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c Shannon Environmental Services
Atlas Environmental Clonminam Industrial Estate,
Portlaow, Co. LXIS, Ireland Tel: 0502 78600
Fax: 0502 78699 Ca//save 7850 504 504 Email: sa/es@at/asirebnd.ie web: ww.at/asireland.ie
Reg. No: 745 Hegarty Metals Processors Limited Trading As Shannonside Galvanising Section 87(l)(b) rec. 1 June 2005 Original
Envirotech Ballycurreen Industrial Estate,
Kinsale Road, Cork, Ireland Tel: 02 1 4962554/49625 18 Fax: 02 1 4962345 Email: [email protected] Web: www.envirotech.ie
Shannon Environmental Services Smithstown Industrial Estate, Shannon, Co. Glare, Ireland Tel: 061 707400 Fax: 061 707407 Email: info&es-Shannon ie
Site Evaluation and Wastewater treatment proposal at Shannonside Galvanising,
Drombanna, Co. Limerick
lSth April 2005
Atlas Environmental lreland Limited T/a At/as Environmental, Envirotech, Shannon Environmental Services
a 3CC company
Registered No: 317186 Vat No: IE 6337186A
Clonminam Industrial Estate, Portlaoise, Co. Laois, Republic of Ireland
DireCtOrs: D. Ryan (Managing), J. O’Regan, K. Murray, lI Davy M. Nolan, G. Kelly, M. Keogh, Co. Secretary: G. Kelly
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Site Evaluation and Wastewater treatment proposal at Shannonside Galvanising,
Drombanna, Co. Limerick
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Table of Contents
1. Introduction 1.1 Background 1.2 Aims
2. Effluent Sources 2.1 Acid Sludge 2.2 Caustic Wash
3. Flow and Load Survey 3.1 Yard Runoff 3.2 Acid Sludge 3.3 Caustic Wash
4. Treatability Study
5. Findings of Treatability Study 5.1 Additional Plant situations
6. Plant Provision Proposal 6.1 summary 6.2 Process Overview 6.3 Sizing of Plant 6.4 Plant Schematic 6.5 Schedule of Equipment 6.6 Terms 6.7 Plant Operating Projections
7. Emission Limit Values of Plant
8. Conclusions
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1. Introduction
1.1 Background
The facility at Shannonside Galvanising currently operates under the guidelines of an IPPC (Integrated pollution Prevention Control) License. The operations conducted on site are the receiving and storage of Iron and steel and the operation of a Galvanising plant consisting of a series of Acid pickling baths, a flux dip bath and a molten Zinc bath.
Over time resultant water losses and leaching from the site has caused some discolouration of the nearby ditch bounding the site into which all water based effluent ex site flows.
In response to this Shannonside Galvanising have committed themselves to addressing the issue of water losses ex site. While there is currently no water based emissions condition on their IPPC license it is their goal that an effective treatment system be installed and that this system be operated in accordance with parameters and conditions to be agreed with the EPA.
With the above in mind Shannonside Galvanizing have engaged the services of Envirotech Ltd., to carry out a full plant evaluation as outlined herein.
1.2 Aims
This report sets out to achieve the following: l To assemble the quantitative information regarding effluent flows and
the nature of same. l To outline methods of reducing on site water usage and to seek
applications where treated effluent can be used as an alternative to ground/treated water.
l To use the quantitative data provided by the flow and load survey in conjunction with a series of laboratory trials in order to outline the best and most effective wastewater treatment options.
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2. Site Profile
2.1 Overall Description
Figure 1 shows an approximate site layout.
Fabrication Building
Galvanising Building
Interceptor Pit for
J all yard rainwater
0
/ .
Roof rainwater runoff goes directly to water course
New effluent d storage bund
Proposed location of Location of treatment plant well point
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2.2 Effluent sources
Yard runoff
The entire site covers an area of somewhat less than one hectare of which all rainwater is collected and passed through two interceptor pits into the ditch at the rear of the site. The sampling point of the flow and load survey was at the outlet of the interceptor chamber. With this all flow data was recorded. Composite samples were also collected over 24 hour periods and analysed.
