Most manufacturing industries generate wastewater. The concerns are varied and numerous. To comply with local or federal government emissions, however, each industrial effluent has to be treated in order to be reused, stored on-site for eventual solids disposal, or disposed of in the local sewer system. The distinctive characteristics and requirements of each industry make their treatment specific to the application.

A treatment method that has been used successfully for decades is Electrocoagulation (EC). This method can dramatically reduce suspended solids without the use of chemicals. In doing so, it can economically increase the on-site potable water supply for process water, reuse, maintaining production and preserving the surrounding environment without discharge problems into municipal sewage systems.

EC’s advantages include:

  • Ease of operation with few moving parts
  • Treats a broad range of contaminants
  • Kills bacteria and pathogens.
  • Breaks emulsions
  • Remove suspended solids
  • Meets discharge requirements in a single treatment.

Traditional EC’s main downside, however, is its susceptibility for anode and cathode passivation and scale buildup which can cause operating efficiencies, premature shutdowns and higher electrical usage.

How Thincell® works to treat water in industry

Thincell’s Process – Stage 1-2

  • Suspended, stabilized and emulsified contaminants exist in fluid
  • Patented proprietary Anode and Cathode prevent electrode passivation
  • Suspended and stabilized contaminants are destabilized, and break into smaller particles.  Emulsified fluids are de-emulsified
  • Bi-polar “Sacrificial Electrodes” release metal ions to form in-situ coagulant

Thincell’s Process – Stage 3

  • Sacrificial electrodes completely dissolve and releases metal ions to form in-situ coagulant
  • Contaminant particles react with in-situ coagulant and form floc.
  • Hydrogen and oxygen bubbles formed at the proprietary cathode and anode carry floc to top of chamber for removal.

Thincell – “The Conductivity Bridge”

  • Patented non-passivating anodes and cathodes – 6” spacing
  • Bi-polar Sacrificial electrodes separated by water molecules form a “conductivity bridge”
  • Thincell treatment is efficient in low conductivity environment
  • Low conductivity treatment is not hindered by passivation.

Water Vision’s Thincell EC technology adds a new dimension to EC treatment. Thincell provides a cost effective on-site solution to contaminant removal.

Thincell Advantages

  • Low capital costs
  • Inexpensive to operate
  • Increased flow rates
  • Minimal maintenance downtime
  • Small equipment footprint
  • Eliminates passivation
  • Fewer & thinner plates reduce weight
  • Treatment of multiple contaminants
  • Low power requirements
  • Minimal operator engagement needed
  • Improved personnel safety
  • Eliminates trucking of water for disposal
  • Not limited by process volumes
  • Consistency of operation
  • No chemicals required
  • Modular design
  • Variety of automated packages available

how does
thincell technology work?

Thincell works in many industrial applications

Food

Food processing is varied and has a broad spectrum of challenges. The effluent is non-toxic and biodegradable but has a high concentration of biochemical oxygen demand and suspended solids. In dairy-based, fruit and vegetable, and other processing facilities Thincell by Water Vision provides a one-step solution to both reduce contaminants and disinfect wastewater. After solids are removed, it de-emulsifies fats, oils and greases, coagulating the total suspended solids for further removal downstream. The wastewater does not require the addition of chemicals so that it is then available for reuse in the facility and the flocculant/sludge might have commercial value as source materials for other food products. Multiple Water Vision studies have demonstrated the effectiveness of Thincell in contaminant removal.

Parameters Source of Water PPM Before Treatment PPM After Treatment % Removal
TSS (Total Suspended Solids) Dairy 520 12 98%
TSS (Total Suspended Solids) Dairy 3480 14 100%
BOD (Biological Oxygen Demand) Dairy 4250 2600 39%
BOD (Biological Oxygen Demand) Dairy 6840 >188 97%
FOG (Fat, Oil, and Greases) Dairy 1110 13.2 99%
VSS (Volatile Suspended Solids) Dairy 33,665 6 100%
BOD (Biological Oxygen Demand) Fruits and Vegetables 22500 2070 91%
TSS (Total Suspended Solids) Fruits and Vegetables 10900 <4 100%
BOD (Biological Oxygen Demand) Grease Trap 1000 248 75%
FOG (Fat, Oil, and Greases) Grease Trap 1300 2.5 100%
FOG (Fat, Oil, and Greases) Grease Trap 18000 86 100%
FOG (Fat, Oil, and Greases) Grease Trap 25000 134 99%
BOD (Biological Oxygen Demand) Chicken Processing 1,000 248 75.2%
FOG (Fat, Oil, and Greases) Chicken Processing 1,300 2.5 99.8%
BOD (Biological Oxygen Demand) Tanker Wash Out 96,000 150 99.8%
FOG (Fat, Oil, and Greases) Food Processing 25,000 4 100.0%
FOG (Fat, Oil, and Greases) Food Processing 18,000 86 99.5%
FOG (Fat, Oil, and Greases) Animal Processing 5,700 90 98.4%
FOG (Fat, Oil, and Greases) Rendering 4,200 54 98.7%

What else can Thincell Handle?

