Animal By-Products Processing Plant – Wastewater System Upgrade

PROBLEM

An animal by-products plant needed a scalable wastewater treatment solution to handle increased production and high contaminant levels while meeting regulatory standards.

SOLUTION

Waterform upgraded the system with UltraBiox + Barrier-FB Purification, improving biological treatment, water reuse, and smart automation.

OUTCOME

The system now handles higher loads, ensures compliance, reduces freshwater use, and enhances efficiency for future growth.

Industry

Rendering Facility

LOCATION

Australia

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UltraBiox + Barrier-FB Purification Treatment System

PROBLEM

An animal by-products processing plant struggled with its wastewater treatment system due to increased production capacity. The existing system was unable to manage the higher wastewater loads, leading to operational inefficiencies, compliance risks, and escalating costs. Key challenges included:

Insufficient biological treatment capacity, unable to handle the increased wastewater load.
High levels of contaminants, such as COD (1,720–2,570 kg/day) and TKN (160–240 kg/day).
Need for a reliable, compliant system that met strict environmental and regulatory standards.
Requirement for scalability without significant infrastructure overhauls.

SOLUTION

Waterform Technologies provided a comprehensive UltraBiox + Barrier-FB Purification Treatment System, designed for long-term efficiency and compliance. The solution focused on enhancing biological treatment, optimising water reuse, and incorporating smart automation. Key components of the solution included:

Biological Treatment Expansion:
- Construction of a 2,000 m³ biological ring tank to accommodate higher wastewater volumes.
- Conversion of existing SBR tanks into two covered buffer tanks for better flow management.
- Installation of new aeration blowers, diffusers, and aeration grids for optimal biological treatment.
Advanced Filtration & Purification:
- Upgrade of the reverse osmosis (RO) system to handle >15 m³/hr feed flow, achieving a recovery rate of >86.5%.
- Integration of a high-efficiency membrane bioreactor (MBR) for superior solid-liquid separation.
- Deployment of a Barrier-FB filtration unit to enable Class A water reuse.
Smart Automation & Monitoring:
- Implementation of 24/7 Site Control remote monitoring for continuous optimisation and troubleshooting.
- Integration of fail-safe instrumentation for DO, TSS, nitrate, and pH monitoring to ensure process control.
- New SCADA-integrated PLC control system for seamless operation.

The project was executed in phases to ensure minimal disruption to operations while transitioning smoothly to the upgraded system.

OUTCOME

The upgraded wastewater treatment system delivered measurable improvements across multiple dimensions:

Increased Treatment Capacity: The biological treatment system now effectively manages peak flows of 170–210 m³/day.
Regulatory Compliance: The plant is fully compliant with environmental discharge regulations, mitigating compliance risks.
Water Reuse & Sustainability: The Barrier-FB filtration system facilitates high-quality water reuse, significantly reducing reliance on freshwater.
Operational Efficiency: Automation and remote monitoring reduce manual intervention, improving response times and operational efficiency.
Cost Savings: The high-efficiency RO system and optimised sludge management reduce energy and chemical costs, lowering overall operational expenses.

The new system has not only enabled future scalability but also supports production growth, reinforcing the plant’s commitment to environmental sustainability.

PROBLEM

Insufficient biological treatment capacity, unable to handle the increased wastewater load.
High levels of contaminants, such as COD (1,720–2,570 kg/day) and TKN (160–240 kg/day).
Need for a reliable, compliant system that met strict environmental and regulatory standards.
Requirement for scalability without significant infrastructure overhauls.

SOLUTION

Biological Treatment Expansion:
- Construction of a 2,000 m³ biological ring tank to accommodate higher wastewater volumes.
- Conversion of existing SBR tanks into two covered buffer tanks for better flow management.
- Installation of new aeration blowers, diffusers, and aeration grids for optimal biological treatment.
Advanced Filtration & Purification:
- Upgrade of the reverse osmosis (RO) system to handle >15 m³/hr feed flow, achieving a recovery rate of >86.5%.
- Integration of a high-efficiency membrane bioreactor (MBR) for superior solid-liquid separation.
- Deployment of a Barrier-FB filtration unit to enable Class A water reuse.
Smart Automation & Monitoring:
- Implementation of 24/7 Site Control remote monitoring for continuous optimisation and troubleshooting.
- Integration of fail-safe instrumentation for DO, TSS, nitrate, and pH monitoring to ensure process control.
- New SCADA-integrated PLC control system for seamless operation.

The project was executed in phases to ensure minimal disruption to operations while transitioning smoothly to the upgraded system.

OUTCOME

The upgraded wastewater treatment system delivered measurable improvements across multiple dimensions:

Increased Treatment Capacity: The biological treatment system now effectively manages peak flows of 170–210 m³/day.
Regulatory Compliance: The plant is fully compliant with environmental discharge regulations, mitigating compliance risks.
Water Reuse & Sustainability: The Barrier-FB filtration system facilitates high-quality water reuse, significantly reducing reliance on freshwater.
Operational Efficiency: Automation and remote monitoring reduce manual intervention, improving response times and operational efficiency.
Cost Savings: The high-efficiency RO system and optimised sludge management reduce energy and chemical costs, lowering overall operational expenses.

The new system has not only enabled future scalability but also supports production growth, reinforcing the plant’s commitment to environmental sustainability.

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