water quality objectives are met, preventive maintenance, instrument calibrations, DMR preparation, and inventory management.

With this Design, Build, Operate solution in place, the facility is experiencing 100% discharge permit compliance and alleviated day-to-day operational challenges.

The Win

• Addressed corporate initiative for water recycling
• Cost savings on water purchasing, chemical/physical treatment, and discharge permit
• 95% or better reuse rate of their wastewater
• Higher quality process water