Cost and environmental benefits

The installation, at BAE Systems’ premises in Samlesbury, near Blackburn, is focused on the organisation’s Central Treatment Facility (CTF) which is key to the production of a range of high precision components for sophisticated military aircraft. 

"BAE Systems identified a number of objectives which centred on the upgrade of the chromate reduction plant, the production of de-ionised water in-house, dye recovery and significant reduction in water consumption,” says Mike Fisher, environmental manager at George Koch.  "The multi-faceted project addressed the recycling of wastes from rinsing operations in order to markedly reduce the volume and cost of ‘bought-in’ water, and to lower the volume of effluent discharge – both elements clearly linked to cost saving potential.”  

He explains that the George Koch solution features facilities that delivered chromium reduction within rinse waters, pH correction and chemically-assisted metal precipitation which ensure that the effluent is of such high quality that further polishing enables re-use for additional production. Alongside this, minimal solid waste production creates further savings in terms of disposal whilst also promoting environmentally approved practices. Additionally, advanced filtration technology ensures the minimisation of waste generated from an additional waste stream – coupled with water reuse – to further reduce costs.

"Key elements of the installation have included an advanced system of specialised filtration units.  Designed to remove solids or organic material prior to dual ion exchange columns, these produce highly purified water, suitable for critical rinsing applications,” continues Mike Fisher.  

"A multi-staged reagent dosing system also removes chromium compounds while correcting the pH of the effluent and precipitating solids thus removing metals for disposal prior to the clarified water being returned to stage one. Advanced ultra-filtration then recovers organics and produces further high quality rinse for re-use,” he adds.  

"The overall result is that the combined system reduces water consumption and wastewater disposal – and their considerable associated costs – while promoting an environmentally sustainable future for the CTF,” comments Tom Mercer, general manager at George Koch’s UK offices.  

The entire George Koch installation – which has included civils works and the provision of services – was completed without interruption to normal operations at the BAE Systems’ site. "This was particularly important to the customer and was successfully delivered despite notable space restrictions at the location arising from the need to build around existing plant facilities,” adds Tom Mercer.  The project is now seeing dramatic water savings and an enhancement of BAE Systems’ commitment to meeting compliance obligations relating to emissions to drain.

"The new CTF water recirculation and effluent treatment plant has achieved, and in some aspects exceeded, its original operational requirements,” adds Neil Lord, facilities manager at BAE Systems Military Air and Information. "We have seen a significant reduction in water usage and a subsequent reduction in cost of chemicals used in the treatment of both incoming and effluent waste.”