Acid Sludge
Shannonside Galvanising use a membrane filtration unit to prolong the life of their acid pickling baths. The acid from each bath is recirculated through a series of ceramic based membranes removing dirt and iron-based particulates. The waste filtrate is left to settle from which the clean decanted acid is returned to the pickling baths and the resultant acid sludge is stored for disposal off site by an approved hazardous waste contractor. This system which has previously been installed by Shannonside Galvanising at considerable capital cost is innovative and we believe it to be unique in Ireland. To date it has achieved great results in terms of bulk acid consumption and in terms of waste acid disposal.
Caustic Wash
In order to maintain the condition of the membrane filtration unit it is necessary to carry out a caustic wash on a regular basis (monthly) to clean down the unit. The resultant caustic based waste stream is also collected and stored for disposal off site.
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I 3. Flow and Load data
3.1 Yard runoff
Total Floz346 m3)
Envirotech Feb Flow and Rainfall Graph
RainfaG mm)
Feb 2005 1 O/02/05 0O:OO:OO - 24/02/05 0O:OO:OO
Flow Rate Flow Rate Volume Rainfall
(l/s) (l/s) (m3) (mm)
11/02/05 09:oo 0.1 1.2 12.1 6.5
12/02/05 09:OO 0.3 3.1 29.7 16.3 13/02/05 09:OO 0.1 1 6.8 1.9
14/02/05 09:OO 0 0.1 2.6 0.3
15/02/05 09:OO 0 0 1.3 0.1 16/02/05 09:OO 0 0 0.6 0
17/02/05 09:OO 0 0 1.1 0.2
18/02/05 09:OO 0 0.1 2.7 0 19/02/05 09:oo 0 0.1 2.7 0.3 20/02/05 09:oo 0 0 2.1 0 21/02/05 09:OO 0 0 1.2 0
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pH Susp.Solids COD BOD Iron Zinc Cr6 OFG @g/l) (mg/l) (mg/l) (mg/l) (mg/l) (mg/l) (mg/l)
Feb 7.43 300 216 51 26.47 19.71 Nd 1 10 Feb 7.16 230 120 29 16.76 11.76 Nd 1 11 Feb 7.22 160 97 28 14.12 11.76 Nd 1 12113 Feb 7.12 20 26 10 1.09 3.39 Nd <I 14/15 Feb 7.14 30 31 11 3.71 3.87 Nd ~1 16 Feb 7.06 40 49 13 1.09 4.68 Nd ~1 17 Feb 7.09 30 46 11 2.42 5.61 Nd ~1 18 Feb 7.15 20 52 18 1.6 5.42 Nd ~1 19 Feb 7.21 40 40 15 0.68 5.47 Nd ~1 20
Composite Sample (Feb 10 to 20) PH 7.14 COD 156 mg/l BOD 41 mg/l Suspended solids 172 mg/l Iron 21.1 mg/l zinc 14.2 mg/l chromiLlnl non-detectable Copper 0.1 mg/l Lead 0.1 mg/l Nickel 0.2 mg/l Silver non-detectable Tin 0.2 mg/l OFG’s 1 .O mg/l
It is clear from the data that rainfall runoff from the yard not only increases the volume of effluent generated but there is a correlating increase of the impurities content of this effluent. This we believe is due to the rainfall
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effectively “‘washing” the yard, particularly evident when heavy rainfall follows a dry spell as in Feb 10 and Feb 11.
In terms of maximum volumes a runoff volume of 29.7m3 was recorded over a 24 hour period in which the rainfall level was 16.9 mm (over half an inch). Even allowing for a 24 hour rainfall of over 5Omm (two inches) which is extremely rare in an Irish context, then the maximum runoff flow would not exceed 88 m3 per day.
