Case Studies

1. Own/Operate Wastewater Treatment System
2. Improving Water Treatment Specialty Chemical Costs
3. Minimizing Operating Costs at an Existing Wastewater Treatment Facility
4. Process Improvement
5. Utility Upgrade Evaluation
   

Case Study 1:

Own/Operate Wastewater Treatment System

A steel producer experienced intermittent violations of permit conditions for blast furnace wastewater for ammonia, phenol and cyanide. To eliminate this problem, the steel producer used cultured micro-organisms for ammonia removal and chlorine dioxide for cyanide and phenol oxidation, at a cost of about $50,000/month for each. Neither process was effective, and both failed to prevent the occurrence of continued violations.

MET (EnCOSS' predecessor) installed, owned and operated a biologically active filtration system for ammonia removal, and later expanded it to remove phenol and cyanide. The monthly cost to the customer was reduced to about ½ the previous amount, the effluent was maintained in compliance, with one exceedance due to high influent conditions, over a 9 year period. The system is still in operation.
 

Case Study 2:

Improving Water Treatment Specialty Chemical Costs

A Company that produces specialty steels was interested in improving their chemical water treatment vendor accountability for performance and in reducing water treatment costs.

EnCOSS, LLC worked closely with the Company's Purchasing, Operations, and Environmental Affairs personnel to develop a customized approach to accomplish this objective, which incorporated:

• A strategic plan
• An approved vendor list,
• Detailed Service Expectations & System by System Performance Specifications
• Tailored commercial terms
• Proposal requirements & format.
• Proposal evaluation strategy, with technical and financial guidance

The result was a cost savings of about 15% (a substantial reduction for the facilities involved), improved service and performance, increased vendor accountability and satisfied operators.
 

Case Study 3:

Minimizing Operating Costs at an Existing Wastewater Treatment Facility

An integrated steel mill was interested in optimizing an older wastewater treatment plant. The plant served a limited number of operations, and some operations contributing to the wastewater treatment system had been discontinued.

EnCOSS, LLC found that 80% of their waste stream was internally generated at the WWTP, and 10% could be treated elsewhere. With low cost modifications focused on influent inventory control, staffing was reduced by two thirds, and operating costs by 50%. This step paves the way for future improvements including the potential for contracted operations of the plant.
 

Case Study 4:

Process Improvement

A steel producer owned a wastewater treatment facility, operated by others, that was designed to produce dense metal hydroxide precipitates, using the HDS process. The system experienced intermittent upsets, and mediocre quality filter cake production.

EnCOSS, LLC evaluated the problem, and identified that a second stage of neutralization was needed to produce the desired solids quality. EnCOSS designed the process modifications, and developed the cost estimate for appropriation. The project is in the approval phase at the customer's corporate office, and should go ahead next year. Annual operating savings are estimated at close to $300,000/year.
 

Case Study 5:

Utility Upgrade Evaluation

A major player in the contracted water services field had provided a preliminary proposal for process water delivery to a large, established industrial client. The client's goal was to economically avoid substantial future repair costs.

EnCOSS, LLC was asked to submit a competitive bid. After thoroughly reviewing the client's needs and scope of work, then assessing alternative technologies and the client's cost structure, EnCOSS, LLC declined to bid. The required restrictions in the scope of work made repair of their existing equipment the most economical choice. The client, upon reviewing the EnCOSS, LLC information, decided not to pursue this project, redirecting their limited resources towards other cost reduction avenues.