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Cover story: making waves in water treatment
Industryfocus
Cover story: making waves in water treatment Countries worldwide are continuing to drive the demand for better-quality drinking water, and many advancing industrial processes require ever purer water; at the same time there is also the question of how best alternative sources of water can be used - for example in processes such as power generation. These conundrums have not been lost on the likes of Siemens, GE, Pentair, and others, who continue to make major investments in water and wastewater treatment technology; GE’s latest acquisition intent for example, could see the company increase its share of the water treatment space with the purchase of Ionics. (See news, page 4.) With this in mind, December’s issue of Filtration + Separation brings together a series of features that focus on some of the different aspects of water treatment, as well as looking at some trends and current thinking. The features also demonstrate how innovation can lead to new processes and ideas that drive water treatment forward. Continuing improvements to the tools and processes available to companies that use water, should ultimately make things better for industry, the consumer and the environment. Below - new Filtration + Separation editor David Hopwood investigates current water treatment issues, both in the industrial and potable water sectors. Pages 18-20: Regular Filtration + Separation contributor Anthony Bennett looks at alternative sources of water and describes how hybridisation can be applied to power generation and water purification systems to increase both water and energy efficiency. Pages 22-24: Companies outsourcing their water treatment needs is nothing new, but the UK’s Spalding power station is fairly unique in that its water treatment needs were outsourced right from the commissioning stage; Ionics’ company Ecolochem effectively worked with the Power Station as part of the planning and implementing stage. Neil Ainger takes a look at the resulting treatment process, and sees how things work in practice. Pages 25-27: And finally, we look at an innovative tertiary sand filter, which is the brainchild of Dutch company Paques.
A global phenomenon in wastewater n recent times the Aquatech trade event for water technology and management has become a barometer for the increasingly international outlook that the water industry displays. This year’s event in Amsterdam, for example, saw 55% of the 800 exhibitors present come from outside the Netherlands, representing a total of 47 countries. And the percentage of visitors from outside the country also rose, from 40% to 57%. Water treatment issues are indeed now being played out on the global stage. In Europe, for example, the EU is having a major influence on developments in the wastewater sector. Under the European Water Framework Directive, wastewater must be put through an extensive treatment process. And the majority of sewage treatment plants may ultimately need to be modified to break down substances such as hormones, medicines and detergents. This could involve industry making substantial capital outlays, but membrane manufacturers such as Zenon think these investments will ultimately prove worthwhile. “Industry still has severe problems with wastewater and I cannot see why so many governments accept that if there is a disturbance in the fabrication process, wastewater discharged must still be of poor water quality,” says Zenon b.v.’s marketing and sales manager Frans Durieux. “It’s just not necessary anymore, because for a similar cost, newer membrane bioreactor technology from suppliers in the industry has proved such a milestone in wastewater treatment that it solves a tremendous amount of problems. It is actually a failsafe because no matter what a company does inside its operation, the exit point can be clear.”
I
14 December 2004
Zenon was one of the first companies to develop an immersed capillary ultrafiltration membrane in the early 1990s, and since then has focused on the issue of particle filtration, eventually coming up with its well-known ZeeWeed technology; Durieux says that because particle filtration has become so important for so many different applications, Zenon and others have simply had to keep on innovating and investing in technologies that deliver cost-effective solutions, “because the problems are still out there.” So what changes have Zenon observed over the past few years? The footprint of solutions has changed substantially, Durieux continues: “we’ve grown from multi-systems to uniquely condensed systems, depending on the different markets using the technology. And the cost of energy consumption has gone down our products now only use about 20%-30% of the energy consumption of 10 years ago,” he adds. In fact, Durieux insists that membrane prices have gone down, because of “new construction technologies and module concepts, which make the implementation of ultrafiltration solutions cheaper and cheaper.” Another development has seen pressurised systems gradually being replaced by submerged (immersed) technologies as the technologies of choice. “It’s a case of companies making best use of the high-tech membrane tools out there,” he continues. “Sometimes, with a Membrane Bioreactor, water reuse is very easy and wastewater can be used directly for cooling tower water or for putting in a Reverse Osmosis (RO) system for getting high-pressure steam. These are technologies that allow companies to earn money back.” Despite this, he explains, many companies only want to invest money in their primary processes, which makes business sense because that’s ISSN 0015-1882/04 © 2005 Elsevier Ltd. All rights reserved