3.2 Acid Sludge
Parameter Result (mg/l) PH 0.1
I Iron (total) I Zinc (total) 1 Hexavalent Chromium I Non detectable I
The volumes generated are in the order of 300 to 500 lines per week. *
3.3 Caustic Wash
Parameter PH
Result (mg/l) 7.4
Iron (total) 3800 Zinc (total) 3.0
I Hexavalent Chromium I Non detectable I
The volumes generated are in the order of 300 to 500 l&es per week. *
* Volumes are an estimate and were provided by Shannonside Galvanising.
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4. Laboratory Trials
Each trial consisted of a combination of all or some of the following waste streams
l Yard runoff. The samples used were mainly from February 10 and 11 as these were the days when pollutants were at their highest level.
l Acid Sludge l Caustic Wash l Flux bath runoff
Various proportions of each were combined according to the volumes as obtained in the flow and load survey and applying the quantities of other point emission sources on an emperical basis. In practice, when a plant would be operational on site the proportion of yard runoff relative to other emission sources would quite simply, be dependant on rainfall levels. The breakdown of mixing for the trials took this into account.
Trial 1 Feed Sample: Process :
Feb 10 composite yard runoff sample. pH adjust to 10.9 and flocculate with addition of 35 ppm of Envirofloc 233.
Parameter Feed Treated % Reduction
PH 7.43 10.17 COD 216 22 89.8 Susp. Solids 300 60 80 Iron 26.47 1.11 95.8 zinc 19.71 1.17 94 Chromium6 nd Nd
Trial 2 Feed Sample:
Process :
Feb 10 composite yard runoff sample plus 10% (by volume) caustic wash. pH adjust to 9.7 and flocculate with addition of 35 ppm of Envirofloc 233.
Parameter Feed Treated % Reduction PH 6.53 8.52
1 COD 1472 I38 I 91.9% I
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1 Susn. Solids 1 2290 1 20 I 99.1% Iron ZiIlC
1440 6.56 99.5% 37.35 0.63 98.3%
Trial 3 Feed Sample:
Process :
Feb 10 composite yard runoff sample plus 10% (by volume) caustic wash. pH adjusts to 10.9 and flocculate with addition of 35 ppm of Envirofloc 233.
Trial 4 Feed Sample:
Process :
Feb 10 composite yard runoff sample plus 2% (by volume) caustic wash. pH adjust to 9.7 and flocculate with addition of 35 ppm of Envirofloc 233.
Trial 5 Feed Sample:
Process :
Feb 11 composite yard runoff sample plus 4% (by volume) caustic wash plus 1% flux rinse. pH adjust to 7.6 and flocculate with addition of 40 ppm of Envirofloc 233.
Parameter 1 Feed 1 Treated 1 % Reduction
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PH 5.9 7.4 COD 191 55 71.1% Susp. Solids 183 51 72.1% Iron 60.17 3.97 93.4% ZillC 223.4 12.77 94.2%
1 Chromium6 1 nd 1 Nd
Trial 6 Feed Sample:
Process :
Feb 11 composite yard runoff sample plus 4% (by volume) caustic wash plus 1% flux rinse. pH adjust to 9.4 and flocculate with addition of 40 ppm of Envirofloc 233.
Trial 7 Feed Sample: Process :
Grab sample ex drain Nov 2004 pH adjust to 9.4 and flocculate with addition of 40 ppm of Envirofloc 233.
Parameter Feed Treated % Reduction
PH 6.8 9.0 COD 146 33 77.4% Susp. Solids 272 35 Iron 46.40 1.233
87.1% 97.3%
ZillC 23.55 0.148 99.4% Chromium6 nd Nd
Trial 8 Feed Sample: Process :
Composite sample plus 1% acid sludge. Acid sludge sample extremely strong (>20% HCL) Requires large quantities of lime to raise pH to precipitation point. Settling volume greater than 50% after 30 minutes.
