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Soybean
Processing Facility Solves Operational Problems with
Effective Water Management Program
Background
The Soybean Processing Facility is an agricultural products
processor making soybean oil and meal. The facility
is relatively new (less than 5 years). In year three
of the plant's operation, water-related problems were
becoming a major operational issue. The plant manager
explains that they "started the plant up with water
treatment equipment that had been used in another facility.
The situation had degraded to a point that the water
quality was causing us major operational problems."
It was also causing:
- Excessive
water, sewer, and chemical consumption,
- Inconsistent
steam quality which lead to production outages and
product quality problems,
- Time
consuming distractions to maintain the water treatment
program. It was costing the facility operational efficiency,
overtime maintenance expenses, and low employee morale.
Relationship
with CROWN Solutions
The managers of the facility knew they had to make an
effective, long-term change. They considered proposals
and design ideas from GE-Betz, Nalco, US Filter, and
CROWN Solutions.
The
vendor selection process took nearly three months. In
the end, the plant management team selected CROWN Solutions
to handle the overall water management strategy as well
as to design, build, and install the water treatment
equipment. The plant manager explains, "We selected
CROWN because they demonstrated a thorough understanding
of our plant's process. They had a number of creative
ideas and a 'can do attitude' that we felt would lead
to an effective resolution of our problems. They were
also a water management company rather than a water
treatment chemical company. That was exactly what we
were looking for."
CROWN
Solutions developed a long-term water management strategy
that required a complete replacement of the pretreatment
equipment for the boiler and cooling tower systems.
System
Design Strategy
The plant manager comments, "we have a very lean staff
here. We were relying on CROWN to provide a turnkey
approach that could be installed with zero downtime."
The
water treatment strategy that CROWN Solutions developed
included the following:
- 750
GPM supply water booster pump skid
- 150
GPM, expandable to 300 GPM Reverse Osmosis (RO) Machine
- 3
million grain, 100 ft3 dual vessel sodium zeolite
softener system
- 10,000
gallon permeate storage tank, level controls, and
600 GPM permeate transfer pump skid.
- 30
ton automated bulk salt and brine makedown system
· Decarbonator for RO reject pretreatment.
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| Twin
alternating 100 ft3 water softening system with
four-inch face piping. The system utilizes PLC control,
high performance, double acting butterfly valves,
and a hardness analyzer. The system has expansion
capability for a third softener. |
150
GPM at 55°F RO machine expandable to 300 GPM. The
system utilizes a 14-inch touchpad operator interface,
PLC controls, remote monitoring capability, sodium
bisulfate feed system, clean-in-place system, and
a chlorine analyzer. |
(Click
here for a larger version.)
The
installation phase of the project required a coordinated
effort between the client and CROWN Solutions. The plant
manager comments, "CROWN developed all the general details
for the project. We requested and received full cooperation
for a number of specific design, automation, and component
features that would make the system consistent with
our plant's existing operation procedures."
"When
it came time for CROWN to complete the system installation,
they brought mobile pretreatment equipment on-site to
keep us running while the new equipment was installed,
debugged, and put in service. The entire process was
brought on-line with minimal effort on our part and
without any production outages. We turned the switch
and it worked."
The
equipment was installed in several phases in order to
maintain production capabilities and capacity. During
the new equipment installation, the mobile pretreatment
equipment and some of the existing pretreatment equipment
was operated and maintained by CROWN Solutions as part
of the installation contract.
Operational
Results
The client tracked several of their plant's operating
characteristics to determine the performance for CROWN
Solutions.
(Click
here for a larger version.)
A
major component to maximize the economic payback strategy
of the project was the utilization of the RO reject
as cooling tower makeup. CROWN Solutions' knowledge
of water treatment equipment and chemical treatment
allowed the development and subsequent implementation
of a strategy that utilizes 100% of the RO reject. The
use of RO reject for the cooling tower makeup actually
increased the efficiency of the cooling tower.
The
measured financial payback on the installed cost of
equipment was 1.4 years. CROWN Solutions maintains an
operating agreement with the client to supervise the
water treatment strategy as well as to provide all maintenance
for the new pretreatment equipment. The plant manager
summarizes the current state of water management at
his facility: "We don't worry about it anymore. We are
able to concentrate on running our plant, and CROWN
takes care of the water."
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