Case Study: Simplified Wastewater Treatment Optimization at a Chemical Plant

Background

A leading chemical plant in the Greater Montreal area specializes in producing cleaning and sanitation chemicals widely used in food processing, beverage industries, and water treatment facilities. Due to the nature of its production—particularly sodium hypochlorite-based products—the facility faced strict wastewater discharge regulations imposed by municipal authorities.

Challenges

The plant encountered several operational challenges with its wastewater treatment system:

Elevated concentrations of chlorine-based contaminants, particularly chloroform.
Inefficiencies stemming from outdated chemical dosing procedures.
Underutilization and improper management of existing treatment infrastructure.
Regulatory pressure for prompt compliance improvement without major capital expenditures.

BIODE's Streamlined Approach

BIODE Engineering Consulting conducted a thorough diagnostic evaluation, determining that significant improvements could be achieved without the need for extensive equipment replacement. The key strategic choices included:

Retention and Optimization of Existing Equipment:
- Maintained original dissolved air flotation (DAF) units and filtration equipment.
- Introduced targeted operational adjustments to enhance efficiency rather than installing new costly machinery.
Efficient Chlorine Management:
- Implemented an innovative aeration process within existing neutralization tanks to effectively reduce chlorine and chloroform levels.
- Optimized pH levels and aeration rates to improve coagulation and flocculation efficiency, significantly reducing chemical usage and operational costs.
Enhanced Process Controls:
- Reintroduced precise chemical dosing protocols tailored to the facility’s specific needs.
- Added automated monitoring and process controls using sensors for accurate, real-time management.
Preventive Maintenance Protocols:
- Introduced comprehensive cleaning and maintenance routines for all wastewater infrastructure components to ensure consistent performance.

Results Achieved

Dramatic Reduction in Contaminants: Successfully reduced chloroform concentrations from previously borderline compliance levels (~158 µg/L) down to significantly below the regulatory limit (~5.5 µg/L).
Cost-Effective Compliance: Achieved full regulatory compliance without major capital investment in new equipment, representing substantial savings.
Improved System Reliability: Streamlined maintenance and enhanced operational procedures increased system reliability, substantially lowering the risk of non-compliance and unexpected downtime.

Conclusion

BIODE’s intervention enabled the chemical plant to meet stringent wastewater discharge standards efficiently, leveraging existing equipment while significantly reducing operational complexity and cost. This case demonstrates BIODE’s expertise in providing sustainable, economically viable solutions tailored to the specific needs of industrial wastewater management.

BIODE Engineering Consulting remains committed to delivering effective, simplified environmental management solutions for industries of all sizes.