Water Conservation at Aqseptence Group Ryan Pauly MnTAP Advisor: - - PowerPoint PPT Presentation

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Water Conservation at Aqseptence Group Ryan Pauly MnTAP Advisor: - - PowerPoint PPT Presentation

Jan 24, 2023 282 likes •536 views

Water Conservation at Aqseptence Group Ryan Pauly MnTAP Advisor: Jane Paulson On-site Supervisor: Paul Johnson Company Overview Headquartered in Germany Collection of water technology companies Johnson Screens New Brighton

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SLIDE 1

Water Conservation at Aqseptence Group

Ryan Pauly

MnTAP Advisor: Jane Paulson On-site Supervisor: Paul Johnson

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SLIDE 2

Company Overview

  • Headquartered in Germany
  • Collection of water technology companies
  • Johnson Screens
  • New Brighton
  • 1904 by Edward Johnson
  • Continuous slot wire wrapped screen
  • Industrial filters and water wells
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SLIDE 3

Products

  • Continuous wire wrapped

screens

  • Water intake
  • Wells
  • Decoration
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SLIDE 4

Motivations For Change

  • Current situation
  • 10 million gallons of water per year
  • High levels of chromium
  • Water recycling systems need improvement
  • Goals
  • Reduce water usage by 30%
  • Recycled water for NSF products
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SLIDE 5

Reasons for MnTAP Assistance

  • Audit water usage
  • Evaluate largest sources of consumption
  • Evaluate current recycling systems
  • Evaluate strategies to:
  • Improve recycling systems
  • Reduce source water
  • Remove chromium from recycled water
  • Determine savings for final recommendations
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SLIDE 6

Approach

  • Investigate water consumption processes
  • Map water flow
  • Quantify water usage
  • Evaluate current recycling systems
  • Identify successes and shortcomings
  • Understand shortcomings
  • Identify material flow
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SLIDE 7

Large Diameter, 25% Fine Wire Electronics, 10% Fine Wire Quenching, 5% Wire Mill, 26% Other, 33%

Water Usage

Approach

  • Identify top water usage areas
  • Screen Machines > Wire Mill
  • Blueprint for recycling system
  • Chromium removal
  • Address remaining areas
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SLIDE 8

Approach

  • Identify top water usage areas
  • Screen Machines > Wire Mill
  • Blueprint for recycling system
  • Chromium removal
  • Address remaining areas

Screen Machines, 31% Fine Wire Electronics, 10% Wire Mill, 26% Other, 33%

Water Usage

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SLIDE 9

Contaminated Water

  • Small particulates and burnt oil
  • Oil-water emulsion
  • Current recycling system
  • Oil-water coalescing separator
  • Flow pattern in reservoir
  • Centrifuge
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SLIDE 10

Recycling System

  • Proposed system: centrifuge and ultrafiltration
  • Centrifuge: particles > 74 microns
  • Ultrafiltration: oil-water emulsion
  • Pilot system
  • 4 machines
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SLIDE 11

Recycling System

  • Process flow diagram
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SLIDE 12

Recycling System

  • New process flow diagram
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SLIDE 13

Recommendations: Recycling System

Recycling System Water Reduced (gallons per year) Implementation Cost Cost Savings (per year) Payback Period Status Large Diameter Implemented 940,000 $4,000 $7,000 6.9 months Implemented* Large Diameter Recommended 1,170,000 $6,000 $8,600 8.4 months Recommended Small Diameter 4,000 $4,000 $30 130 years Recommended Total 2,100,000 $14,000 $15,600 10.8 months

  • *Additional ultrafiltration columns need to be added
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SLIDE 14

Chromium Removal

  • NSF certification
  • Proposed solution: ion exchange
  • Regenerable resin
  • Pilot scale system
  • Colorimeter
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SLIDE 15

Chromium Removal

  • Process flow diagram
  • Multiple location options
  • Following ultrafiltration
  • Next to reservoir
  • Additional cost for

automation

  • No downtime
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SLIDE 16

Recommendations: Chromium Removal

Ion Exchange Location Water Reduced (gallons per year) Implementation Cost Cost Savings (per year) Payback Period Status Next to Reservoir 120,000 $4,500 $870 5.2 years Recommended Following Ultrafiltration 120,000 $2,700 $870 3.1 years

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SLIDE 17

Fine Wire Screen Machines

  • Electronics cooling water
  • Quenching water
  • Solution
  • Closed loop system with chiller
  • Recycling system
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SLIDE 18

Recommendations: Fine Wire

Waste Reduction Option Water Reduced (gallons per year) Percent Reduction Implementation Cost Cost Savings (per year) Payback Period Status Closed Loop Cooling Water 780,000 100% $4,500 $4,700 11.5 months Recommended Recycling System 390,000 95% $3,700 $2,900 15.3 months Recommended Total 1,170,000

  • $8,200

$7,600 13 months

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SLIDE 19

Quenching Water

  • Excess water applied to weld
  • Limited control
  • Solution
  • Globe valves and flow meters
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SLIDE 20

Recommendations: Quenching Water

Quenching Water Reduction Water Reduced (gallons per year) Percent Reduction Implementation Cost Cost Savings (per year) Payback Period Status With Recycling Systems 82,000 29% $3,300 $600 5.5 years Recommended Without Recycling Systems 175,000 29% $3,300 $1,700 2 years

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SLIDE 21

Wire Mill

  • Wire washing stage
  • Minimal contaminants in samples
  • Air wipe in Use
  • Suggestion
  • Shutoff water
  • Further testing necessary
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SLIDE 22

Recommendations: Wire Mill

Waste Reduction Option Water Reduced (gallons per year) Implementation Cost Cost Savings (per year) Payback Period Status Cleaning Water in Wire Mill 2,070,000

  • $15,400
  • Testing Required
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SLIDE 23

Summary

Waste Reduction Option Water Reduced (gallons per year) Percent Reduction Implementation Cost Cost Savings (per year) Payback Period Status Large Diameter Implemented 940,000 95% $4,000 $7,000 6.9 months Implemented* Large Diameter Recommended 1,170,000 95% $6,000 $8,600 8.4 months Recommended Small Diameter 4,000 95% $4,000 $30 130 years Recommended Ion Exchange from Reservoir 120,000 100% $4,500 $870 5.2 years Recommended Fine Wire Screen Machines 1,170,000 > 95% $8,200 $7,600 13 months Recommended Cleaning Water in Wire Mill 2,070,000

  • $15,400
  • Testing Required

Quenching Water 82,000 29% $3,300 $600 5.5 years Recommended Total (Excluding Wire Mill) 3,500,000 37% $30,000 $25,000 14.4 months

  • *Additional ultrafiltration columns need to be added
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SLIDE 24

Personal Benefits

  • Interaction with wide variety of

people

  • Application of principles learned

in school

  • Design and construction of

recycling system

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SLIDE 25

Questions?