Managing wastewater at chemical process industries (CPI) facilities requires a tailored approach, and effective treatment promotes sustainable operations while avoiding potential regulatory penalties
For many consumers and businesses, wastewater simply disappears down the drain and out of sight. However, for industrial producers of liquid waste — such as chemical manufacturing companies — wastewater requires careful consideration. This byproduct of the industrial process poses challenges and opportunities that demand both innovation and responsibility, making proper wastewater management a pivotal part of safe and sustainable operations.
Risks of improper treatment
Wastewater management is critical in the chemical process industries (CPI) because it ensures the safe and compliant disposal of liquid waste. Improperly managed wastewater poses significant risks of environmental pollution and legal repercussions (Figure 1). Regulatory violations can lead to penalties, legal actions and expensive cleanup costs. Managing these requirements demands substantial time and resources, involving investments in infrastructure, personnel and continuous monitoring, but is well worth the effort to avoid non-compliant situations. In water stressed areas, tailored solutions become even more vital to address these challenges effectively. Beyond financial and operational impacts, failing to manage wastewater responsibly can harm a company’s reputation, affecting stakeholder trust and corporate social responsibility (CSR) commitments.
FIGURE 1. Properly managing wastewater a CPI facility can reduce the risk of environmental pollution and legal repercussions
Advanced treatment methods
To effectively manage wastewater in the CPI, a combination of advanced treatment methods is essential to address various contaminants and ensure that the treated water meets regulatory standards for discharge or reuse. The sections below describe several key processes employed in advanced wastewater treatment.
Wastewater pretreatment. The initial step in the treatment process focuses on preparing wastewater for further treatment or discharge. This step includes pH adjustment, oil and water separation, flocculation, sedimentation and filtration. A pH adjustment ensures the wastewater’s acidity or alkalinity is neutralized, preventing corrosion and enhancing subsequent treatment processes. Oil-and-water separation techniques, such as dissolved air flotation, remove oil and grease from wastewater. Flocculation involves adding chemicals to clump suspended particles together, making them easier to remove during sedimentation and filtration.
Screening and grit removal. Physical processes are used to remove large solids and organic matter from wastewater. Screening removes large debris, while grit removal eliminates heavy particles like sand and gravel. Sedimentation allows heavier solids to sink to the bottom, forming sludge that is later treated or disposed of, reducing the load on subsequent treatment stages and improving overall efficiency.
Biological treatment. Biological processes are used to remove dissolved and suspended organic matter. In activated sludge systems, microorganisms consume organic pollutants, converting them into biomass that settles out as sludge. Trickling filters, which use a bed of media for microorganisms to grow on, degrade organic matter as wastewater passes over them. These processes significantly reduce biochemical oxygen demand (BOD) and suspended solids.
Advanced purification. Further purification is achieved through advanced methods such as filtration, chemical precipitation, ion exchange and membrane processes like reverse osmosis. Filtration removes fine particles, while chemical precipitation targets specific contaminants for removal. Ion exchange and membrane processes provide high levels of purification, producing water suitable for reuse or discharge into sensitive environments.
Precipitation, flocculation and clarification. Precipitation involves adding chemicals to wastewater to form insoluble compounds that settle out as sludge. Flocculation enhances this process by aggregating fine particles into larger flocs, making them easier to remove. Clarification follows, where the flocs settle in a clarifier tank, leaving clear water for further treatment. These processes are effective in removing heavy metals, suspended solids and other contaminants from wastewater.
Liquid direct injection. Non-hazardous liquid materials undergo thermal treatment at a thermomechanical treatment facility (TTF). This method securely destroys a variety of liquid contaminants and is ideal for highly regulated industries, and those seeking alternatives to traditional wastewater treatment or solidification.
Product substitution. Advanced laboratory analytics play a significant role in identifying opportunities for wastewater reuse in other manufacturing processes. By substituting raw materials with more sustainable alternatives, companies can reduce the volume and toxicity of wastewater generated. This proactive approach minimizes waste at the source and supports circular economy principles.
Evaporation. Evaporation occurs when water in liquid waste is separated utilizing heat, leaving behind solid residues. The remaining solids can be composted, used as fuel, or used as energy-generation feedstock at a TTF. This process can be conducted through solar evaporation ponds or mechanical evaporators, depending on local conditions. Evaporation is particularly useful for reducing the volume of wastewater and concentrating contaminants for easier handling and disposal.
Water reuse in facilities. Water reuse is essential in industrial operations, especially for cooling processes and chemical dilution. Implementing water recycling systems helps conserve water resources and reduce the environmental footprint of manufacturing activities. Reused water can be treated to meet specific quality requirements, making it suitable for various industrial applications. For example, treated wastewater can be used for boiler feedwater, irrigation and even as a raw material in certain production processes.
