This is an illustrative scenario showing how Reynolds & Bauhm equipment can be configured for this application. Every site has unique requirements — contact us for a solution tailored to your specific wastewater characteristics.
Electroplating job shop generating 50 m3/day of mixed rinse water containing nickel 85 mg/L, chromium 45 mg/L, zinc 120 mg/L, copper 30 mg/L, and cyanide 15 mg/L from various plating lines. Must meet sewer discharge limits of total metals <2 mg/L, cyanide <0.2 mg/L, pH 6-9.
Step-by-step process configuration from raw wastewater to compliant discharge.
Acidic nickel/zinc rinse, alkaline chromium rinse, and cyanide-bearing streams collected in separate batch tanks. Segregation prevents unwanted chemical reactions and enables targeted treatment for each metals group.
Alkaline chlorination at pH 10.5 oxidises cyanide to cyanate then to nitrogen gas and carbonate. Sodium hypochlorite dosed via ORP-controlled system. Cyanide reduced from 15 to <0.1 mg/L in 45-minute reaction.
Chromium reduced from Cr6+ to Cr3+ with sodium metabisulfite. All streams combined and pH adjusted to 8.5 with caustic soda. Heavy metals precipitate as hydroxides. Ferric chloride (50 mg/L) enhances coagulation.
Lamella clarifier with 2-hour retention captures metal hydroxide precipitates. Effluent metals <1 mg/L. Underflow sludge at 3% solids thickened to 8% before dewatering. Overflow pH adjusted to 7.0 with CO2.
Plate filter press dewatering metal hydroxide sludge to 35% solids. Contaminated filter cake classified as hazardous waste disposed via licensed contractor. Filter press cycle time 4 hours including automatic cloth wash.
The specific equipment selected for this application, sized for the flow rate and contaminant load.
Multi-stage pH control for precipitation at pH 8.5, acid for Cr6+ reduction, CO2 for final adjustment.
View EquipmentNaOCl, NaHSO3, NaOH, FeCl3 dosing with day tanks, containment, leak detection.
View EquipmentSS construction, 30 m2 settling area, metal hydroxide separation, sludge hopper.
View Equipment630x630mm plates, 30 chamber, automatic hydraulic closure, cloth wash, 35% cake solids.
View EquipmentRepresentative performance data based on typical operating conditions for this equipment configuration.
Explore the full range of equipment used in this and similar applications.
Discover how these treatment processes connect to form complete wastewater treatment solutions.
Reynolds & Bauhm follows a structured engineering methodology for every project. We begin with detailed wastewater characterisation, process selection based on contaminant profiles, pilot testing where required, and full-scale design with performance guarantees. Our multidisciplinary team of chemical, mechanical, and electrical engineers ensures seamless integration of process, mechanical, and control disciplines.
Comprehensive influent analysis including COD, BOD, TSS, heavy metals, pH, temperature, and flow profiling.
Process flow development with P&IDs, mass balances, and hydraulic modelling validated by CFD where appropriate.
On-site pilot trials validate performance guarantees under actual operating conditions before capital commitment.
FAT, SAT, performance trials, operator training, and handover documentation ensuring operational readiness.
| Pre-Treatment | Screening, grit removal, and flow equalisation |
| Primary Treatment | DAF or lamella clarification for solids and oil removal |
| Secondary Treatment | Biological oxidation (activated sludge, MBBR, or SBR) |
| Tertiary Treatment | Filtration, UV disinfection, or chemical polishing |
| Sludge Management | Thickening and dewatering via belt press or centrifuge |
| Control System | PLC with HMI touchscreen and optional SCADA integration |
| Chemical Dosing | Automated coagulant, flocculant, and pH correction |
| Materials | SS316L, duplex, or rubber-lined carbon steel |
85 – 98% chemical oxygen demand reduction depending on process configuration and influent variability.
90 – 99% suspended solids reduction through combined physical and biological treatment stages.
Tertiary treatment enables up to 80% water recycling for non-potable process applications.
Our engineers will adapt this equipment configuration to your specific wastewater analysis, flow rate, and discharge requirements.
Our expertise spans multiple industries with sector-specific water treatment solutions.