The 2010 Global Water Awards: Industrial Water Project of the Year

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For the project commissioned in 2009 that represents the most impressive technical achievement in the field of industrial water.

Dow Freeport, USA

What is it?
The adoption of Nalco’s 3D TRASAR technology to optimise operations and save water at Dow Chemical’s sprawling 5,000- acre production site in Freeport, Texas.

Who is responsible?
Nalco provided the technology, which was adapted by a Dow/Nalco team to classify cooling tower systems based on a variety of control parameters.

What makes it special?
* Dow Chemical’s vast production site at Freeport, Texas, has a voracious appetite for water. By optimising water use in the site’s 80 process and comfort cooling tower systems, the company was able to achieve annual savings of 1 billion gallons of water (3.8 million m3) – enough to sustain the entire population of Freeport for three years.
* The implementation of Nalco’s gamechanging 3D TRASAR technology – which automatically maintains optimal chemistry of the water used in cooling systems, greatly reducing the quantity of water and energy needed to run them – has saved Dow $4 million in annual maintenance costs.
* More than 10,000 3D TRASAR cooling water automation units are installed around the world, enabling water savings of more than 75 BGD (284 million m3) every year. Large-scale applications like Freeport allow Nalco to refine its technology in real-world situations – a vital tool to improving the process for the future.

Mars Food Water Recycling Plant, Australia

What is it?
A water treatment and recycling plant serving Mars Food Australia’s manufacturing site in Berkeley Vale, NSW. The plant employs ultra-filtration and reverse osmosis technology to treat both wastewater and stormwater at the site, reducing the company’s reliance on mains water in a drought-afflicted region.

Who is responsible?
Veolia Water Solutions & Technologies designed and supplied the RO unit, with Siemens Memcor supplying the UF technology. Bekaert provided the RO membrane modules.

What makes it special?
* Water resources are at a premium in New South Wales, which has been particularly hard hit by Australia’s “Big Dry”. Following the commissioning of the tertiary treatment plant in February 2009, Mars Food Australia was able to halve its water consumption, drastically reducing its reliance on local groundwater resources.
* The new state-of-the-art facility not only recovers and treats wastewater streams from the food manufacturing process. Mars also expanded its spill management ponds to collect and store stormwater from all hard surfaces at the site, meaning that every drop of rainwater is captured, recycled and reused.
* The importance of the project is underscored by the fact that 17% of the capital cost was provided through a grant from the New South Wales government’s Central Coast Water Savings Fund. It is a clear demonstration of how constructive collaboration can result in a “win-win” situation for industry and the environment.

Philip Morris Wetlands Project, USA

What is it?
A 15-hectare free water surface wetland created to treat industrial wastewater from Philip Morris’s Park 500 tobacco processing facility near Richmond, Virginia.

Who is responsible?
CH2M Hill designed and implemented the wetland.

What makes it special?
* Tobacco wastewater contains naturally high nitrogen and phosphorus loads, which can result in algal blooms, adversely impacting aquatic life and polluting surface water sources. Park 500 is the only known application of a natural wetland system to treat tobacco wastewater.
* Treated effluent from the existing onsite wastewater treatment plant is routed through a newly created wetland, where natural processes result in measurable reductions in the effluent’s nutrient loads.
* The process involved gathering support from a wide variety of stakeholders, including government representatives, environmental NGOs, academic institutions and local property owners. CH2M Hill and Philip Morris have shown ingenuity and leadership in reducing the impact of industry on a natural water ecosystem – by creating one of their own.

PNZ Enhanced Oil Recovery Pilot, Middle East

What is it?
A fully integrated water treatment plant to enhance the recovery of heavy oil at the Wafra oil field between Saudi Arabia and Kuwait. The facility consists of de-oiling and de-gasification pretreatment facilities, as well as two seeded slurry brine concentrators that produce steam generator feedwater.

Who is responsible?
GE provided the brine concentrators, a three-stage oil/water separation system, a de-gasifier, a vapour recovery system and a heat integration system. Kharafi National was responsible for the construction.

What makes it special?
* The Partitioned Neutral Zone between Saudi Arabia and Kuwait is a harsh and remote operating environment. In order to enhance the recovery of heavy oil at the Wafra oil field, Kuwait Gulf Oil Company and Saudi Arabian Chevron needed access to large volumes of highpurity water suitable for steam generation. The facility supplied by GE and Kharafi recycles untreated oily sour produced water originating from a carbonate oil reservoir, producing up to 35,000 barrels per day of high-purity distillate for use as highpressure boiler feed water.
* The process uses just 5% of the energy normally required for single-effect steam evaporation.
* The project is the first successful largescale produced water evaporator treatment system used for steam generation in an enhanced oil recovery application in the Middle East.