Toyota Industrial Equipment Manufacturing (TIEM) Wastewater Treatment Plant (WWTP)

Background

The Toyota Industrial Equipment Manufacturing (TIEM) Plant in Columbus, Indiana manufactures industrial fork lifts. The ferrous metal finishing, phosphatizing and painting operations yield wastewater with high metals concentration

Project Requirements

Complete Water Services (CWS) was retained to increase the capacity and effectiveness of the plant’s WWTP.

• Double the capacity of existing system to 86,400 gpd
• Reuse as much of existing system hardware as possible
• Design/Build system with small footprint (40’ X 45’)
• Improve stability, efficiency, ease of operation and maintenance
• Effectively treat a wide range of contaminants
• Increase capability to treat surges of contaminant volume and concentration
• Return as much treated water as possible to the plant for process water
• Aggressive schedule, coincident with planned plant maintenance shutdowns
• Tight budge

TIEM agreed with CWS’ proposal of a cost-saving two phased approach.

Phase 1

• Flow equalization
• pH neutralization
• Chemical flocculation/coagulation
• Clarification
• Sludge de-watering
• 40% of original treatment plant equipment was reused
• During the scheduled 5 day plant shutdown, equipment from the original plant was disassembled, moved and incorporated into the new WWTP. Final tie-ins were made, and the new WWTP was operational before the manufacturing plant went back online.

Phase 2

• Ultrafiltration
• Reverse Osmosis
• More than 90% of treated water to be recycled into the plant
• Treated water will exceed TIEM’s stringent purity require­ments for final-rinse process water.
• As with Phase I, the WWTP will be designed to allow all modifications, final tie-ins and startup to be completed during scheduled plant shutdown.

Results

• Design Maximized Use of Existing Equipment
• Brought On-Line With No Interruption of Manufacturing

These products support automotive, aerospace, cryogenics, high-energy physics, telecommunications, electronics, structural, textile, microwave and nuclear applications.  During the manufacture of these technical ceramics, wastewater is generated that is high in metals and Total Suspended Solids.

CWS was retained to upgrade and replace the existing pretreatment system with one that would continually meet discharge requirements.

Project Requirements:

• Influent flow rate of 10 gallons per minute
• Pretreatment for metals and solids
• Design/build of new system in limited space allotted while existing system remained online
• Reuse of some of the existing equipment

System Components:

• Filtration
• Flow equalization
• Tank for emergency flow or high concentration wastewater holding
• Neutralization/coagulation/flocculation
• Clarification/sedimentation
• Sludge dewatering
• CWS completed the system with no interruption in plant operations
• Design maximized the use of existing equipment
• Effluent consistently meets discharge limits

• Repair or replacement of journals
• Rubber roll covers
• Mechanical repairs
• Balancing

Repair activities are different for each roller that enters the facility.  Any combination of the above can be conducted on the roller or its associated parts.  These activities can be comprised of any of the following:

• Solvent cleaning
• Burning bar/lancing to remove journal
• Lathe removal of existing cover material
• Machining
• Welding
• Thermal metal spraying
• Abrasive blasting
• Application of rubber cover material
• Wet grinding of new cover
• Application of surface coating

These repair activities generate process wastewater which is constantly changing.  CWS completed a design/build of a flexible pretreatment system that removes grit, adjusts pH, removes oil & grease, removes Total Suspended Solids, and removes metals to levels that consistently meet the required discharge limits.

Project Requirements:

• Design/build of a multi-staged treatment process
• Small space for treatment system (20’ x 40’)
•  Influent rate of 40 gallons per minute
• Increase the capability to treat surges of flow volume and contaminant concentrations
  

System Components:

• Oil separation and grit removal
• Flow equalization
• Neutralization/coagulation/flocculation
• Dissolved air flotation
• Effluent monitoring
• Maximized the layout of process equipment in limited space
• Effluent concentrations meet discharge limits

Pacific viewers – 6:30am local time

We offer this service under a variety of models. Benefits to your company or organization include:

• Prolong the life of plant equipment through proper maintenance and repair
• Reduce plant downtime and its impact on production
• Reduce administrative, management, and training costs
• Ensure the proper use and application of all treatment chemicals
• Avoid costly fines for non-compliance
• Minimize surcharges
• Avoid the potential impacts of staff turnover

Complete Water Services will operate your treatment plant schedule appropriate for the treatment process. As a minimum we will perform the following services:

• Onsite analysis and process operations
• Sample collection, analysis, with required decision making compliance reporting
• Residual solids management
• Chemical management
• Preventative maintenance
• Emergency Response available

Reference Projects

Community College, North GA

A 60,000 gpd sanitary treatment system which includes a lift station, activated sludge treatment lagoon, holding pond and a 36,000 gpd land application system.

