As for the consumption of chemical reagents, the economic impact of a WWTP does not lie exclusively in its initial investment, but in its contribution to the treatment of water in the ceramic process and in the efficiency with which it is managed over time. Chemical reagents play a fundamental role in this context.
In the industrial ceramic context, where water is not just a waste product but a raw material that conditions the stability and repeatability of the processes, the role of the WWTP takes on a new dimension, since the treatment plant must not only treat the dirty water correctly, but also stabilize the quality of the water that returns to the process. Any chemical deviation in the reclaimed water has an impact on formulations, drying, glazes and, therefore, on the quality of the final product.
Focusing on water purification treatments whose objective is the recovery in the atomizer, reagents containing chlorides, sulfates or other parameters that increase conductivity, lead to increased consumption of deflocculants in the process of preparing the slurry prior to the atomizer, and may even increase energy consumption and CO2 emissions, due to not being able to achieve the usual density values. At Grins Industrial Solutions, through its Grins Environmental Engineering division, we understand that the true value of a WWTPI is not simply to comply with the effluent treatment, but to ensure that this treatment is constant, efficient and compatible with the technical requirements of the production process. Here, chemical reagents are of great importance.
And to that end, reagents should not be viewed as an expense, but as a critical process control tool. Poor dosing or incorrect selection not only drives up costs, it generates unnecessary sludge, causes operational instabilities and forces continual adjustments by the maintenance team. The correct use of chemical reagents can optimize the process.
For us, the reagent is a technical variable, not a fixed cost.
Every project starts in the laboratory. Our technicians perform Jar-Tests with real discharge samples, not generic simulations. The goal is to find the optimal combination of products and concentrations to obtain clear, stable water with the lowest possible chemical consumption.
This work is repeated at three key moments:
- In the system design, to define the dosing configuration and automation.
- In commissioning, to adjust the actual values after installation. Here, the use of chemical reagents is essential.
- In periodic monitoring, to readjust dosages if the process or discharge changes.
Why do many wastewater treatment plants overspend and generate more problems?
- Because the solids concentration or contaminant load is not adequately measured.
- Because the dosing systems are not calibrated or adapted to the actual flow rate.
- Because there is no monthly analytical monitoring to detect deviations.
- Because operator training does not include technical criteria to adjust parameters.
- Because the impact of treated water on the production process is not considered.
In relation to the results of an optimized dosage, we could talk about an average dose of reagents (Coagulant+Flocculant) of 100 ppm market and with Grins 25 ppm, with a frequency of adjustment [weekly – monthly] and a chemical cost per m3 market of 0.30 – 0.40 € and with Grins of 0.15 – 0.25 €.
Technical follow-up with chemical criteria
Our service is not limited to product delivery. We apply a rigorous technical approach that includes the use of chemical reagents:
- Monthly analysis of relevant parameters (COD, solids, turbidity, pH, etc.).
- Revision and calibration of dosing pumps.
- Periodic Jar-Test assays to confirm or correct the chemical strategy.
- Continuous training for plant technicians on adjustment and control criteria.
All oriented to maintain a stable, efficient and aligned system with the requirements of the ceramic process.
