Water Recycling: Tactics to Secure Water Supply for Expansion and Reduce Water Management Costs

The food and beverage industry faces rising water supply and effluent discharge costs due to climate change and regulatory changes. For instance, the Environment Agency (EA) has reduced borehole extraction by 10%, and some water companies are restricting supply. These challenges can hinder expansion plans, but with early consideration, capital investment in water reuse technology can support growth, drive long-term efficiency and address sustainability goals.

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According to the Environment Agency's "Food and Drink Manufacturing Water Demand Projections to 2050" report, the two most impactful measures for managing water demand are the recycling of cooling water and the reuse of treated effluent. High water users stand to benefit significantly from recycling water for various purposes:

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• Cooling water for equipment and machinery.
• Cleaning and sanitation of floors, walls, and equipment.
• Boiler feed water in steam generation processes.
• Irrigation of landscaping and grounds.
• Process water, with sufficient treatment.
• In-product use, such as washing fruit and vegetables.

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Available Technologies

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There are a range of options available depending on the ultimate use of the water, these include:

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• Membrane Filtration: Ultrafiltration and Nanofiltration removes particles and contaminants, producing high-quality water for various non-potable and potable uses.
• Ultraviolet (UV) Disinfection: Exposes water to UV light to destroy microorganisms and ensure pathogen-free water.
• Ozone Treatment: Uses ozone to disinfect water and reduce chemical contaminants.
• Biological Treatment: Employs microbial activity to break down organic matter in wastewater.
• Electro-deionization (EDI): Combines ion exchange and electrolysis to produce high-purity water.
• Activated Carbon Filtration: Removes organic compounds and chlorine, improving water taste and safety.

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Alpheus has extensive experience in the design and implementation of a range of technologies. Our Project Engineering team collaborates closely with clients to propose the most appropriate and cost-effective solutions tailored to a site's unique needs.

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Case Studies and Examples

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Innovative Solution Using Treated Effluent from a Nearby Municipal Treatment Plant

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A power plant collaborated with a nearby municipal treatment works to treat and reuse effluent, to achieve significant sustainability improvements. Alongside our parent company, Anglian Water, we designed, built, and operated a solution to acquire high-purity water through an innovative membrane process. This process used final effluent from the nearby sewage works to supply the demineralisation plant at the power station for boiler-feed water production, reducing the financial and environmental costs associated with mains water use.

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Commissioned in October 2000, the water reuse plant at the Flag Fen sewage treatment works treated final effluent using Ultrafiltration (UF) and Reverse Osmosis (RO) membrane technology to supply ultra-pure water to the power station. The fully automated plant operated on a supply-on-demand basis, requiring minimal human intervention. The project significantly reduced mains water use, chemical discharges, and heavy goods traffic to and from the site, earning numerous process and environmental awards.

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Recovering Treated Effluent to Supply 75% of a Plant's Water Needs

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One of our clients, a large fresh meals manufacturer, has been an early adopter of effluent recycling technology and has implemented and continues to extend schemes across multiple sites. At one of their Lincolnshire sites, around 75% of treated effluent is reused on-site. The effluent undergoes ultrafiltration through Membrane Bioreactors to remove suspended solids and microorganisms like E. coli, followed by nanofiltration to eliminate dissolved contaminants such as heavy metals. UV disinfection destroys pathogens, enabling the water to be reused for cleaning, cooling, and washing purposes. Through proactive maintenance and optimisation activity, the plant regularly exceeds the 75% target for reusable water, thus reducing mains water consumption and discharge costs.

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Upgrade and Optimisation Solutions for Existing Plants

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Upgrades to existing processes can improve efficiency and reduce costs. For example, we recently started a project with a food and beverage client to recycle part of 300m³ of final effluent per day for on-site reuse rather than incurring discharge costs. The solution involves installing a tank and pump system to divert treated water for screen washing. The estimated payback period is just over 12 months, after which the client will continue to save on water supply and discharge costs.

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The Danger of Delaying

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We are currently collaborating with a client in the early stages of a construction project, who approached us as they were facing significant water supply challenges. Due to local water supply restrictions, the project has been unable to secure mains water, leading to considerable cross-regional tankering costs to ensure adequate water for the construction phase. An alternative desalination solution is being developed to meet the future needs of the plant. Although this is an extreme example, it highlights the severe impact supply issues can have and underscores the critical importance of thorough advance planning.

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In conclusion, addressing water supply challenges early through innovative recycling and treatment solutions can drive efficiency, sustainability, and cost savings in the food and beverage industry. For advice and further information about reducing water management costs in the short and long term, contact enquires@alpheus.co.uk or call 01234 686100.