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Category Archives: Effluent treatment

Constantia Uitsig Effluent Treatment Plant

A2V designed and supplied a new effluent treatment plant to the new winery completed in 2017.

The plant comprises the following:

  • locally manufactured inclined auger screen to remove skins and pips from the effluent
  • settling tank to remove settle-able solids
  • pH balancing tank

Inclined auger screen

New Factory Upgrade, Sopura, Westake

A2V assisted Sopura in upgrading their new premises to a custom designed chemicals manufacturing facility as a turnkey project. Our scope of work included the design and supply of following:

1. A platform supporting mixing tanks for batch mixing of various chemicals.
2. An epoxy lined bund to contain any corrosive chemical spills from the manufacturing process.
3. Hoods and extraction systems for ventilation corrosive, toxic fumes
4. An effluent plant for pre-treating effluent prior to disposal to the municipal sewer.

Chemical Batching Facility

Quality Beverages

A2V recently completed two projects for Quality Beverages, Epping Industria:

  • An effluent pre-treatment plant to increase the pH of their effluent to within bylaw requirements.
  • A chlorine dosing system to disinfect the City’s water supply to the highest standards required by Quality Beverages.

The effluent plant included the construction of a new sump over the exiting sewer line while the line remained in service. A pH dosing system was installed into the sump that rectifies the pH as the effluent flows out the the sewer system.

Effluent Treatment Plant Layout

Effluent Treatment Plant Layout

Pelmanco Recylcing Effluent Treatment Plant

Pelmanco Recycling recover plastic from landfill sites which they then recycle into raw plastic materials. The recovered plastics are washed before they are fed into the recycling process. This washing process was using a substantial amount of water. Furthermore, Pelmanco were being penalised by the City of Cape Town for discharging effluent that did not comply with its bylaws.

A2V were appointed to design a system that would clean the water to a level where it could be reused to wash more recovered plastic before being discharged to sewer.

The system implemented comprises the following key elements:

  • Screening to remove coarse solids from the effluent
  • Coagulant dosing equipment
  • A Tube Settler to remove flocculated particles
  • Sand filtration to remove any particles carried over from the settling process

The project successfully reduced the wash water consumption by 70%, a significant saving on Pelmanco’s operational costs. Screened solids are now removed to landfill and the council is satisfied that the settled sludge can be discharge directly to sewer.

Pelmanco's mechanical screen

The flocculator and tube settler at Pelmanco.

Three Streams Smokehouse Effluent Treatment Plant

A2V were appointed to refurbish the existing effluent treatment plant.

Our investigation confirmed that the original design was satisfactory for the current effluent flows, but that the aeration system needed to be replaced. This was done in a phased approach with minimal disruption to the operation of the plant.

The new aeration system has improved the oxygen transfer capacity of the plant which has been performing better that ever since being recommissioned.

Newly disc diffuser aeration system

Perdeberg Winery Effluent Plant

Perdeberg winery is located outside Wellington in the Western Cape. it is one of the largest wineries in South Africa.

The original Effluent Treatment Plant (ETP)  at Perdeberg Winery comprised the following elements:

  1.   An inlet works with a channel auger screen for the removal of larger solids and two settling chambers for the removal of grit.
  2. A balancing dam to equalise the highly variable effluent flows and organic loads from the cellar.
  3. A raw effluent feed pump station lifts the effluent from the balancing dam into a contact tank where pH adjustment is achieved through the addition of lime.
  4.  The bulk of the COD is removed by an anaerobic process comprising two stages; acid fermentation followed by methane formation. This is achieved in two anaerobic ponds through which effluent is recycled at a continuous rate to ensure proper mixing and pH control.
  5. An aerobic pond serves to polish the effluent from the anaerobic ponds from where it is discharged to an irrigation dam.

Unfortunately the plant had never operated satisfactorily due to a number of shortcomings in its design. A2V were approached for a proposal to identify and rectify these shortcomings. We determined that there were two main problems with the plant:

Perdeberg Winery - Anaerobic (UASB) ponds and a Perd

1.     1. Solids Removal 

The existing channel screen and settling basins were ineffective. This led to an accumulation of non-biodegradable solids in the balancing dam and anaerobic ponds which has in turn led to:

           Reduced equalisation capacity

           Blocking and tripping problems with the Raw Feed Pumps.

           A reduction of treatment capacity in the anaerobic ponds where active biomass was largely been replaced by solids.

            Blocking problems in the interconnecting pipework.

 2.     Recycle Rate 

The recycle rate measured on site was found to be inadequate which had the following negative effects on the process:

          Poor mixing in the active zone of the anaerobic ponds, leading to poor treatment.

          Due to lower flow rates in the pipe work, there was a propensity for solids to settle out which lead to added to the problem of numerous pipe blockages.

          The pH and alkalinity control was not as effective, which led to poorer performance and ultimately acidification (failure) of the anaerobic biomass.

 A preliminary check on the plant hydraulics suggested that the current plant design was limiting the recycle rate that could be achieved.

 

A2V proposed a cost effective solution , making use of existing infrastructure as far as possible:

1.       The existing auger screen was retained and refurbished with a larger aperture basket.

2.       The equalisation pond was converted to a settling pond through the addition of a floating decanter.

Installation of a floating decanter into the equalisation dam

3.       The recycle pumps were refurbished with larger impellers and motors to achieve a higher recycle rate.

Lime mixing tank for pH adjustment

4.       Bottlenecks in the interconnecting pipework were removed to facilitate higher recycle rates.

5.       Scum baffles were fitted to the anaerobic ponds to prevent debris from blocking pipework.

The solution was implemented in a phased approach starting in January 2012. Immediate improvements in plant performance and operability were achieved after implementation.

 

Aaldering Vinyards and Wines – Effluent Treatment Plant

Aaldering Cellar is a boutique cellar located in the Devon Valley, Stellenbosch. The cellar will process approximately 150 tons of grapes per annum from February of the 2012 harvest season. The ultimate future capacity of the cellar will be approximately 200 tons per annum.

(more…)

Rust en Vrede MBR Effluent Plant

The effluent plant at Rust en Vrede is designed as a Membrane Bioreactor (MBR) and was commissioned in 2007 as the first MBR treating winery effluent in South Africa. (more…)