Industryfocus already delivered desalination projects, particularly for brackish where companies earn their money. The challenge is, therefore, for water, which contains a mix of fresh and sea water. “Desalination governments to ‘persuade’ companies that certain pollutionin the UK and in parts of Europe on a larger reducing methods must be implemented. “It scale is probably not something that’s going to makes sense for the environment, but it also “It’s a case of happen for some time, but in places like Spain, makes sense for the industry,” adds Durieux, where there are water shortage problems, you “because after five years they will still be companies making can already see a lot of applications of RO earning but will have forgotten the the best use of the technology for desalination,” he says. investments that went before.” In the UK, the southeast particularly, where In the long term, he says, projects are likely to high-tec membrane there are also water shortage issues, certain get much larger. “It is also much more cost tools out there” effective to go with Membrane Bioreactor - Frans Durieux, Zenon b.v projects are already underway - Thames Water’s Beckton project, for example. And (MBR) technology, which is an advanced other water companies such as Anglia and technology with superb water quality and a Southern Water have looked at the feasibility of such technologies. unique robustness, so I see the number of applications growing.” In some of the Mediterranean markets as well, the poor quality of This is also likely to be helped by the reducing costs of installing water has meant the construction of huge desalinisation plants. such technology, as well as the increased penalties for discharging This has thrown up opportunities for companies such as Cuno, poor quality wastewater. which is working with one of Spain’s largest irrigation companies. In fact Spain has just announced a US$4.6 billion plan to build 15 Trends in the potable water sector to 20 desalinisation plants along its southeastern coast to supply the growing tourism industry along that stretch of the Mediterranean. Desalination So, how feasible is it for companies looking to expand into some It’s not just industrial water usage that governments worldwide are form of desalination? “We get involved in RO technology to remove salt from brackish water,” says Lloyd, “so the technology tackling - the implementation of the European Water Framework exists, and membranes themselves are becoming more of a Directive is one of the drivers for preventing the contamination of commodity item so the cost of capital projects is coming down, drinking water sources in Europe. but clearly there are operating costs that have to be considered. But these sources remain at risk, and top priority is being given to High power costs, replacement membranes and a lot of prethe further development of water treatment technologies like treatment is required, as well as the expertise required to operate membrane filtration, UV and advanced oxidation. This is being and maintain RO plants being quite high.” prompted by the increasingly strict standards imposed in respect Severn Trent builds and design systems and needs certain of microbiological safety and the discussion concerning endocrine membranes from specific manufacturers. The company has substances in the environment. And ways of recycling water for various applications are also being recently been looking at low-fouling membranes, says Lloyd. “The life of the membranes can be influenced by fouling on the developed. Filtration + Separation spoke to Ian Lloyd, operations membrane and while you can clean the membrane either in situ or director of Severn Trent Services, based in the UK, which has outside, fouling can shorten its life - you’ve got to get the pre-treatment right, because there are certain elements and conditions of the water that affect the membrane life and performance.”
Point-of-Use filtration applications
Taking a step up: It isn’t just GE that is marching onwards in the water space, the potential acquisition of Ionics being its latest target; Pentair has also invested heavily in water, its acquisition of Wicor Industries creating a US$2 billion water giant. Filtration+Separation
The residential point-of-use sector is another area that has seen an increase in the number of filtration companies trying to break into. An important thrust of Cuno’s strategy, for example, is its residential line of products; these include point-of-use or point-of-entry filtration systems for the home, as well as drinking water systems, including undersink, counter top, and various other RO systems for drinking water. In addition, the company manufactures whole-house filter systems that are placed at the point of entry to treat water for the whole home, for drinking water but also water softening that helps protect household appliances such as boilers. Cuno’s European marketing manager Paul Lanham
December 2004 15
