Smelting Sustainability: NuWater’s Holistic Water Treatment for Optimal Efficiency
NuWater has been a trusted partner to the largest aluminum smelter in the Southern Hemisphere since 2016, demonstrating a long-term commitment to providing innovative and effective water treatment solutions. Located in Richards Bay, the facility faced significant challenges during a drought period, necessitating the urgent identification of an alternate and reliable water supply. In response, NuWater engineered and installed a 2 million liters per day (MLD) seawater desalination plant. Following a successful handover period, the client opted for self-operation, supported by NuWater’s ongoing assistance and expertise.
Recently, the aluminum smelter once again turned to NuWater, this time to undertake a comprehensive refurbishment of the existing water treatment system and to manage its operations for the next three years. Furthermore, a critical additional requirement was to explore and implement strategies to significantly increase the efficiencies of their vital water-cooling systems.
Ensuring Uninterrupted Operations in a Demanding Industry
Operating for approximately two decades, the aluminum smelter plays a crucial role in producing high-quality primary aluminum for both domestic and international export markets. The facility receives raw materials sourced globally through the Richards Bay Coal Terminal (RCB) harbor. These materials undergo extensive processing before being shipped to markets worldwide. The smelter also serves the local South African market, manufacturing aluminum in various forms to meet domestic demand. The reliability and efficiency of their operations are paramount to their continued success and contribution to the economy.
Returning to Expertise: NuWater for Refurbishment and Optimization
In 2020, recognizing the need to ensure the long-term performance and efficiency of their water treatment infrastructure, the aluminium smelter contacted NuWater to undertake a complete refurbishment of the existing plant. This led to NuWater securing a comprehensive 36-month operation and maintenance contract. The agreement encompassed not only the necessary refurbishment and updates but also the integration of newer and more efficient water treatment technologies to optimize performance.
During this period of collaboration, the smelter also sought NuWater’s expertise in identifying potential methods to enhance the efficiency of their crucial water-cooling systems. Their initial suggestion involved treating the cooling water directly. However, through in-depth research and analysis of the entire system, NuWater’s engineers determined that treating the feed water before it entered the cooling towers would yield the most effective and resource-efficient outcome.
To demonstrate the viability and benefits of this approach, NuWater proposed and installed a rental ultrafiltration and reverse osmosis unit on a trial basis as a proof of concept. The system has since been successfully installed and is currently awaiting its full operational start-up, poised to deliver significant improvements.
NuWater’s Tailored Solution for Enhanced Water Efficiency
Prior to NuWater’s intervention, the aluminium smelter relied solely on municipal water to replenish its cooling systems. However, driven by a strong commitment to their current sustainability initiatives, they sought a solution that would enable them to significantly improve their water usage, reduce their overall water consumption, and consequently lower their associated water expenses.
The system implemented by NuWater is a sophisticated containerized Ultra Filtration (UF) and Reverse Osmosis (RO) system with a production capacity of 850 cubic meters per day. NuWater’s primary objective was to provide the client with the highest quality water at the lowest possible chemical consumption rate, while also minimizing the need for extensive operator interaction.
The introduction of lower feed water salinity into the cooling system is projected to dramatically increase the number of cycles the water can effectively run through the system – by up to seven times. This significant improvement will translate into an estimated 68% decrease in wastewater discharge and a substantial ±20% reduction in the overall water supply requirement for the cooling towers.
A Holistic Approach to Water Management
NuWater’s approach went beyond simply addressing the initial request to treat the cooling water. Our team conducted a comprehensive and in-depth analysis of the entire water system at the aluminium smelter to identify the most effective and holistic solution. This comprehensive assessment allowed us to offer the best overall value at the lowest cost, while also eliminating the need for the smelter to incur additional consultation and design expenses associated with engaging a third-party consultant.
By taking a holistic perspective, NuWater provided a solution that not only addressed the immediate need for cooling water optimization but also contributed to the smelter’s broader sustainability goals and long-term operational efficiency.
Contact NuWater today to explore how our holistic approach can provide the optimal water treatment solutions for your specific industrial needs.
About NuWater Water Treatment
NuWater is a smart water treatment solutions company. We have evolved from a dynamic new start-up to becoming industry leaders who are at the forefront of intelligent water treatment solutions. We provide real solutions, solutions that are sustainable, mobile, adaptable, resourceful and efficient. Solutions that are changing lives, communities, businesses, ecosystems, and environments for the better.
NuWater is your business partner when it comes to water treatment and liquid waste management. Our appetite for innovation and our constant drive to search for new, cutting edge, novel technologies ensures that we can meet the needs of our customers. We are a technology-led engineering company that designs, builds, finances, operates and maintains water treatment plants. Plants that treat contaminated water for the provision of high-quality drinking and industrial process water from almost any water source.