new water treatment plant for AECI MINING EXPLOSIVES
A R30 million state-of-the-art water treatment plant at AECI Mining Explosives’ nitrates manufacturing facility in Modderfontein, Johannesburg is saving the city 400 million litres of potable water a year, which is enough for 4 624 people annually!
This is only the beginning according to Dean Mulqueeny, Group Executive: AECI Water who is on a mission to move industry off the potable water grid as far as possible. The aim is to replace one billion litres over the next five years! “To get the ball rolling, we are working with other AECI Group businesses on water recycling projects, specifically in Chloorkop, Sasolburg and Umbogintwini where we have large-scale manufacturing operations. Test work is currently being done to enable front-end engineering design,” said Dean.
As far as the AECI Mining Explosives project is concerned, there were three water sources available:
Process sewage effluent (PSE) water
Effluent water from site run-off
Cooling tower blowdown from the No. 9 and No. 11 Nitric Acid plants’ cooling towers
Since each source has different chemistry, different technologies were applied to ensure they were all treated properly and sustainably. A unique approach was designed and developed including three technology “blocks”, namely:
Dissolved Air Flotation (DAF)
DAF reduces precipitated phosphates and suspended solids.
Ultrafiltration (UF)
UF removes proteins, suspended solids and turbidity as well as most bacteria and some viruses. At AECI Mining Explosives, the three UF “trains” installed were aquasource, membrane and submerged systems.
Reverse Osmosis (RO)
RO removes dissolved ions and lowers the dissolved salt concentration. The treated water is then stored in a tank before being distributed to the cooling towers and demineralisation plant.
Among the benefits for AECI Mining Explosives are:
• Cost savings of approximately R11/m3
• Less potable water usage, alleviating pressure on the water network and enabling “business with purpose”
• Less waste water discharged from site, leading to additional savings in operating expenses
This success story shows AECI’s collective commitment to shaping “a better world” in line with the global sustainability agenda. May there be many more in the future.