Water Reuse System Saves Money at Large Industrial Packaging Plant

GoalReduce water costs by implementing a sustainable alternative water source for production processes and boiler makeup.

<p><!-- wp:acf/two-cols-text {"name":"acf/two-cols-text","data":{"option_change_padding_block":"1","_option_change_padding_block":"field_6629e1de35327","padding_options":"py-to-60","_padding_options":"field_6629e0d2860af","background_colour":"blue","_background_colour":"field_6629e20935328","block_options_clone":"","_block_options_clone":"field_662a1b96b768f","block_title":"Overview","_block_title":"field_6629f36ac5d6b","block_content_clone":"","_block_content_clone":"field_662a1b96b76fb","text_list_0_text_item":"\u003cul class=\u0022list-check-mark\u0022\u003e\r\n \t\u003cli\u003e\u003cb\u003eIndustry: \u003c/b\u003ePaperboard Manufacturing\u003c/li\u003e\r\n\u003c/ul\u003e","_text_list_0_text_item":"field_662a1bf77d245","text_list_1_text_item":"\u003cul class=\u0022list-check-mark\u0022\u003e\r\n \t\u003cli\u003e\u003cb\u003eApplication: \u003c/b\u003eWater for production processes and 600 psi boiler system\u003c/li\u003e\r\n\u003c/ul\u003e","_text_list_1_text_item":"field_662a1bf77d245","text_list_2_text_item":"\u003cul class=\u0022list-check-mark\u0022\u003e\r\n \t\u003cli\u003e\u003cb\u003eProblem: \u003c/b\u003eWater availability concerns and large price increases from municipal water supplier that negatively impacts plant economics.\u003c/li\u003e\r\n\u003c/ul\u003e","_text_list_2_text_item":"field_662a1bf77d245","text_list_3_text_item":"\u003cul class=\u0022list-check-mark\u0022\u003e\r\n \t\u003cli\u003e\u003cb\u003eSolution\u003c/b\u003e: Install custom engineered membrane filtration equipment to reuse water from an on-site pond.\u003c/li\u003e\r\n\u003c/ul\u003e\r\n\u0026nbsp;","_text_list_3_text_item":"field_662a1bf77d245","text_list_4_text_item":"\u003cul class=\u0022list-check-mark\u0022\u003e\r\n \t\u003cli\u003e\u003cb\u003eResult\u003c/b\u003e\u003cb\u003e: \u003c/b\u003eSelf-sustaining water solution that saved the plant over $1,800/day, with savings of  $2.3MM over 5 yrs.\u003c/li\u003e\r\n\u003c/ul\u003e","_text_list_4_text_item":"field_662a1bf77d245","text_list":5,"_text_list":"field_662a1bb97d244"},"mode":"edit"} /--><!-- wp:heading {"level":5} --></p> <h5 class="wp-block-heading">Customer Challenge</h5> <p><!-- /wp:heading --><!-- wp:paragraph --></p> <p>Due to recent droughts and infrastructure upgrades, a large paperboard manufacturer had received multiple price increases from the local water company. A more cost effective water source was needed to provide the 550,000 GPD necessary for production processes and boiler makeup water. An on-site pond was identified as a potential water source.</p> <p><!-- /wp:paragraph --><!-- wp:heading {"level":5} --></p> <h5 class="wp-block-heading">Recommended Solution</h5> <p><!-- /wp:heading --><!-- wp:paragraph --></p> <p>While using the local pond water was appealing in terms of sustainability and cost savings, the suspended and dissolved solids level was too high for use as boiler feedwater.&nbsp;&nbsp;</p> <p><!-- /wp:paragraph --><!-- wp:paragraph --></p> <p>To address this, Chem-Aqua proposed a 3-step process, of:</p> <p><!-- /wp:paragraph --><!-- wp:list {"ordered":true} --></p> <ol class="wp-block-list"><!-- wp:list-item --> <li>Disc filter to remove suspended solids down to 100 micron</li> <!-- /wp:list-item --><!-- wp:list-item --> <li>Ultrafiltration system to remove the suspended solids down to 0.02 micron</li> <!-- /wp:list-item --><!-- wp:list-item --> <li>Reverse osmosis system to remove 98% of the dissolved solids</li> <!-- /wp:list-item --></ol> <p><!-- /wp:list --><!-- wp:paragraph --></p> <p>A pilot program was initially conducted to prove the concept.&nbsp;</p> <p><!-- /wp:paragraph --><!-- wp:heading {"level":5} --></p> <h5 class="wp-block-heading">Results Achieved</h5> <p><!-- /wp:heading --><!-- wp:paragraph --></p> <p>The results from the pilot study were so successful that the plant immediately purchased the full-scale system. After new equipment was delivered and installed, the plant realized a savings of over $1,800/day. The 5 year savings was $2.3 million.</p> <figure class="image"><img src="/link/41f5f00455324dca9b98d7bf08a918d6.aspx" alt="" width="350" height="318" /> <figcaption>Pond Used As Source Water</figcaption> </figure> <figure class="image"><img src="/link/b6446ae3e6c9456794d26dc2f4d06d9f.aspx" alt="" width="350" height="317" /> <figcaption>Spin Filter and Membrane Filtration Equipment</figcaption> </figure> <figure class="image"><img src="/link/0d95ceb9c6354fe88a542e9e4538b8b5.aspx" alt="" width="300" height="272" /> <figcaption>Complete System With Tank, Disc Filter, Ultra-Filtration, and RO System</figcaption> </figure> <p><em>CS4-007</em></p> <p><!-- /wp:paragraph --><!-- /wp:paragraph --><!-- wp:acf/two-cols-text-ctas {"name":"acf/two-cols-text-ctas","data":{"option_change_padding_block":"1","_option_change_padding_block":"field_6629e1de35327","padding_options":"py-to-60","_padding_options":"field_6629e0d2860af","background_colour":"white","_background_colour":"field_6629e20935328","block_options_clone":"","_block_options_clone":"field_662a2539a7d03","block_text_list_0_block_title":"","_block_text_list_0_block_title":"field_662a2573bc047_field_6629f36ac5d6b","block_text_list_0_block_excerpt":"","_block_text_list_0_block_excerpt":"field_662a2573bc047_field_6629f37dc5d6c","block_text_list_0_show_cta_button":"1","_block_text_list_0_show_cta_button":"field_662a2573bc047_field_662b4b6278ee7_field_6629f386c5d6d","block_text_list_0_block_cta_button":{"title":"Download PDF","url":"https://www.chemaqua.com/en-us/wp-content/uploads/sites/6/2024/07/CS4-007.pdf","target":""},"_block_text_list_0_block_cta_button":"field_662a2573bc047_field_662b4b6278ee7_field_6629f39cc5d6e","block_text_list_0_use_special_button":"0","_block_text_list_0_use_special_button":"field_662a2573bc047_field_663af6cb5a467","block_text_list":1,"_block_text_list":"field_662a2550bc046"},"mode":"edit"} /--></p>