Industryfocus remains challenging, cautions Lanham. “Media and health issues explained that there has been a definite move towards finished are driving consumers’ appetite for purer water but in places like product appliances, especially in the white goods arena. One such the UK and Germany, for example, consumers feel that their water example is the point-of-use water cooler, already very big business is of the finest quality and because of that it’s difficult for in the commercial sector. “You’re starting to see these in the home, companies like us to break into,” he says. with a very good filtration system on them making it a complete Another issue regarding Southern Europe is the cultural habit of package - almost like a white good,” he says. drinking bottled water - breaking into that And as more and more companies cotton on to market for Cuno is also difficult. “Even though the idea that this could be a market ready for “the new EU they know that their mains water is not great exploiting, one of the well-known residential they’ve been drinking bottled water for years, filter makers - Brita - is starting to suffer, says represents a big so changing that perception is difficult. And of Lanham. “Brita is very well established with its opportunity for us, course, price is very important in Southern system, but what we’re starting to see now is a as water is poor Europe; as Cuno is a high-end producer we lot more technically-based products coming find it difficult to compete. But in established into the market which are effectively hidden compared with the markets (such as Scandinavia) water filters undersink for example. As we understand, rest of Europe” remain very important.” Brita’s water filter business has suffered as a - Paul Lanham, Cuno Another marketplace that Cuno and others result. Some people are predicting that the are looking at are the new European countries. water cooler will be a major kitchen appliance, “The new EU represents a big opportunity for us as the water is and the other area we’re heavily involved in is refrigerator filters; poor compared with the rest of Europe,” says Lanham. these US-style side-by-side fridges are becoming more and more popular in Europe and they usually have integrated water dispensers Severn Trent Services has already had a certain amount of success in Poland, says and ice machines, which all need filtering.” Ian Lloyd. “The Polish authorities are upgrading their water Companies such as Cuno, Zenon and GE are also becoming more treatment infrastructure because of compliance issues, and as with savvy in distributing these products into the homes. “In Europe we any developing economy, people’s expectations on quality and use various channels, distributors, agents, door-to-door selling, service go up, so the business we’ve had has been in water and we work with companies who sell products over the internet,” treatment, such as disinfection and refurbishment, and not so says Lanham. “And Cuno Inc in the US has very established sales much wastewater. Also, there are certain areas within Eastern channels too, such as plumbing wholesale dealers, water quality Europe that have problems with Arsenic in the water, and we’ve dealers, and even swimming pool merchants - there are just so received interest in our arsenic removal technology. That’s a key many different routes to market for us.” thrust of our activities.” However, trying to sell such systems in certain areas of Europe
The industry today is characterised by new membrane technology. One example is US company Trisep’s Spirasep membrane, which scooped an International Aquatech Innovation Award at the European show earlier this year. The Spirasep is a spiral wound ultrafiltration membrane module, which uses backflushing and aeration scrubbing of the membrane to prevent fouling. The plaudits came as a result of the Spirasep being a “classic example of product innovation owing to the specific properties of the membrane. As it is a product that can be used internationally, this membrane module has the potential to capture an important place in water and wastewater treatment systems,” the award’s judges explained. 16 December 2004
www.filtsep.com
Cover story: making waves in water treatment Countries worldwide are continuing to drive the demand for better-quality drinking water, and many advancing industrial processes require ever purer water; at the same time there is also the question of how best alternative sources of water can be used - for example in processes such as power generation. These conundrums have not been lost on the likes of Siemens, GE, Pentair, and others, who continue to make major investments in water and wastewater treatment technology; GE’s latest acquisition intent for example, could see the company increase its share of the water treatment space with the purchase of Ionics. (See news, page 4.) With this in mind, December’s issue of Filtration + Separation brings together a series of features that focus on some of the different aspects of water treatment, as well as looking at some trends and current thinking. The features also demonstrate how innovation can lead to new processes and ideas that drive water treatment forward. Continuing improvements to the tools and processes available to companies that use water, should ultimately make things better for industry, the consumer and the environment. Below - new Filtration + Separation editor David Hopwood investigates current water treatment issues, both in the industrial and potable water sectors. Pages 18-20: Regular Filtration + Separation contributor Anthony Bennett looks at alternative sources of water and describes how hybridisation can be applied to power generation and water purification systems to increase both water and energy efficiency. Pages 22-24: Companies outsourcing their water treatment needs is nothing new, but the UK’s Spalding power station is fairly unique in that its water treatment needs were outsourced right from the commissioning stage; Ionics’ company Ecolochem effectively worked with the Power Station as part of the planning and implementing stage. Neil Ainger takes a look at the resulting treatment process, and sees how things work in practice. Pages 25-27: And finally, we look at an innovative tertiary sand filter, which is the brainchild of Dutch company Paques.
