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.
Automotive component surface treatment line generating 80 m3/day of mixed rinse water containing phosphates 180 mg/L, nickel 35 mg/L, oil 250 mg/L, fluorides 45 mg/L, and TSS 800 mg/L. Must meet sewer discharge of phosphate <2 mg/L, nickel <0.5 mg/L, fluoride <10 mg/L, oil <5 mg/L.
Step-by-step process configuration from raw wastewater to compliant discharge.
CPI oil separator removes free oil and floating solids. 1-hour retention. Oil skimmer recovers cutting oil for recycling. Effluent oil reduced to 35 mg/L. CPI sludge removed via bottom scraper.
Calcium chloride (300 mg/L) precipitates phosphate as hydroxyapatite at pH 9.5. Ferric chloride (80 mg/L) coagulates TSS and adsorbs fluoride. Anionic polymer aids flocculation. Rapid mix 2 minutes, flocculation 15 minutes.
Lamella clarifier captures phosphate precipitate, metal hydroxides, and coagulated solids. Effluent phosphate <1.5 mg/L, nickel <0.3 mg/L, fluoride <8 mg/L. Sludge at 4% solids. Automatic desludging to thickener.
Bone char adsorption column reduces fluoride from 8 to <4 mg/L. EBCT 20 minutes. Regeneration with 1% NaOH every 48 hours. Spent regenerant neutralised and discharged. Provides reliable fluoride compliance margin.
Sand filter captures residual precipitates. Final pH adjusted to 7.0 with CO2 dosing. Effluent meets all sewer discharge parameters with safety margin. Online phosphate and fluoride analysers for continuous monitoring.
The specific equipment selected for this application, sized for the flow rate and contaminant load.
Oil separator 15 m3/h, 1h retention, oil skimmer, bottom scraper, SS construction.
View EquipmentCaCl2, FeCl3, polymer, caustic, CO2 dosing with day tanks and metering pumps.
View EquipmentSS clarifier 40 m2, phosphate precipitate separation, automatic desludging.
View EquipmentFluoride adsorption column, 1.2 m diameter, 20 min EBCT, NaOH regeneration.
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.