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Composite analysis from Trials 1,2,3,4,6 and 7
PI-I COD BOD Suspended solids Iron Zinc
cllromium Copper Lead Nickel Silver Tin OFG’s
9.14 29 mg/l 13 mg/l 33 mg/l 1.2 mg/l 0.7 mgA non-detectable CO.1 mg/l CO.1 mg/l CO.1 mg/l X0.1 mg/l CO.1 mg/l cl.0 mg/l
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5. Findings of Treatability Study
In the course of the Jar testing the following points became evident
The Iron, Zinc and other particulates precipitate readily out of solution when the pH is raised in excess of a value of 9. The resultant solids can be very easily settled with the use of a high molecular weight polyelectrolyte which binds the colloidal particles to form large floes with good settleability, leaving a clear supernatant. The yard runoff samples are very treatable, as indeed are combinations of yard runoff, caustic wash and flux rinse. The acid sludge is very difficult to treat in conjunction with the rest of the waste. Large quantities of lime are required to be added in order to form a precipitate that can be settled. Even at very high rates of dilution (500: 1) no satisfactory settleability was observed, and a large and bulky sludge volume was produced. This type of acidic waste is best suited for treatment separate from the main volumetric waste source (yard runoff). To factor into the plant design the ability to treat the acidic waste would require lime storage and dosing facilities, a clarifier much greater in scale and much larger sludge handling facilities. The best way forward in terms of effective treatment of all effluents in terms of performance, operator input and both capital and running costs is to install a system that treats all site effluent streams with the exception of the acid sludge which should be retained for off site treatment.
5.1 Additional Plant Situations
Water Reuse
In the interest of water conservation possible applications for on site usage of treated effluent were investigated.
Yard Washings Cooling Pit top up Membrane Unit Washdown.
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Considering the quality of the treated effluent, the installation of a receiving vessel, distribution line and pump can be carried out which will result in water usage savings of at least 5 cubic metres per week.
Pickling Tank Rupture
In the event of a rupture on site of one of the pickling baths the liquid is initially retained in the underground bund in the Galvanising building. From there the following are the potential treatment scenarios.
The acid or flux mix can be tankered off site for treatment by an approved hazardous waste disposal contractor.
The liquid can be pumped into IBC’s for temporary storage. These can then be drip fed through the plant for treatment over a subsequent period. The rate of addition will have to be managed according to operational factors such as strength of liquid, rainfall levels and storage bund levels. It would be preferable that the plant be run at a lower hydraulic throughput in order to cope with the greater solids loading to the clarifier and sludge tank. However the scale of the plant is such that there is ample hydraulic capacity to do this with perhaps the exception of extreme rainfall conditions. Conversely should groundwater levels be very low then it may require the addition of well water to provide the necessary dilution to pass the acid etc. through the plant.
In the event of an acid bund rupture the acid could be pumped into IBC’s and passed through the existing membrane filtration unit. This plant currently achieves an excellent level of recovery and may prove the most cost effective and efficient solution to the issue of a tank rupture, should it arise.
Notwithstanding the above we recommend that Shannonside Galvanising seek guidance from the EPA as to the most appropriate course of action in the event of such an occurrence.
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6. Plant Proposal
6.1 Introduction
Shannonside Galvanising commissioned Envirotech to carry out a flow and load survey to quantify the amount of rainwater generated and identify a process to treat this wastewater as well as size and specify plant and equipment taking into account the following criteria:
(a) Plant and equipment will meet EPA guidelines on IPC licensing conditions (b) Plant is designed with a sufficient level of automation to enable
(i) Minimal labour input (ii) Designed for duty/standby specification to within IPC remit as well as prevent extra capital costs for replacement of plant into the future. (iii) Plant to have hydraulic and technical capability to meet current operating conditions as well as capacity to deal with significant increases into the future.
6.2 Process Overview
The effluent is pumped at a fured rate fkom the storage bund into a 3 stage mixer unit where caustic addition takes place. The pH is monitored and linked electronically to the caustic pumps which control dosing rates to maintain the pH at a preset level (in this case a value of 9). The unit is sized to allow sufficient retention time and a paddle agitator gives the required mixing for the metals to precipitate out of solution. Polyelectrolyte is also dosed into the final stage of the 3 stage mixer which allows the colloidal particles to form larger floes which will then settle out in the clarifier. A dose rate of 30 to 50 ppm has demonstrated suffkient flocculation in the trials. The clarifier is a cylindrical vessel with a conical base which permits separation of the dense and cleaned phases of the liquid under quiescent conditions. The liquid flows through the central upward inflow pipe in the central well. The flocculated material settles to the base of the clarifier and the clear supernatant decants over the top of the clarifier for discharge.