A global phenomenon in wastewater n recent times the Aquatech trade event for water technology and management has become a barometer for the increasingly international outlook that the water industry displays. This year’s event in Amsterdam, for example, saw 55% of the 800 exhibitors present come from outside the Netherlands, representing a total of 47 countries. And the percentage of visitors from outside the country also rose, from 40% to 57%. Water treatment issues are indeed now being played out on the global stage. In Europe, for example, the EU is having a major influence on developments in the wastewater sector. Under the European Water Framework Directive, wastewater must be put through an extensive treatment process. And the majority of sewage treatment plants may ultimately need to be modified to break down substances such as hormones, medicines and detergents. This could involve industry making substantial capital outlays, but membrane manufacturers such as Zenon think these investments will ultimately prove worthwhile. “Industry still has severe problems with wastewater and I cannot see why so many governments accept that if there is a disturbance in the fabrication process, wastewater discharged must still be of poor water quality,” says Zenon b.v.’s marketing and sales manager Frans Durieux. “It’s just not necessary anymore, because for a similar cost, newer membrane bioreactor technology from suppliers in the industry has proved such a milestone in wastewater treatment that it solves a tremendous amount of problems. It is actually a failsafe because no matter what a company does inside its operation, the exit point can be clear.”
I
14 December 2004
Zenon was one of the first companies to develop an immersed capillary ultrafiltration membrane in the early 1990s, and since then has focused on the issue of particle filtration, eventually coming up with its well-known ZeeWeed technology; Durieux says that because particle filtration has become so important for so many different applications, Zenon and others have simply had to keep on innovating and investing in technologies that deliver cost-effective solutions, “because the problems are still out there.” So what changes have Zenon observed over the past few years? The footprint of solutions has changed substantially, Durieux continues: “we’ve grown from multi-systems to uniquely condensed systems, depending on the different markets using the technology. And the cost of energy consumption has gone down our products now only use about 20%-30% of the energy consumption of 10 years ago,” he adds. In fact, Durieux insists that membrane prices have gone down, because of “new construction technologies and module concepts, which make the implementation of ultrafiltration solutions cheaper and cheaper.” Another development has seen pressurised systems gradually being replaced by submerged (immersed) technologies as the technologies of choice. “It’s a case of companies making best use of the high-tech membrane tools out there,” he continues. “Sometimes, with a Membrane Bioreactor, water reuse is very easy and wastewater can be used directly for cooling tower water or for putting in a Reverse Osmosis (RO) system for getting high-pressure steam. These are technologies that allow companies to earn money back.” Despite this, he explains, many companies only want to invest money in their primary processes, which makes business sense because that’s ISSN 0015-1882/04 © 2005 Elsevier Ltd. All rights reserved
Industryfocus already delivered desalination projects, particularly for brackish where companies earn their money. The challenge is, therefore, for water, which contains a mix of fresh and sea water. “Desalination governments to ‘persuade’ companies that certain pollutionin the UK and in parts of Europe on a larger reducing methods must be implemented. “It scale is probably not something that’s going to makes sense for the environment, but it also “It’s a case of happen for some time, but in places like Spain, makes sense for the industry,” adds Durieux, where there are water shortage problems, you “because after five years they will still be companies making can already see a lot of applications of RO earning but will have forgotten the the best use of the technology for desalination,” he says. investments that went before.” In the UK, the southeast particularly, where In the long term, he says, projects are likely to high-tec membrane there are also water shortage issues, certain get much larger. “It is also much more cost tools out there” effective to go with Membrane Bioreactor - Frans Durieux, Zenon b.v projects are already underway - Thames Water’s Beckton project, for example. And (MBR) technology, which is an advanced other water companies such as Anglia and technology with superb water quality and a Southern Water have looked at the feasibility of such technologies. unique robustness, so I see the number of applications growing.” In some of the Mediterranean markets as well, the poor quality of This is also likely to be helped by the reducing costs of installing water has meant the construction of huge desalinisation plants. such technology, as well as the increased penalties for discharging This has thrown up opportunities for companies such as Cuno, poor quality wastewater. which is working with one of Spain’s largest irrigation companies. In fact Spain has just announced a US$4.6 billion plan to build 15 Trends in the potable water sector to 20 desalinisation plants along its southeastern coast to supply the growing tourism industry along that stretch of the Mediterranean. Desalination So, how feasible is it for companies looking to expand into some It’s not just industrial water usage that governments worldwide are form of desalination? “We get involved in RO technology to remove salt from brackish water,” says Lloyd, “so the technology tackling - the implementation of the European Water Framework exists, and membranes themselves are becoming more of a Directive is one of the drivers for preventing the contamination of commodity item so the cost of capital projects is coming down, drinking water sources in Europe. but clearly there are operating costs that have to be considered. But these sources remain at risk, and top priority is being given to High power costs, replacement membranes and a lot of prethe further development of water treatment technologies like treatment is required, as well as the expertise required to operate membrane filtration, UV and advanced oxidation. This is being and maintain RO plants being quite high.” prompted by the increasingly strict standards imposed in respect Severn Trent builds and design systems and needs certain of microbiological safety and the discussion concerning endocrine membranes from specific manufacturers. The company has substances in the environment. And ways of recycling water for various applications are also being recently been looking at low-fouling membranes, says Lloyd. “The life of the membranes can be influenced by fouling on the developed. Filtration + Separation spoke to Ian Lloyd, operations membrane and while you can clean the membrane either in situ or director of Severn Trent Services, based in the UK, which has outside, fouling can shorten its life - you’ve got to get the pre-treatment right, because there are certain elements and conditions of the water that affect the membrane life and performance.”
