Innovative Solution Recycling Treated Effluent from a Nearby Municipal Treatment Plant

SECTOR
Municipal
SERVICE
Design, Build, Finance & Operate
Image of water recycling plant incorporating microfiltration and reverse osmosis

A major integrated energy company, with operations spanning from energy sourcing and generation to the supply of gas and electricity to millions, envisioned becoming the most trusted energy leader in the shift toward a low-carbon future.

Their turbine power station used mains water in its demineralisation plant for boiler-feed production—a common but costly process with significant financial and environmental impacts, from chemical regeneration, rinse water, waste chemicals, and wastewater disposal.

Alpheus, and the wider Anglian Water Group, approached the power station with a proposal to supply high-purity water via an advanced membrane process, utilising sewage works final effluent as its raw water source.

This approach would reduce reliance on mains water while addressing operational issues in the station’s demineralisation plant.

With sustainability high on their corporate agenda, our client was eager to proceed with the design, construction, and operation of a treatment plant that would deliver both financial and environmental advantages through the supply of ultra-pure water for boiler feed production.

Their primary goals for the project were:

  • Reducing demineralisation plant operating costs
  • Overcome operational issues, including fouling and downtime.
  • Minimising the plant’s environmental and carbon impact
Process flow chat for water recycling plant

Services Provided

Following successful feasibility and site trials, a 10-year Design, Build, Finance and Operate (DBFO) contract was signed for the Flag Fen Water Reuse Plant (Peterborough) which operated successfully from 2000 to 2012.

Commissioned in October 2000, the water reuse plant was installed on land at the Flag Fen sewage treatment works. The final effluent from the municipal sewage treatment plant was treated at the water recycling plant using a combination of Ultra-Filtration (UF) and Reverse Osmosis (RO) membrane technology to supply the ultra-pure water for use at the power station via an installed 1.5km pipeline.

The high-tech fully automated plant ran on a supply-on-demand basis, benefitting from telemetry,  remote access and regular proactive operator maintenance, providing stable and reliable performance.

The treatment process:

The recycling plant comprised three main elements:

  • An inlet rotating drum screen (150 µm pore size) to remove larger particles from the sewage effluent.
  • Micro-filtration (MF) membranes (0.1 µm nominal pore size) in twin banks of 17 modules to remove fine solids, including micro-organisms.
  • Reverse osmosis (RO) membranes in twin banks of six vessels (in 4:2 arrays) to remove around 95% of all dissolved ions in the MF filtrate.


At the time of commissioning, it was one of only two membrane effluent recycling plants in the world. Its successful delivery and operation demonstrates the certain feasibility of sewage treatment final effluent as an effective water resource.

The Outcome

Alpheus successfully operated the Flag Fen water reuse plant for over 12 years (until the power plant closed), supplying high-purity water to the power station and delivering substantial financial, environmental, and social benefits to the customer.

Improved performance and reliability

  • The Power Station's demineralisation plant run times between regenerations increased from every 8 hours to over 60 hours (a volume increase from 530 m3 to 7,000 m³).
  • The demineralisation plant’s availability increased from 78% to 98% - with almost 20% more demineralised water being produced.
  • The reduced organic matter in the water supply has ensured steam purity consistently within the turbine manufacturer’s specification and prevented fouling on anion resin.

These performance improvements led to:

Significant operating cost reductions

  • The reduced regeneration frequency and associated effluent pumping reduced the demineralisation plant’s power consumption by 20%.
  • The significant reduction in fouling on the anion resin at the demineralisation plant reduced the need for cleaning to once every four years, from every 2-3 months previously.
  • An 87% decrease in total chemical volumes used in regenerations resulted in a bulk chemical delivery reduction to just three a year, from thirty.
  • Significant trade effluent charge savings.

Environmental benefits

  • Environmental and social benefits included a 20% decrease in power used by the demineralision plant and therefore significant carbon reductions, a substantial decrease in the reliance on mains water, fewer chemicals discharged to the sewer, and less heavy goods traffic to and from the site.
  • The station’s trade effluent discharge to the public sewer was reduced by 87% (over 28,000 m³ per year), leading to significant trade effluent charge savings.

Health and safety improvements

  • Health and safety benefits were also achieved by reducing the handling of highly corrosive chemicals and traffic on site.

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