Part I
Industrial water treatment plants WWTPI
In ceramics plants, industrial wastewater management cannot be treated as a secondary element. The correct sizing, automation and maintenance of a WWTP is critical to ensure the stability of the process, reduce operating costs and avoid incidents that compromise production.
As a specialized chemical engineering company, we design and implement purification solutions adapted to the composition of ceramic effluents, with a technical approach focused on the needs of the operator maintenance.
Chemical engineering applied to the ceramic process
Each plant has different discharge conditions, variable loads of solids, presence of glazes, deflocculants, metallic salts, and additives specific to the ceramic process. Our design methodology starts with the chemical analysis of these streams and their behavior in the laboratory to define the appropriate type of physicochemical treatment, the configuration of equipment (decanters, flocculators, thickeners, filter presses), the selection of optimal reagents for the composition of the effluent, the automation of measurements (pH, conductivity, flow, sludge level, etc), and the planning of operational maintenance and consumption control.
Each installation is delivered with the parameters set to operate stably from start-up, with documented protocols and training for plant technical personnel.
Installation and start-up with technical support
The installation of a WWTP at a ceramic plant requires detailed planning to integrate with the production schedule and minimize interference.
Our technicians work with the maintenance managers to ensure an orderly and progressive start-up.
Elements we include:
- Hydraulic and electrical assembly and control integration.
- Functional tests by line and by stages.
- Initial reagent loading and controlled start-up.
- Technical training for operators and maintenance managers.
- Technical documentation delivered in clear format.
Technical management of wastewater treatment plants
A poorly managed WWTPI generates costs, downtime and inefficiencies. That is why we offer a periodic technical follow-up service adapted to the day-to-day work of the maintenance manager and operators, and with specific tasks aimed at maintaining the performance of the installation:
Main follow-up tasks:
- Verification of the general operation of the WWTPI.
- Daily maintenance of the system and filter press.
- Control, calibration and cleaning of measurement sensors.
- Review of the condition of dosing pumps.
- Detection of leaks or losses in critical lines.
- Jar-testing and fine-tuning of dosages.
- Replenishment of reagents to maximum levels.
- Measurement and control of pH, conductivity and flow rates.
- Stock control of chemical products (sewage treatment plant, outdoor pond, osmosis).
- Monthly collection of outgoing samples for treatment quality control.
Monthly water analysis
We complement the plant monitoring with monthly analyses of the main parameters of the treated water. These data are interpreted and discussed with the plant’s technical manager in order to:
- Identify possible process deviations.
- Adjust dosages or treatment sequences.
- Evaluate the evolution of the installation’s performance.
Parameters analyzed monthly:
- Total hardness
- Conductivity
- Salinity
- pH
- Suspended matter
- Total dissolved solids
- COD
- Boron
- Zinc
- Aluminum
- Iron
In addition, Jar-Tests are repeated whenever variations in the discharge are detected.
A well-designed and managed WWTPI offers:
- Stability in the process without interruptions or accumulation of residues.
- Operational reliability without the need for overdosing or reactive actions.
- Costs under control with rational consumption of reagents and reduction of sludge generation.
- Traceability and technical control with data available for decision making.
- Expert support with technical support from a specialized chemical engineering company.
At Grins Environmental Engineering, we design and install industrial wastewater treatment plants with the maintenance and day-to-day operation of the ceramic process in mind.
We are specialists in the design, installation, commissioning and maintenance of industrial wastewater treatment plants for the ceramics sector (WWTP).
If you are considering the renovation of your WWTP, its integration with new production plants or just looking for a reliable technical support for your current system, send us an email to info@grins.es.
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