Reuse in water-stressed areas
Managing wastewater in water-stressed regions presents unique challenges, but advanced treatment technologies can support water conservation and sustainable industrial operations (Figure 2). For example, locally generated wastewater can be tested and treated for reuse in various industrial processes. The treatment process involves comprehensive pre-treatment steps, such as pH adjustment, oil-water separation, flocculation, sedimentation, and filtration. Treated water can then be discharged to a publicly owned treatment works (POTW) facility for further treatment and reintegration into the natural water cycle.
FIGURE 2. Managing wastewater in water-stressed regions presents unique challenges, but advanced treatment technologies can support water conservation
TTFs can reuse reclaimed wastewater, as well as rainwater. These practices not only conserve precious natural resources but also set a model for what’s possible in sustainable wastewater management. Collaboration with local industries and municipalities highlights how facilities can support water conservation efforts in regions facing significant water stress.
Determining the right solution
Selecting the appropriate wastewater treatment solution is crucial for ensuring efficient and compliant operations in the CPI. Several factors must be considered to tailor the treatment approach to specific needs and challenges. These factors are described in the following sections:
Material. Different materials require specific treatment methods. For example, chemicals and hazardous waste need specialized techniques to ensure safe disposal.
Volume. High-volume generators may prefer advanced wastewater treatment methods, while smaller volumes might be better managed through evaporation.
Contaminant level. Varying levels of contamination necessitate different disposal methods to ensure complete treatment.
Regulations. Compliance with local, state, and federal regulations is critical, with some waste materials requiring adherence to multiple regulatory bodies.
Sustainability goals. Aligning treatment methods with sustainability goals, such as zero-landfill policies, can drive environmentally friendly practices.
Cost. Treatment costs vary based on material type, contamination level, and volume.
Credits. Utilizing environmentally friendly disposal methods may qualify for credits from regulatory bodies, reducing overall costs.
Future requirements. Ensuring the scalability of treatment solutions to meet future business needs is essential for long-term sustainability.
Selecting a wastewater partner
Choosing a reliable partner for wastewater management is crucial for ensuring operational efficiency and regulatory compliance. When selecting a liquid-waste solutions provider, it is important to evaluate several factors. First, assess the provider’s capability to handle all waste disposal needs, including logistics and hazardous waste treatment. This ensures that the provider can manage the diverse waste streams that may be generated by your operations. Next, consider the provider’s expertise and regulatory track record. A partner with extensive industry experience and a strong history of compliance will be better equipped to navigate the complex regulatory landscape and avoid potential legal issues.
Scalability is another critical factor; the provider should be able to manage your current waste volumes and accommodate future growth. This ensures that your wastewater management strategy remains effective as your business expands. Additionally, sustainability commitments are essential. Look for a provider that supports waste diversion, energy consumption reduction and other environmentally friendly practices. By aligning with a partner that prioritizes sustainability, your company can enhance its CSR efforts and reduce its overall environmental impact. Evaluating these factors thoroughly will help you select a wastewater treatment partner that can support your operational needs and long-term sustainability goals.
Sustainable practices
Effective wastewater management is essential for CPI professionals to ensure compliance, protect the environment, and maintain operational efficiency. To achieve the desired results, companies need to implement advanced treatment methods and tailored solutions and make sure they select the right treatment partners. These practices enable CPI facilities to achieve sustainable wastewater treatment and contribute to broader environmental goals. In today’s complex regulatory, social and economic landscape, environmental stewardship is paramount. Adopting a sustainable waste management strategy can help your company maintain compliance and establish itself as an eco-conscious leader with all your important stakeholders. By exploring advanced wastewater management practices and understanding their implementation, your business can align with objectives that support both environmental and financial goals.
Edited by Scott Jenkins
Author
Bryon Lawrence is the sales leader at Reworld LLC (445 South Street, Morristown, NJ 07960; Phone: 1-800-950-8749; Email: [email protected]). Lawrence is a veteran of the environmental services industry, specializing in commercial and industrial byproduct management. For the last 25 years, he has committed himself to managing complicated projects and providing pragmatic solutions to a heavily regulated industry. Lawrence holds a master’s of business administration (MBA) degree from Walsh College, and a bachelor’s in environmental policy from the University of Michigan School of Natural Resources. Throughout his career, he has been active with several industry organizations, including the Environmental Management Association (emaweb.org), the Institute of Hazardous Materials Management (www.ihmm.org) and the Suppliers Partnership for the Environment (www.supplierspartnership.org).