Industrial Bakery, Atlanta GA

A 40,000 gpd industrial treatment system for high strength bakery waste which includes screening, equalization, pH control, activated sludge system, clarification and belt press operation for solids dewatering.

Wastewater Generation

Although the manufacturing processes may be very different across the food service industry, the wastewater generated has similar characteristics and similar problems including:

• pH excursions caused by acid and caustic cleaning processes and the use or manufacturing of acidic products such as vinegar (acetic acid) and citric acid.
• High levels of settleable solids and suspended solids caused by cleaning operations and in-product loss during production.
• High levels of five-day biochemical oxygen demand (BOD5) and chemical oxygen demand (COD). BOD5 is a 5-day bio-assay type test and can be considered a measure of biodegradability as it relates to wastewater treatment. COD is a chemical degradation test that takes a few hours to complete and is used as a surrogate to BOD5.
• Excessive fats, oils and grease (FOG) caused during bakery operations, fryer and cooker cleaning; product loss during transfer; and in blending and cleanup operations. It should be noted that each pound of FOG generates approximately 2 pounds of BOD5.

Treatment System Components

The most common treatment processes for the specialty chemicals industry:

• Equalization
• pH adjustment
• Screening
• Clarifiers / Settlers
• Dissolved Air Flotation
• Recycle systems
• Solids handling
• Discharge monitoring

CWS is capable of providing the following services related to your water and wastewater handling needs:

• Water and wastewater treatability studies
• Product loss evaluations
• Engineering and design
• Complete water and wastewater treatment systems
• Design-build (D-B); design-build-operate (D-B-O); design-build-operate-finance (D-B-O-F)
• Equipment Components

This Kings Hawaiian bakery in Oakwood is the first outside of California and is the latest in a series of water and wastewater treatment projects undertaken thin the bakery sector by the CWS Team.  “We have been fortune to have built up experience and the expertise to serve the food market’s water and wastewater treatment needs.  We look forward to many more such projects across all the USA.  Although we are based in Georgia, our clients are spread for coast to coast” says Jim Lewis, CEO of Compete Water Services.

“You may think that water supply and waste water treatment is not a very innovative business. However, we found a company in Complete Water Services that, on a daily basis, finds ways to use cutting edge technology, and recycle / re-use systems to bring water supply and waste water management into the 21^st Century. We think our viewers will be interested in what this company does, and how they do it” said Gordon Freeman, Executive Producer of the show.

As part of the show, How2Media will be sending a film crew to spend time at the company’s Marietta, Georgia facilities, to try and get the story behind the story, and to show the “World’s Greatest!…” viewers why Complete Water Services was selected as the best in their category, and therefore featured on the show.

“World’s Greatest!…” is a thirty minute show dedicated to highlighting the world’s greatest companies, products, places, and people. Each show is a fast paced tour around the world featuring behind the scenes footage, informative interviews, and exciting visuals.

How2Media is a 21^st Century television production company. Their award winning programming can be seen on national cable channels and local network affiliates across the country.

Watch this Blog for more details.

Sub-contracting of your water treatment plant operations allows you and your staff to concentrate on your core business. Under the direction of Certified Operators, CWS will manage the operations, maintenance and environmental compliance of this critical process.

Benefits to your company or organization include:

• Prolong the life of plant equipment through proper maintenance and repair
• Reduce plant downtime and its impact on production
• Reduce administrative, management, and training costs
• Ensure the proper use and application of all treatment chemicals
• Avoid costly fines for non-compliance
• Minimize surcharges
• Avoid the potential impacts of staff turnover

Complete Water Services include:

Onsite analysis and process operations
Sample collection, analysis, with required decision making compliance reporting
Residual solids management
Chemical management
Preventative maintenance
Emergency Response available

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