July 2012, Vol. 24, No.7


PepsiCo (Purchase, N.Y.) is installing an integrated water reuse system at its snack-food production plant in Santiago, Chile. As part of a wastewater treatment plant upgrade, the manufacturing facility is increasing its wastewater treatment capacity by 20% and incorporating environmentally beneficial technologies.

Siemens Industry Automation Division (Munich) will provide an integrated system for the operation. The plant’s wastewater first passes through a starch-recovery system and is screened before it moves on to primary treatment, which includes oil and grease removal. Following this stage, it will flow to a Siemens MemPulse membrane bioreactor system to separate and treat liquids and solids. Next, the water will be pretreated before it passes through tertiary treatment, including a reverse-osmosis system and a Barrier M ultraviolet disinfection system, both also from Siemens.

The system is predicted to reduce freshwater consumption by up to 70%. It is expected to become operational in 2012.


The new, 100-million-L/d seawater, reverse-osmosis desalination facility in Chennai, India, installed a custom gravity intake screen capable of handling a peak flow rate of 11,060 m3/h. Johnson Screens (Australia) Pty Ltd (Geebung [Brisbane], Queensland) built and supplied the intake screen.

The screen has a diameter of 5.5 m and a height of 2.65 m with a manhole and provisions for air-bursting and chlorination. The entire construction was in super-duplex stainless steel, used to resist the highly corrosive seawater.

When the new desalination plant is completed in mid-2012, it will supply 100 million L of potable water a day to reduce stress on Chennai’s groundwater resources.


The POSCO Cold Rolling Mill Steel Plant in Maharashtra, India, will install a zero-liquid-discharge wastewater recycling technology in 2013. The system, manufactured by GE Water & Process Technologies (Trevose, Pa.), marks the first steel-mill application of a complete GE zero-liquid-discharge system containing electrodialysis reversal.

The system will include two electrodialysis reversal trains for water reclamation. GE also will provide technical services, including operator training, during installation and commissioning of the new facility.


Black & Veatch (Overland Park, Kan.) is designing a new hydroelectric powerhouse in Wisconsin for We Energies (Milwaukee). The new Twin Falls Powerhouse will replace a nearly 100-year-old facility and boost the facility’s capacity. The new facility is located on the Menominee River across from the Upper Peninsula of Michigan.

The original Twin Falls Powerhouse began operation in 1912. The existing facility uses five generating units to produce 6.1 MW of power. The new environmentally friendly powerhouse will use two larger turbines that will improve efficiency and reliability. The upgrade will boost the powerhouse capacity to 9.0 MW. The existing facility, which sits on the Michigan side of the Menominee River, will remain in operation while the new powerhouse is built on the Wisconsin side of the waterway.

Construction is planned to begin in spring 2014. We Energies’ goal is to have the new powerhouse ready for operation the summer of 2016.


To prevent combined sewer overflows, the city of Namur, Belgium, installed a system of vortex-powered stormwater treatment devices. Situated at the confluence of the Meuse and Sambre rivers, Namur’s complex wastewater and stormwater network was discharging previously overflow wastewater through nearly 50 separate outfalls directly into the rivers.

Some 25 km of new connecting pipeline to a new treatment plant have been retrofitted to the existing sewer network. In the city’s central area, limited space, complex underground services, and level topography required a network operated under pressure, rather than by gravity. A total of 54 pumping stations inject wastewater from neighborhood sewers into the collection network.

After storms, overflows of the pumping stations could cause unwanted discharges into the rivers. So, 33 Storm King® units, manufactured by Hydro International (Bristol, England), have been installed. They are spread among 37 of the pumping sites and control onward flows, preventing overloading of the downstream network. They also provide pretreatment of sediments, grit, and floatables.


Earlier this year, Clean Water Services (Hillsboro, Ore.) and Ostara Nutrient Recovery Technologies Inc. (Vancouver, British Columbia) unveiled their nutrient recovery facility at the Rock Creek Advanced Wastewater Treatment Facility in Hillsboro.

The facility, which is the second in continued public–private partnership, uses Ostara’s Pearl® Nutrient Recovery Process to recover phosphorus and nitrogen from wastewater and transform them into Crystal Green®, an environmentally friendly slow-release fertilizer, which can be used by nurseries and other businesses throughout the region. The Rock Creek facility features two Pearl 2000 fluidized-bed reactors that will generate a combined capacity of 1090 Mg (1200 ton) of fertilizer every year.

The technology reduces operations and maintenance costs and provides revenue from the sale of the fertilizer. The combination of cost savings and revenue are projected to pay off in 6 years the $4.475 million project cost.


The Delta–Mendota Canal/California Aqueduct Intertie project is a 150-m (500-ft) underground canal and pumping station that will move water from the state-controlled California Aqueduct to the federally controlled Delta–Mendota Canal. The linking of these two canals is expected to improve water supply reliability in a part of California hardest hit by dry conditions. The canals are linked via two 2700-mm-diameter (108-in.-diameter) pipes with a pumping capacity of 13 m3/s (467 ft3/s).

The pumping station has four 1000HP Titan® Vertical Holloshaft motors, manufactured by US Motors®, a member of the Nidec Motor Corp. (St. Louis) family of brands, and drive pumps manufactured by Cascade Pump Co. (Santa Fe Springs, Calif.). Each pump is rated at 227,000 L/min (60,000 gal/min).



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