Dairy Waste

Reduction of contaminants in in dairy processing facilities is an excellent application for Thincell. The technology disinfects the waste water in a single step.

Thincell EC Treatment – Food Processing

Applications:

Reduction of contaminants from dairy based food processing facilities is an excellent application for the Thincell EC system. The Thincell process reduces contaminants and disinfects the waste water in one step.

The Thincell system de-emulsifies the fats oils and greases (FOG) and coagulates total suspended solids (TSS) for separation and removal in downstream processes.

The treated water can be discharged or reused as part of the facilities process.

The separated floc can be dewatered and disposed or recycled. Since Thincell does not require the addition of chemicals, the floc/sludge by-product may have commercial value as a source material for other food products.

Dairy Based Waste Water and Process Water

Milk , Ice Cream, Cheese, Yogurt Processing Plants

Parameters Untreated PPM Treated PPM % Removal
TSS (Total Suspended Solids) 520 12 98%
TSS (Total Suspended Solids) 3480 14 100%
BOD (Biological Oxygen Demand) 4250 2600 39%
BOD (Biological Oxygen Demand) 6840 >188 97%
FOG (Fat, Oil, and Greases) 1110 13.2 99%
VSS (Volatile Suspended Solids) 33,665 6 100%

Vegetable and Fruit Processing

In this food processing application, after fibrous and pulpy materials have been screened and simple sugars have been metabolized into complex hydrophobic compounds, Thincell oxidizes the volatile organics and disassociates the complex compounds which are then coagulated as total suspended solids (TSS) for separation and removal downstream. Separated floc watered and disposed or recycled. Treated water can be discharged or reused.

Applications:

Reduction of contaminants from vegetable and fruit based facilities is an excellent application for the Thincell EC system. The Thincell process reduces contaminants and disinfects the waste water in one step.

After the fibrous and pulpy materials have been screened out and simple sugars have been metabolized into complex hydrophobic compounds, the Thincell system oxidizes the volatile organics and dissociates the complex compounds which are coagulated as total suspended solids (TSS) for separation and removal in downstream processes. The separated floc can be dewatered and disposed or recycled.

The treated water can be discharged or reused as part of the facilities process.

Since Thincell does not require the addition of chemicals, the floc/sludge by-product may have commercial value as a source material for other food products.

Vegetable and Fruit Industry Based Waste Water and Process Water

Fruit, Vegetable, Juice, Sugar Cane, Brewery Waste Processing

Parameters Untreated PPM Treated PPM % Removal
BOD (Biological Oxygen Demand) 22500 2070 91%
TSS (Total Suspended Solids) 10900 <4 100%

Electrocoagulation application results from online content and literature review.

Grease Traps

Liquid oils and greases from rendering and food processing contaminant water scheduled for discharge. After solids are screened and floating materials are removed, Thincell de-emulsifies fats, oils and greases and oxidizes volatile organics. The in-situ coagulant flocculates Total Suspended Solids (TSS) for separation and removal downstream. Since there are no chemical additives, the floc/sludge by-product may have commercial value after processing.

Thincell EC Treatment – Food Processing

Applications:

Reduction of contaminants from liquid grease traps is an excellent application for the Thincell EC system. The Thincell process reduces contaminants and disinfects the waste water in one step.

After solids are screened and floating greases and oils are removed, the Thincell system can be utilized to treat the remaining contaminated water. Thincell de-emulsifies the fats oils and greases (FOG) and oxidizes volatile organics, resulting in lower BOD concentration. Thincell’s in-situ generated coagulant flocculates total suspended solids (TSS) for separation and removal in downstream processes.

The treated water can be discharged or reused as part of the facilities process.

The separated floc can be dewatered and disposed or recycled. Since Thincell does not require the addition of chemicals, the floc/sludge by-product may have commercial value as a source material for other food products.