Point-of-Use filtration applications
Taking a step up: It isn’t just GE that is marching onwards in the water space, the potential acquisition of Ionics being its latest target; Pentair has also invested heavily in water, its acquisition of Wicor Industries creating a US$2 billion water giant. Filtration+Separation
The residential point-of-use sector is another area that has seen an increase in the number of filtration companies trying to break into. An important thrust of Cuno’s strategy, for example, is its residential line of products; these include point-of-use or point-of-entry filtration systems for the home, as well as drinking water systems, including undersink, counter top, and various other RO systems for drinking water. In addition, the company manufactures whole-house filter systems that are placed at the point of entry to treat water for the whole home, for drinking water but also water softening that helps protect household appliances such as boilers. Cuno’s European marketing manager Paul Lanham
December 2004 15
Industryfocus remains challenging, cautions Lanham. “Media and health issues explained that there has been a definite move towards finished are driving consumers’ appetite for purer water but in places like product appliances, especially in the white goods arena. One such the UK and Germany, for example, consumers feel that their water example is the point-of-use water cooler, already very big business is of the finest quality and because of that it’s difficult for in the commercial sector. “You’re starting to see these in the home, companies like us to break into,” he says. with a very good filtration system on them making it a complete Another issue regarding Southern Europe is the cultural habit of package - almost like a white good,” he says. drinking bottled water - breaking into that And as more and more companies cotton on to market for Cuno is also difficult. “Even though the idea that this could be a market ready for “the new EU they know that their mains water is not great exploiting, one of the well-known residential they’ve been drinking bottled water for years, filter makers - Brita - is starting to suffer, says represents a big so changing that perception is difficult. And of Lanham. “Brita is very well established with its opportunity for us, course, price is very important in Southern system, but what we’re starting to see now is a as water is poor Europe; as Cuno is a high-end producer we lot more technically-based products coming find it difficult to compete. But in established into the market which are effectively hidden compared with the markets (such as Scandinavia) water filters undersink for example. As we understand, rest of Europe” remain very important.” Brita’s water filter business has suffered as a - Paul Lanham, Cuno Another marketplace that Cuno and others result. Some people are predicting that the are looking at are the new European countries. water cooler will be a major kitchen appliance, “The new EU represents a big opportunity for us as the water is and the other area we’re heavily involved in is refrigerator filters; poor compared with the rest of Europe,” says Lanham. these US-style side-by-side fridges are becoming more and more popular in Europe and they usually have integrated water dispensers Severn Trent Services has already had a certain amount of success in Poland, says and ice machines, which all need filtering.” Ian Lloyd. “The Polish authorities are upgrading their water Companies such as Cuno, Zenon and GE are also becoming more treatment infrastructure because of compliance issues, and as with savvy in distributing these products into the homes. “In Europe we any developing economy, people’s expectations on quality and use various channels, distributors, agents, door-to-door selling, service go up, so the business we’ve had has been in water and we work with companies who sell products over the internet,” treatment, such as disinfection and refurbishment, and not so says Lanham. “And Cuno Inc in the US has very established sales much wastewater. Also, there are certain areas within Eastern channels too, such as plumbing wholesale dealers, water quality Europe that have problems with Arsenic in the water, and we’ve dealers, and even swimming pool merchants - there are just so received interest in our arsenic removal technology. That’s a key many different routes to market for us.” thrust of our activities.” However, trying to sell such systems in certain areas of Europe
The industry today is characterised by new membrane technology. One example is US company Trisep’s Spirasep membrane, which scooped an International Aquatech Innovation Award at the European show earlier this year. The Spirasep is a spiral wound ultrafiltration membrane module, which uses backflushing and aeration scrubbing of the membrane to prevent fouling. The plaudits came as a result of the Spirasep being a “classic example of product innovation owing to the specific properties of the membrane. As it is a product that can be used internationally, this membrane module has the potential to capture an important place in water and wastewater treatment systems,” the award’s judges explained. 16 December 2004
www.filtsep.com