Treatment of 60m3/h of effluent, loaded with MES and reused in industry

How can cutting water be recycled in the kitchen manufacturing industry?

The kitchen factory recycled industrial effluent to reduce waste. Water cooled the stone-cutting saws. It was essential to recover and reuse this water. The plant recovered this water, which was loaded with fine particles and minerals. Then it optimised it. A buffer tank collected the water before physico-chemical treatment. As a result, coagulation, flocculation and lamellar decantation effectively separated the contaminants. In this way, the water met the strict quality requirements. Finally, it could be recycled.

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Étapes de coagulation-flocculation appliquées dans le système de recyclage des effluents industriels, garantissant une eau de qualité pour réutilisation
Système modulaire pour le traitement des effluents industriels.

How is the stone-cutting industry reinventing water recycling?

The kitchen manufacturing industry was looking to recycle water to reduce wastage. Our customer wanted to install a recycling system to cool the saws. This would reduce water consumption and the costs associated with its use. The aim was to recover water while eliminating fine mineral particles. In addition, the solution had to adapt to the space constraints and specific operations of the site.

This recycling process requires the following elements:

    • The process water flow rate varies according to the use of the saws, with a maximum of 50 m³/h.
    • A buffer tank smoothes the flow upstream of the lamella clarifier.
    • The process uses coagulation, flocculation and settling.
    • The installation is compact and modular to fit into the limited space of the plant.
    • The installation is located outside the building.
    • A sand filter finishes the job.

Optimising the treatment of cutting water using jar-tests

In this cutting water recycling project, the team found laboratory tests essential for fine-tuning the process. Firstly, these tests simulated the coagulation and flocculation of fine particles in the water. These particles were mainly micro-sand and minerals from the cut stones. Next, the team determined the optimum dosages of coagulants and flocculants. This reduced flocculation times to 5 minutes, a considerable time saving compared with conventional processes. Thanks to this efficiency, the team has designed more compact installations. As a result, the space required and the associated costs have been reduced.

The tests revealed a number of challenges, including the presence of sticky, heavy sludge, which made pumping difficult. So the team adjusted the excessively high polymer rates to reduce them while maintaining satisfactory performance. These adjustments then facilitated sludge extraction and improved system management. In addition, the lower rates reduced the operational costs associated with sludge management. Finally, the tests adapted the system and ensured efficient water recycling, while complying with the requirements.

Decanter-coagulation combination: A process adapted to the recycling of industrial water

The proposed solution uses an advanced treatment process to meet the challenge of water recycling. Firstly, the process includes coagulation, flocculation and lamella settling stages, designed to treat cutting water. Secondly, the plant had to recycle up to 60 m³/h of water used to cool the saws. This water contained suspended matter, mainly fine mineral particles and micro-sand. The objective was therefore to install a high-performance system to treat this effluent while respecting space constraints. Lastly, this solution had to fit in with the restricted dimensions, while guaranteeing optimum water management.

Concrete results: Reduction of waste and optimisation of resources

Optimising the treatment of cutting water

The cutting water treatment project has exceeded expectations. Firstly, the optimisation of coagulation, flocculation and Lamella settling achieved a material removal rate of 98%. This guarantees high-quality water, suitable for recycling in the industrial process. Secondly, the compact, modular design of the installations has reduced the amount of space required. Finally, this optimisation facilitated their integration and reduced infrastructure costs and production interruptions.

Reduction of waste

Precise adjustment of polymer rates solved the problems of sticky sludge and made pumping more efficient. It also reduced sludge management costs. This optimisation then strengthened the sustainability of operations. It has also opened up opportunities for expansion to support future growth. So this project shows how a well-calibrated solution turns a challenge into a strategic advantage.

Project stages :

  • We design the lamella clarifier.
  • We design a solution tailored to the specific constraints of the site.
  • We manufacture and integrate electromechanical equipment.
  • We deliver and install the equipment on site.

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Year of production

2022

Technology

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