The development of Autoneum’s innovative water treatment system exemplifies a commitment to sustainability and the efficacy of iterative problem-solving.
The Challenge
In 2020, Aqualytix was engaged to investigate a potential contamination issue originating from a condensate return identified as the “Dirty Return.” This contamination posed significant challenges for the boilers, which require pure, clean water for optimal operation.
Darren Brown, our lead customer engineer on this project, stated: “Once we identified the source of the contamination, we implemented a temporary diversion of the contaminated condensate to avert further complications with the boilers. Subsequently, we devised a comprehensive solution. Although we encountered several challenges, we successfully developed a system that safely stored the high-temperature contaminated water, filtered and conditioned it, rendering it suitable for reuse in the hotwell to supply the boiler. This innovation will conserve water, energy, and chemicals for the customer.”
The Solution
In 2023, Autoneum commissioned a customised system designed to treat and reuse contaminated water. The system captures the contaminated water in a storage tank, processes it, filters it, and subsequently repurposes it as clean water for boiler use. This bespoke solution is uniquely tailored to meet Autoneum’s specific requirements, marking it as a pioneering advancement in the field.
The Results
Within the first month of operation, Autoneum achieved a remarkable conservation of approximately 45,000 litres of water, which is now utilised in the boiler rather than being discarded. This significant water savings is accompanied by several additional benefits:
- Cost Savings: Reduced water consumption translates into considerable financial savings.
- Chemical Savings: The boiler requires fewer chemicals for treatment.
Salt Savings: The water softener operates less frequently, yielding savings of approximately one pallet of salt monthly. - Energy Efficiency: A decrease in boiler blowdown contributes to energy savings.
- Carbon Footprint Reduction: By reusing water and decreasing the need for additional treatment and disposal processes, the system significantly reduces the customer’s carbon footprint.
Mark Roberts, Maintenance Supervisor at Autoneum said “We have been clients of Aqualytixs for several years, and while this project faced its challenges, we are very satisfied with the results. We look forward to the savings and efficiencies the system will bring us. I would like to extend our gratitude to Aqualytixs, especially to Darren, for his support throughout the process.”
Future Potential
Autoneum’s achievements with this system present opportunities for other clients facing similar challenges. As the system undergoes further refinement, it can be implemented across additional sites, enhancing efficiency and sustainability throughout the industry.
Autoneum’s tailored water treatment system serves as a compelling example of how customised solutions can yield significant savings and enhance sustainability. As we continue to optimise the system, the benefits will only expand, underscoring the critical role of innovation in industrial processes.
To find out more about how Aqualytix can support you in sustainable solutions, head over to Aqualytix – Severn Trent Services