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I 1 I I I I I 1 I I 1 I 1 I 1 1 I 1 1 1 I
l Sludge is drawn off periodically via positive pumps to a sludge holding tank. These pumps are operated on a timed basis, the intervals established in the course of operation. The collected sludge can then be tankered off site for disposal by an approved waste disposal contractor, or alternatively a plate and frame press can be installed, to create a solid cake.
l A loop with air driven positive pumps drives the sludge from the holding tank through the filter press under pressure of up to 7 bar. Clear water is returned to the collection bund while the insoluble sludge material builds up on the press filter manifold. When the pressure reaches a maximum the unit is can then be shutdown and the solid waste collected. A compacting time of 2 to 4 hours can deliver a cake with up to 50% dry solids using this technique, giving rise to reduced offsite disposal charges.
In the course of the trials a pH value of 9 was sufficient to precipitate the zinc out of solution. Should a higher value be required over time then this would have an upward effect on pH discharge values. As a result of this the inclusion of a post treatment pH correction unit has been included in the plant design. This involves the supply of a single chamber mixing unit c/w pH monitoring, acid storage and pumping and chamber agitation. Alternatively (or additionally) the treated effluent can be supplemented with well water which is readily available on site. This can also achieve a level of neutralisation by dilution which eliminates the need for further acid dosing. The capacity of the well is up to 8500 gallons per hour (38.6 m3/hr) which will also help to “clean” the downstream watercourse if diverted there.
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6.3 Plant Sizing
During the 10 day flow and load period a volume 66.346 m3 was measured from the total yard runoff. As rainfall conditions are the greatest hydraulic source of water borne waste then the scale of the plant must be able to cope with worst-case rainfall conditions. The highest 24 hour value was 29.6 m3 with 16mm of rainfall. To allow for a potential rainfall of 50mm in 24 hours and to allow for yard expansion then it is our opinion that a plant rating of six cubic metres per hour gives more than adequate capacity for the present and into the future. Indeed the plant would generally run at a reduced flow and/ or reduced time in real terms over the year. The level of automation in the plant facilitates this.
6.4 Plant layout
See attached Schematic (over).
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(Under Ground)
Flocculation Chamber
~ hemical Bund
\ Proposed Proposed point for point for PH Plate Frame Filter Correction Press
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6.5 Schedule of Equipment
Option I 1 no 3m3 three stage flocculation chamber c/w pH measurement and adjustment, chemical dosing equipment, agitation equipment and all associated spares. Incl. SS access walkway.
3 metre length x 1 metre height x 1 metre width
1 no 12 m3 stainless steel clarifier (304 grade) complete with outlet weir and access ladder.
3 metres high by 2.6 metre diameter
1 no 5m3 sludge holding tank c/w decanter valves, access ladder and of painted mild steel construction.
3.5 metres high by 1.5 diameter.
2 no. Grundfoss forward feed pumps; variable speed drives c/w Magflo flowmeter, pipework, valves, fittings, level control and bracketing for transfer from underground bund to flocculator unit.
2 no. Grundfoss transfer pumps to clarifier with variable speed drive and ultrasonic level control c/w pipework, valves, fittings, bracketing and baseplates.
2 no. Grundfoss sludge transfer pumps c/w pipework, valves, fittings and overflow pipework to drain.
2 no. Sandpiper Air operated diaphragm pumps from sludge holding tank to press to pressure rating of 7 bar c/w all pipework, valves, fittings and bracketing.
Supply installation and commissioning of reconditioned plate and fiarne membrane press.
Supply, installation and commissioning of 1 no post treatment pH correction chamber c/w pH monitoring and control, 1 no. chemical dosing pump and 1 no approved IBC storage bund.
