Industrial Wastewater Treatment System

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Industrial Wastewater Treatment System

• Specifications Certification
• Permit limits (link to Environmental Web Page)
• (1 MGD 694 GPM)
• Total Capacity 1600 GPM (Caustic)
• Redundant Capacity 800 GPM-Full redundancy
  (process is limited by precipitator piping)
• Demand ( Load of Red. Cap.) 750-800 GPM,
  average (94-100) 1000 GPM, peak (85) usually
  due to rain, RO Flush, or Regen
• Technology Continuous flow system utilizing pH
  adjustment with 50 diaphragm grade caustic
  solution in the Mixing Basin Settling of fine
  particles in Surface Impoundment (two ponds)
  prior to discharge to 001 Outfall (thence Keegans
  Bayou, to Brays, to Houston Ship Channel,
  Waterbody Segment Code 1007 of the San Jacinto
  River Basin).
• Maintenance Schedule Annual - clean inspect
  precipitators Monthly - PM of rotating mixers
  Weekly - instrument calibration Daily - Visual
  structure inspection.
• Regulatory Considerations National Pollutant
  Discharge Elimination System (NPDES) TNRCC
  wastewater permits Water reuse recycle Agency
  inspections Proposed copper limit (Active
  September 2004).
• Dates East precipitator - est. 1968 West
  precipitator - est. 1980
• SCADA Monitoring Influent Trough pH, Basin pH,
  Effluent pH, Flow rates, Caustic tank level
  Ammonia
• FMEA Vulnerability Issues (RPNgt 150) Copper,
  Nickel, Capacity of Plant, Ammonia, Fluorides
  Contamination, Dirty PH sensors, IW Plant Flow
  meters, Broken Main, Line System-Pumps and Piping

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Item 3f. Flow Schematic Industrial Wastewater
Treatment System Caustic Option
Wastewater From Ultrapure Water Plant
NaOH
Inlet trough
Tube Settlers
Neutralization Basin (2)
28,000 gal.
Precipitator
(2) 40,000 gal.
Polishing Lagoons
Typical 810,000 gal. Maximum 2,290,000 gal.
Industrial Wastewater from Buildings 1 2
Semiconductor Manufacturing (Including BUMP CU
Resin System Pretreatment)
Outfall 001 pH Flow Meter Composite Sampler
Discharge To Unnamed Surface Drainage Along
Southern Most Property Line
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Flow Schematic Industrial Wastewater Treatment
System
Wastewater From Ultrapure Water Plant
Polymer
Filtered Water Return
Lime Slurry
Decanted Water Return
Inlet Trough
Tube Settlers
Neutralization Basin (2)
28,000 gal.
Sludge Blowdown
Precipitator
(2) 40,000 gal.
Sludge Pit
Polishing Lagoons
Typical 810,000 gal. Maximum 2,290,000 gal.
Filter Press
Industrial Wastewater from Buildings 1 2
Semiconductor Manufacturing (Including BUMP CU
Resin System Pretreatment)
Dewatered Filter Cake to Landfill
Outfall 001 pH Flow Meter
Composite Sampler
Discharge To Unnamed Surface Drainage Along
Southern Most Property Line
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Industrial Wastewater Treatment System

• Description The IW Plant is used to treat waste
  water generated by the site that contains
  contaminates that must be discharged in a
  regulated manor. It is a continuous (gravity)
  flow system utilizing pH adjustment with 40 lime
  or 50 caustic solution in the Mixing Basin
  addition of Coagulation Polymer precipitation
  and removal of solids in the precipitator
  settling of fine particles in the surface
  Impoundment (two ponds) prior to discharge to 001
  Outfall.
• System Specs There are environmental permit
  requirements that must be strictly adhered to in
  this 24 hrs/day 365 day/year operation. To find
  the latest permit requirements follow this link
  Permit limits (link to Stafford Environmental Web
  Page)
• Critical Equipment
• Inlet Trough-Feeds into both mixing basins
• 2 redundant 6 schedule 80 pvc lines connecting
  the site to IW Plant
• Rosemount pH meter - Model 1050A
• Mixing Basins
• 2 - Mixing Basins capable of flowing 1000 GPM
• 2 - Lightin Mixer Model 324-TEQ-7-52
• 2 - Rosemount pH meters - Model 1050A
• Lime System
• 316 SS piping with a continuous loop to keep lime
  slurry moving
• 10,000 Gallon Steel Tank Open Top
• 2 - 2 Wilden Air Operated Diaphragm pumps
  Model M8
• 2 - Air operated Lime Valves - 3/4 316SS Velan
  Ball Valves w/ UHMWPE seats and Ferguson
  Actuators serial number 329-20300
• Siemens 505 PLC PH Control with SCADA Interface
• Local - OMEGA CN76000 PH Control (Used for Lime
  and Caustic Control)

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Industrial Wastewater Treatment System

• Critical Equipment
• Precipitators
• 2 - 9 Partial Flume flow troughs with Sonar flow
  detection (Fischer Porter 50US3000 Flow
  Transmitter and 805H028U03 Transducer)
• 2 - Precipitators capable of flowing 1000 GPM
• 2 - Rosemount pH meters - Model 1050A
• Desludge System
• 2 - Timer Controlled
• 2 - Sludge Beds
• 1 2 Wilden Air Operated Diaphragm pumps
  Model M8
• 1 Netzsch Filter Press 630LP/III (Located at HF
  Plant)
• 001 Outfall
• 16 Piping from IW Treatment Plant to Surface
  Impoundment Inlet Troughs
• Inlet Trough to both Surface Impoundment
• 2 Surface Impoundments (ponds)
• 16 Valves and Piping (allow for isolation of
  individual ponds) leading to sampling well and
  out to 001
• Rosemount pH meters - Model 1055
• 9 Partial Flume flow trough with Sonar flow
  detection (Fischer Porter 52FT1000 Flow
  Meter-Transmitter and Transducer)
• ISCO Automatic Refrigerated Sampler (Model
  3710FR)
• Chlorine Dioxide Algae Treatment System
  (Contact Ron Robertson at Ashland Chemical
  713-941-1766)

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Industrial Wastewater Treatment System
Recovery Procedure
1. Identify the best method of re-establishing IW Treatment service.
2. Coordinate with Operations Team and mechanical/electrical suppliers for support.
3. Notify suppliers as necessary to supply portable generators and mechanical/electrical manpower as needed.
4. Coordinate electrical needs with Operations Team and High Voltage crew.
5. Coordinate connections and temporary equipment locations with Operations Team.
6. Review scope of work with mechanical and electrical contractor(s).
7. Coordinate with security to ensure adequate space and temporary fencing is made available for equipment and piping.
8. Notify Facilities personnel, customers, safety, and environmental personnel as required for clean up activities if necessary.
9. Notify Electrical Team for emergency electrical work if necessary.
10. Coordinate with Operations Team, electrical crew and suppliers for establishing start up requirements and operating sequence of rental equipment.
11. Coordinate with suppliers to ensure consumables, i.e. diesel fuel, are kept on hand.