Case Study: Ford Motors Company – Dagenham, Essex

Supply of polishing filtration system for Ford wastewater treatment plant

Project ID:

Company: Ford Motors
Location: UK
Year: 2001
Description: Supply of polishing filtration system to Ford’s wastewater treatment plant
Goal:
  • Reduce COD, residual oil and particulate matter
  • Recycling the polished effluent back to the plant as washwater
  • Save water and energy costs
Capacity: 500 m3/day
Water Source: Ford industrial effluent

The Problems:

  • Existing quartz-sand media filtration system clogged frequently.
  • The effluent contaminated the nearby water sources.
  • Values of COD, residual oil and particulate matter were above permitted limits for dumping into water source.

Challenges:

  • Recycling the polished effluent back to the plant as washwater.
  • Save water and energy costs.
Parameter Existing Values Required Value
Turbidity (NTU) 50 < 5
COD (PPM) 750 < 50
TSS (PPM) 150 < 5
Residual Oil (PPM) 15 < 1
Energy Cost   Minimize
Water Cost   Minimize

Technical Solution:

The following processes were carried out:

  • Trials were carried out in a site pilot plant comparing AFM® to quartz sand.
  • Full scale filtration system was revamped accordingly with the following processes:

AFM® - Catalytic Media filtration with coagulation.

Final disinfection using Sodium Hypo-Chlorine.

Results:

Parameter Required Value Before treatment After treatment
Turbidity (NTU) 5 50 1
COD (PPM) 50 750 30
TSS (PPM) 5 150 5
Residual Oil (PPM) 1 15 1
Water saving (%) Minimize 0 74%
Electricity saving (%) Minimize 0 21%
  • Following AFM® performance with the effluent polishing plant, quartz sand was replaced with AFM® at the process water inlet filtration system.
  • Three rapid gravity filters, each requiring 20 tons of quartz sand, were replaced with 18 tons of AFM® each.
  • Following the successful implementation of Dryden Aqua’s AFM® in its Essex plant, Ford Motors had decided to implement the same solution in its Paint Shop in Valencia, Spain.

Dryden Aqua’s Deliverables: