Selecting the Right Process Wastewater treatment plants for a Closed Circuit water

Industrial process water treatment systems come in various types and sizes, tailored to meet specific needs. Among these, a crucial category includes systems designed for filtering water circulating in closed-loop circuits. These installations are commonly found in manufacturing facilities where process water is used for cooling machinery, particularly cutting tools and other machining equipment. Industries such as stone processing, glass manufacturing, ceramics, and concrete production rely heavily on such systems. This is mainly due to the fact that there is a large consumption of production water, which generates significant process costs. In addition, this water must be of appropriate quality to maintain high production standards.

For instance, in stone processing plants, the water is typically laden with fine stone particles, while glass processing facilities see only finely ground glass as the primary contaminant. Despite differences in the industries, a common trait of these pollutants is their high concentration relative to the volume of water.

High Water Usage in Material Processing

Industries such as glass, stone, and ceramics consume large amounts of process water during cutting and grinding. Contaminants like glass or stone dust are introduced into the water by machining tools. Despite variations in machines or tools, the chemical composition of these pollutants typically remains consistent within each industry, regardless of location manufacturing. For instance, stone processing may show slight differences depending on the type of rock—granite, marble, or sandstone—but the overall nature of the contaminants is generally similar. The difference that appears is mainly due to the chemical composition of the pollutants.

Key Factors in Choosing a Water Treatment System

Selecting the right water treatment system requires consideration of several critical factors:

1. Water Flow Rate and System Capacity
   The system’s size depends on the total water flow rate, typically expressed in liters per minute (l/min) or cubic meters per hour (m³/h). This figure should account for the combined water discharge from all machines connected to the system, including water used for cleaning machines, products, or facility floors. Summing all these sources provides a comprehensive measure of the required treatment capacity. Therefore, the total inflow of dirty water into the purification system must be taken into account.
2. Post-Treatment Water Quality Requirements
   Water quality needs vary depending on its intended use. For coarse machining processes, lower-quality treated water may suffice. However, finishing operations and machines with internal cooling systems demand significantly cleaner water. An example of this would be the difference in water quality required for cutting stone compared to the requirements for polishing stone.
3. Nature and Volume of Contaminants
   Different processes generate varying amounts and types of pollutants. Glass processing typically introduces finer particles than stone processing. Even within the same industry, contamination levels can vary—for example, cutting large stone blocks produces coarser waste compared to polishing, which generates finer particles. Similarly, in the glass processing process, the particles that end up in the water have different sizes depending on the type of machine and the process.

Common Wastewater treatment plants

1. Vertical Clarifiers
   Vertical clarifiers, also known as sedimentation tanks, are among the most popular systems due to their simplicity and reliability. These systems effectively handle high volumes of mineral-laden wastewater (250–4000 l/min) without clogging, making them ideal for stone, glass, and ceramics industries. Their robust design minimizes mechanical component exposure to contaminants and supports continuous operation with minimal maintenance. However, their size, particularly height, might be a limitation for some facilities.

2. Pressure Filtration Devices for the Glass and Stone Processing Industries
   In the glass and stone processing sectors, pressure filtration devices play a crucial role in maintaining water quality and ensuring efficient operations within closed-loop systems. These systems include filter presses, Filcore filters, and gravel filters, each designed to meet specific filtration needs depending on the type and volume of wastewater produced.

   Filter Presses: Effective for High-Volume Water and Sludge Treatment
   Filter presses are widely used in industries that generate large amounts of sludge and heavily contaminated water. These devices dewater sludge collected in vertical clarifiers and simultaneously produce large quantities of clean water. For example:

   In stone processing, water treated by filter presses can achieve turbidity levels below 10 NTU, ensuring it is suitable for reuse in cutting or polishing processes.
   In glass processing, the water’s turbidity often drops even further, to below 5 NTU, making it clean enough for applications requiring higher quality standards.
   Filter presses are particularly effective for facilities dealing with substantial volumes of wastewater, offering a dual benefit of waste reduction and clean water recovery.

   Filcore Filters: Specialized for High-Quality Water in Glass Processing

   The glass industry, which often requires ultra-clean water, benefits significantly from the use of Filcore filters. These devices are designed to provide water clarity levels as low as 1 NTU, which is equivalent to drinking water transparency. Their compact size makes them an excellent choice for smaller operations or facilities with limited space. Filcore filters are especially effective in processes where maintaining consistent water quality is essential, such as in glass cutting and polishing.

   Both filter presses and Filcore filters address the unique challenges posed by wastewater in the stone and glass industries. Stone processing produces dense sludge that requires robust filtration, especially during block cutting or slab polishing.
   Glass processing generates finer particulates, making precision filters like Filcore essential for maintaining water clarity suitable for high-precision machinery.
   By incorporating advanced pressure filtration systems, industries not only meet environmental regulations but also achieve cost savings through water reuse and reduced sludge disposal. This makes pressure filtration an indispensable solution in achieving sustainable and efficient production in the glass and stone sectors.

3. Gravel Filters
   Gravel filters are primarily used for secondary filtration of pre-treated water. These systems are unsuitable for handling heavy sediment loads but are excellent for polishing water that has already undergone initial treatment.
4. Dehydrators for Sludge Removal
   Though not a standalone treatment system, sludge dehydrators significantly enhance water quality by continuously removing sludge from sedimentation tanks. These systems are especially beneficial in stone processing plants, maintaining sedimentation tank efficiency by preventing sludge buildup.

Tailored Water Treatment Solutions by Silkam

Silkam offers a wide range of closed-loop wastewater treatment plants systems tailored to specific industry needs. Whether your operation involves stone, glass, ceramics, or other materials, Silkam provides scalable solutions, including vertical clarifiers, filter presses, and specialized systems like Filcore. By assessing your facility’s machines and water usage, Silkam ensures precise system recommendations. Contact us today to optimize your water treatment process and enhance efficiency across your operations.

With a well-chosen production water treatment system, you will reduce the cost of doing business by significantly reducing water consumption. In addition, you will eliminate downtime associated with machine cleaning and repair. An additional advantage of a well-chosen treatment plant is that it extends tool life and improves the quality of machining.
The benefits to the environment are invaluable in the process.