Hulamin Pty Ltd

PROJECT TITLE:

Reverse osmosis and effluent plant for the new proposed powder coating plant

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Customer profile

Hulamin is an aluminium semi-fabricator business located in South Africa which also supplies customers across Africa and the world with a variety of products. Its support structure comes in the form of sales offices in South Africa, the USA and Europe as well as a network of international agents, leading manufacturers and distributors across man industries across the globe.

The company is involved in a wide range of industries namely – Automotive, Building, Electrical, General electrical, Packaging, Renewable energy as well as Transport. They specialise in rolled products, extrusions and containers. An example of one of their products is packaging foil they produce for the food and beverage industry as well as can ends.

Technical Situation

Hulamin have a new powder coating plant, therefore they were looking at acquiring two water treatment systems. The first system was a water treatment plant that would be able to produce a flowrate of between 3 –3.5 m3/hr and a conductivity of 2 ms/m using municipal water as its feed water and use this as process water . The second system was a 4 m3/hr effluent plant that would be treating process wash water and correcting it to suitable sewer discharge standards.

Solution

In order to meet Hulamin’s requirements, the Watericon engineers decided on a specially designed Reverse osmosis system coupled with a CIP system as well as an effluent plant design. The Reverse Osmosis system was decided upon to meet the 3 – 3.5 m3/hr and 2 ms/m specifications and the effluent plant was designed to correct the water to meet municipal sewer discharge standards.

The Reverse osmosis and effluent treatment plant consisted of the following :

  • pH correction of feed water ( Effluent)
  • Dosing systems for chemical make-up/addition – coagulant/flocculant dosing ( Effluent)
  • Mixing tank with In-line static mixing to aid chemical reactions ( Effluent)
  • Settling ( Effluent)
  • Physical filtration ( Effluent)
  • Feed water tank (RO)
  • Physical filtration (RO)
  • Membrane filtration (RO)
  • CIP system (RO)

Process description

The feed water for the effluent plant was drawn from a storage tank, and then fed through a chemical dosing program. This included dosing pumps, dosing tanks, skids and pumps. The system was designed with in-line static mixing to aid the reaction time with the chemicals. The effluent then went through a settling process, the clean water overflow was pumped through a filter for final polishing. The sludge was collected in a tank and its disposal was the responsibility of a waste collection company. The clean water was in a storage tank and then pumped to the various points of use such as toilets, wash water and the cooling tower.

The membrane filtration process starts off at the municipal feed water tank. From this tank, the water then enters a physical filtration process. After filtration, the water is sent to a break tank before it enters the Reverse Osmosis process. After Reverse osmosis, the water is then stored in a water storage tank ready to supply the appropriate process.

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