Liquid Grease Trap Wastes

Parameters Untreated Treated % Removal
BOD (Biological Oxygen Demand) 1000 248 75%
FOG (Fat, Oil, and Greases) 1300 2.5 100%
FOG (Fat, Oil, and Greases) 18000 86 100%
FOG (Fat, Oil, and Greases) 25000 134 99%

Electrocoagulation application results from online content and literature review.

The Metals

Metals

Manufacturing and processing industries producing metal contaminants are varied. They can include metal plating, galvanizing, electronics components, photo processing, machine shops, and iron or steel conversion facilities. Rinse waters can contain oils, chemicals, product fines and acids used for surface preparation. Thincell EC treatment effectively removes heavy metal particulates and entrained hydrocarbons from produced water in the processes. Floc generated from the Thincell process can often be of commercial value for recycling into new products or sold. Wastewater can be reused for continued processing or effectively discharged into municipal systems without the need for further treatment. Manufacturers can reduce disposal costs, testing fees, and need for large volumes of fresh make-up water. EC is less expensive than chemical coagulation with easier metal oxide dewatering and less sludge volume. Water Vision plating industry results demonstrate the effectiveness of Thincell technology for industrial wastewater treatment.

Contaminant Removed Source of Water PPM Before Treatment PPM After Treatment % Removal
Chrome Plating 900 <.003 100.0%
Chrome Plating 210 0.0216 100.0%
Cadmium Plating 31 0.34 98.9%
Cyanide Plating 25.1 0.98 96.1%
Copper Plating 287 0.48 99.8%
Gold Plating 6 ND ND
Lead Plating 24 0.01 100.0%
Nickel Plating 25 0.0731 100.0%
Nickel Plating 43 0.3 99.3%
Tin Plating 50 0.08 99.8%
Zinc Plating 80 0.008 100.0%

Electrocoagulation application results from online content and literature review.

Metal Plating

Metal platers remove metal residue from the rinse water tank with Thincell EC so it can be reused for process water. Resale of segregated metal oxides as a result of Thincell treatment can also be a profit center for the facility.

Thincell Treatment – Metal Plating

Metal Plating Rinse Water – Treatment for Reuse

Metal platers use electrocoagulation to remove metals from the plating rinse water tank, enabling them to reuse the treated water as process water.

With no water discharge, they avoid potential environmental liability associated with downstream upsets or offsite disposal and save on:

  • Water disposal (sewer) cost
  • Testing and Monitoring fees
  • Cost of fresh make-up water
  • Segregated metal oxides (floc generated as part of the EC process ) can be sold or recycled as raw components for new products.

Contaminant Removed Source of Water PPM Before Treatment PPM After Treatment % Removal
Chrome Plating 900 <.003 100.0%
Chrome Plating 210 0.0216 100.0%
Cadnium Plating 31 0.34 98.9%
Cynanide Plating 25.1 0.98 96.1%
Copper Plating 287 0.48 99.8%
Gold Plating 6 ND ND
Lead Plating 24 0.01 100.0%
Nickel Plating 25 0.0731 100.0%
Nickel Plating 43 0.3 99.3%
Tin Plating 50 0.8 99.8%
Zinc Plating 80 0.008 100.0%

Electrocoagulation application results from online content and literature review.

As compared to chemical treatment, electrocoagulation is:

  • 88% less expensive than most chemical coagulation programs
  • Metal oxides dewater 76% easier and produce 83% less sludge volume

Machining Wash Water

Machining operations used in the production of metallic industrial components use water for cooling and oil for lubrication. Wash water is often contaminated with the combination of the two liquids, requiring processing before being allowed to be discharged into municipal sewage. Thincell treatment produces noticeable results that allow solids and floc to be segregated, dewatered, dried and disposed of in an environmentally suitable manner.

Thincell EC Treatment – Industrial

Oily Process Wash Water Machining & Manufacturing

Before Thincell treatment
Wash water was dark and contaminated with residual oil.

Waste Minimization

After Thincell treatment,
water phase discharged to municipality and solid/floc segregated, dewatered, dried, and disposed.

Textile Dyes

Pulp and Paper/Textiles

Pulp and paper manufacturing is a water-intense industry and a highly polluting process. The industry generates more than 500 different chlorinated organic compounds formed during the chemical reactions between wood fiber lignin and bleaching agents. Effluents contain high chemical oxygen demand (COD), suspended solids, toxicity and color additives. Dyes and inks, in the paper and textiles industries are handled effectively unlike conventional water treatment technologies.

Dyes and inks are designed to pass through filters and are inherently difficult to remove conventionally. Thincell effectively removes dyes and allows process waters to be reused.

 

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