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Turnkey water treatment system

13 August 2010

Following an in-depth review of requirements, industry recommendations and an evaluation of available technologies, Puresep was commissioned to provide a turnkey water treatment system to supply purified and sterilised water, on demand

The Puresep water treatment system includes a PureFLOWmembrane separation plant, which boasts what the company describes as ’high quality’ system design and PLC process control and is being used by production plants in the UK.

The Water Treatment ProcessBeverage water is fed into an inlet buffer tank and supplies the PureFLOW RO (reverse osmosis) plant by a VFD (variable frequency drive) controlled pump. The RO membrane separation process utilises high rejection, semi-permeable PA (polyamide) membranes to reject dissolved ions from the feed water.

The feed water is boosted to 10-12 bar, to drive the separation process, with 20% of this feed water becoming the concentrate waste stream, containing 97-99% of the unwanted ions.

Owing to the feed water chemistry, the Puresep technical team recommended an anti-scalent dosing system. PureCare-100 anti-scalent is used to prevent membrane deposits as the concentration effect takes place. This helps ensure the smooth running of the plant and assists in the efficiency and cost effectiveness of the membranes.

Treated water is then fed into a sterile vented 50,000l stainless-steel tank at a rate of 20m³ per hour. The tank level is maintained to ensure water is available for the 24-hour batch make up production program with process control to ensure minimal water is stored or wasted at the end of a production cycle.

Water is drawn from the product water tank via a centrifugal pump controlled using a VFD and passes through a UV (Ultraviolet) treatment process, to ensure it’s sterilised. The treated water tank also has a recirculation sequence to ensure the stored water is consistent in quality.

When the batch product ‘make up’ is active, the treated water supply route is open allowing supply lines to be flushed and followed by the ‘totalising’ of liquid ingredient into the selected batch tank. The Puresep water system control panel is fully integrated with the plants existing controls.

The Ethernet communication interface allows essential data transfer to and from the onsite SCADA control, including batch volume required, current volume produced, system status and demand signals.

“Puresep was chosen because of its recommendations for a bespoke system that ensures cost effectiveness and plant efficiency. We also know its 24/7 services levels and expert engineers are second to none,” says the onsite project manager.

“The water system design and installation featured integrated tank CIP functionality coupled with process control and instrumentation to facilitate additional future water saving benefits,” says Giles Fawcett, technical services manger, Puresep Water Technologies. “To further enhance our offering we have 24/7 servicing in place from expert engineers.”

Water treatment from Puresep: As water costs rise the treatment and recycling of site water for use in other processes is becoming more financially advantageous. As a water process company, Puresep offer several state of the art technologies. For the purpose of this article, three complementary technologies will be looked at; Ultraviolet irradiation (UV), PureSec Electrochlorination and PureChlor Chlorine dioxide. These have recently been installed at food and beverage sites across the UK.

UV is primarily employed as a disinfection process that inactivates waterborne pathogens without using chemicals. This is a result of the UV light changing the DNA and protein structure of viruses and bacteria and stops them from reproducing.

Advantages of UV disinfection include that it is effective for all microorganisms, including bacteria, viruses, fungi, and protozoa such as cryptosporidium. Also, it has low capital, operating and maintenance costs; it is compact and easy to retrofit and operate. Efficacy is independent of pH – there is no impact to the aesthetic quality of the water (taste, odour and colour); and safe and environmentally-friendly.

The Puresep Water UV system was recently installed at a soft drinks site, as the third stage sterilant. The incoming town’s water was dosed with a chlorine sterilant, and then fed through carbon beds to remove the chlorine and finally through the Puresep UV system, to ensure viruses and bacteria are kept to extremely low levels.

PureSec Electrochlorination is the instantaneous production of sodium hypochlorite solution. Where sodium chloride is converted to low strength (1%) liquid chlorine by electrolysis. Salt and power are the raw materials for the process and the availability and source of the salt often determines the most appropriate Electrochlorinator design for a particular application.

Over recent years Electrochlorinaton has gained favour, owing to the elimination of transportation and storage of chlorine gas or other disinfection chemicals meaning it’s a safe, reliable and economic method of disinfection. It’s well suited to the treatment of drinking water, wastewater, cooling water, as well as other industrial applications. Lower operating cost and high level of safety means Electrochlorination is appropriate in many instances.

Puresep has recently installed a PureSec Electrochlorination system at Britvic soft drinks where the electrochlorinator replaced a chlorine gas system. The electrochlorinator produces 36kg per day of chlorine and is then fed to a storage vessel, which has a pressure transmitter that enables automated on demand batch make up.

The dosing system is fully automated with a duty standby dosing pump which automatically energises the standby unit following any error signals fed back to the PLC.

“We chose the PureSec Electrochlorination system owing to its high level of safety and efficiency, and the specialised knowledge of the Puresep engineers,” says Kevin Cunningham, engineering support team leader at Britvic Soft Drink.

Finally, PureChlor Chlorine dioxide is where chlorine dioxide is produced through the tightly controlled mixing of Puregen base reagents. Chlorine dioxide is a powerful disinfectant making it an effective, fast acting killer, by breaking down cell walls and attacking bio film leaving no resistant strains. It’s well suited to a range of water treatment applications. PureChlor is PLC Controlled with full safety features and multiple point of use.

Applications include:
 Sterilisation, recovery and recycle of wastewater
 CIP disinfection
 Feed water treatment
 Effluent treatment
 Product water

Benefits include
 Hugely efficient low chemical usage ensuring a safer environment for everyone
 Zero harmful chlorinated by-products
 Easy future expansion
 Single chemical storage area, so no need for bulk storage
 Fast acting killer unaffected by the PH range it operates in

The PureChlor Chlorine Dioxide system has been installed at Universal Beverages, where the system feeds five points of use, these applications are: de-aerated liquor, softened towns water, CIP lines x 2, and post carbon filtered water. ”The PureChlor Chlorine dioxide system is very efficient for our needs and the fact we can use one system with numerous points of use makes it operationally beneficial and cost effective,” says Chris Newall, operations director, UBL.

There are numerous options to efficiently and effectively treat water; the fundamental issue is to understand which option best suites the plant in question, the application and the financial viability. A company such as Puresep Water can offer in depth consultancy services to review and assist companies with their water treatment needs to ensure performance and cost targets as well as legal requirements are met.

Puresep Water Technologies chosen to provide water treatment solution for soft drinks manufacturer

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