The Water-Autonomous Factory

Minimising Industrial Effluent flows and the use of mains water in Industry

By Alice Holleworth

What is a water-autonomous factory?

Current use of water within industry

Methods of obtaining water

Methods of recycling and reusing waste water

Conclusion

Contents

A water Autonomous factory is an industrial establishment running off a completely self sufficient water supply.

The Water-Autonomous Factory

Water is becoming expensive

Industry use can be limited

Industry use can strain supplies

Large energy costs associated with treatment and

distribution

Can therefore result in cost, water and energy savings!

Benefits of Water Autonomy

Industry Water Use

23% of global freshwater usage

Increased extraction and therefore wastewater output

Harmful industrial by-products

- Chemicals

- Grease

- Floating solids

Raised temperatures

Problems

Water is a necessity during manufactureUsed for

- Processing - Washing - Diluting - Cooling - Transportation

Industry dependant – commodities such as food, paper, chemicals require largest quantities

Uses of Water in Industry

70%

23%

7%

Agri-cultureIndustryDomestic

Freshwater Use

Industrial water use is a vastly broad topic, this presentation will focus on the farm and food industry

People in industrialised countries drink between 2-5 litres per dayThey “eat” about 3000 litres

It takes800 to 4000 litres to grow a kg

of wheat2,000 to 16,000 litres of water to

“grow” a kilogram of beef2,000 to 8,700 litres of water to

grow a kilogram of cotton

Farm and Food Industry

Methods of Obtaining water off the grid - Rainwater harvesting

Methods of minimising effluent flows through treatment and recycling

- Waste stabilisation ponds - Leach field - Horizontal flow reed bed

Achieving a Water-Autonomous Factory

Rainwater Harvesting

Enclosed catchment area

Rainwater StorageSand filter

Main tank

PumpOverflow

Factory

Factory tank

A dairy farm requires 120 litres of water per cow per dayMains water costs £31 - £100 per cow per yearAnnual cost of £9300 - £30,000 for cows aloneRWH requires 24 square metres of roof per cow.Typical costs of a system for a farm with a herd of 300 cows costs range from £5000 - £10,00040% capital costs secured through grantTax incentives

Rainwater Harvesting

Waste levels increasingCan be toxic or contain

poorly degradable compounds Waste is industry dependant Can be Biological, physical

or chemical

Focussing on treatment of Farm and food industry waste and this is biological

Minimising Effluent Flows

PreliminaryPhysical removal using a filter

PrimaryRemoval of suspended solids

SecondaryMicroorganisms break down organic matter

TertiaryPrepares effluent for re-use

Four Treatment Stages

Sustainable Treatment Methods

Waste Stabilisation Ponds

Leach Fields

Horizontal Flow Reed Beds

Waste Stabilisation Ponds

Primary treatment in anaerobic pond – Suspended solids removalSecondary treatment in a facultative pond – Treatment of organic matterTertiary treatment in a maturation pond – Removes pathogens and nitrogen

Low cost, low-maintenance, highly efficient, entirely natural and highly sustainable

The maturation pond has an added benefit as it can also be used to rear fish

Leach Field

Septic tank provides primary treatment

Effluent fed into underground perforated pipes laid in

gravel filled trenches

Average trench

1m deep, 0.8m wide

Geotextile fabric

– prevents plugging the pipe

Sand/topsoil fills trench to ground level

Tertiary treatment stageConstant water level maintained, less oxygen, therefore ideal for removing nitrogen

Horizontal Flow Reed Bed

Summary

Advantages of such methodsLow set up costsLow operation costs due to no energy requirementsLife span of 20+ years

Disadvantages Require large land area, costs dependant on price of landPre-treatment may be requiredMay negatively affect soil and groundwater properties

Huge benefits to water-autonomy

Reduces strainReduces harmful effluentProtects environmentCuts costsSaves energy

Conclusion

Any Questions

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Ben Aim, R. (2007). Reuse and Recycling of Water in Industry. Retrieved February 7, 2011, from Asia Institute of Technology: http://www.albuw.ait.ac.th/Login/images/RRIW.pdf

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Freerain Ltd. (1999). Freerain: Introductory Guide to Rainwater Harvesting Systems & Their Installation. Retrieved February 7, 2011, from Freerain Web Site: http://www.freerain.co.uk/content/introduction%20guide%20to%20rainwater%20harvesting.pdf

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References