1 no spare pH probe 1 no spare 7.7 l/hr chemical dosing pump.
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a I a 1 a I I 1 a a a a a a a 1 a a a a I
Construction of main distribution panel, ultrasonic panel, sludge panel and flocculation panel incl. supply of working drawings for above panels.
Installation of cable tray, cables, brackets and panels.
Supply of all materials re above.
Installation and electrical commissioning.
Commissioning of plant to reach stated operational performance as stated in section 7, for a period of 21 days or until such performance levels are reached on a consistent basis.
Training of operators to appropriate competency levels and furnishing of all operational manuals.
6.6 Terms
Options available for on purchase or lease ownership for Shannonside Galvanising.
Option 1 Entire schedule as listed above.
Option 2 Schedule as listed above less supply of membrane filter press, sandpiper sludge pumps and associated works.
Option 3 Schedule as listed above less supply of electrical panels, all plant electrical installation and commissioning.
Option 4 Schedule as listed above less supply of electrical panels, all plant electrical installation and commissioning. Less supply of membrane filter press, sandpiper sludge pumps and associated works.
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6.7 PLANT OPERATING PROJECTIONS
Chemical Usage Based on a dosage as per jar tests of 0.04% of flow a maximum dosage rate of 2.4 litres per hour would be required to bring the pH to a sufficient precipitation level at maximum flow. Taking into actual running volumes of 5000 m3 per annum the annual caustic consumption would be in the region of about 2 tonnes per annum. Polyelectrolyte consumption would amount to approx. 200kg.
Sludge Disposal On a solids removal rate of 500g per cubic metre of effluent and a cake solids reading of 50% then an estimated cake quantity of 5 tonnes per year would be generated from the treatment operation.
Acid disposal Using current cleaning and recovery practices acid sludge retention is approx 20 tonne per annum. As previously mentioned, the requirements to treat this stream on site include lime storage, handling and dosage facilities, greater clarification size and sludge handling equipment and an estimated minimum fivefold increase in sludge cake generation.
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7. Emission Limit Values of Proposed Plant
The following are the proposed Emission Limit Values for the treatment facility at Shannonside Galvanising. The plant has a rated Hydraulic Capacity of six cubic metres per hour and at current site activities and effluent levels is designed to deliver an effluent quality to the following parameters:
Pararneter PH COD BOD Suspended solids Iron zinc Chromium Copper Lead Nickel Silver Tin OFG’s
ELV (Emission Limit Value) tit010 50 mg/l 20 mg/l 35 mg/l 2.0 mg/l 0.5 mg/l 0.5 mg/l 0.5 mg/l 0.5 mg/l 0.5 mg/l 0.5 mg/l 0.5 mg/l 1 .O mg/l
A commissioning period of 21 days is included or until such time as compliance to the above standard is achieved.
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1 I I 1 1 II I 1 I I I I II I 1 1 1 R R I I
8. Conclusion 0 ‘i .: ,, , ; :
The aim of this study was to impart to Shannonside Galvanising the following information. ele/
The amount of wastewater generated currently on site over a specific time period.
The relevant parameter loadings of this influent in the best and worst case scenarios in the course of the study.
Treatability study to identify a. Potential Emission Limit Values on final discharge with new
plant and equipment input. b. Feasibility of in house treatment of all waste streams. c. Identify opportunities for reuse of treated effluent in house in
the interests of conservation. d. Annual chemical usage and sludge disposal projections.
Resultant from the above; Plant provision, sizing and costing taking into account, plant loadings, minimization of labour input and EPA guidelines required for IPC license compliance with regard to in house operation.
Envirotech would like to thank all those in Shannonside Galvanising for their input and professionalism during the course of this study with a special thanks to Declan O’Regan, Peter Skehan and Frank Bateman for the time and assistance afforded to us and we at Envirotech look forward to working together with Shannonside Galvanising into the future.
Signed on beh
V Seamus Curtin Technical Consultant
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EPA Export 25-07-2013:14:56:15
