Supply Chain - Renewables & Energy Management - Plant Optimisation
2
results
Related Content
Case Studies
(left) Cardiff WwTW and (right) Afan WwTW - Courtesy of Google Earth[/caption]
ADD process diagram - Courtesy of Dŵr Cymru Welsh Water[/caption]
The pipework from the biogas booster pump to the container includes connections for a gas analyser and an in-line gas meter, as well as a safety slam-shut valve. The gas analyser monitors the levels of methane, carbon dioxide, oxygen, and hydrogen sulphide in the biogas. The readings are used by the CHP control system to adjust the engine performance, or to trip on high levels. The in-line gas meter monitors the flow rate of biogas to each CHP engine and the gas slam-shut valve is used to isolate the container in the event of a gas leak or fire alarm.
New biogas booster set install at Cardiff WwTW – courtesy of Morgan Sindall[/caption]
Installation of foam probe and suppression nozzles at Cardiff WwTW - Courtesy of Morgan Sindall[/caption]
Installation of new Endress+Hauser prosonic gas flow meters at Cardiff - Courtesy of Morgan Sindall[/caption]
Mini CS & Company News
- Reverse Osmosis System at a Major Sewage Treatment Works
Reverse Osmosis System at a Major Se...The challenge
The steam boilers at the STW were facing an operational headache. High levels of Total Dissolved Solids (TDS) in their main water supply meant the boilers had to frequently release water. And not just any water — scalding hot, 185-degree water under 10 bar pressure. The process was energy-draining as each release required more fuel to bring the incoming water back up to temperature. Our team at PBJ Engineering, alongside our partners Lubron and Roger Huelin & Co Ltd, were entrusted with a critical mission: to introduce an effective water purification solution that could address this challenge.The solution
Enter the Reverse Osmosis (RO) plant, provided by Lubron. Integrating this plant drastically reduced the boiler's need to release water. By controlling the release, the boilers consume less energy, translating into noticeable savings. Beyond energy conservation, there were added benefits: the boiler's chemical treatment needs were curtailed due to reduced wastage, and a cleaner water feed minimised the risk of internal scaling.[caption id="attachment_9649" align="alignnone" width="1200"]
Courtesy of PBJ Engineering[/caption]
One of the stand-out features of our approach was the care taken to minimise operational disruptions. Our meticulous planning ensured that the RO plant's integration only led to a brief half-day interruption. What's more, our team introduced extra valves and bypass routes to the design, ensuring that should any unexpected issue arise, the system would smartly bypass the RO plant, guaranteeing zero downtime. During our installation, we unearthed inefficiencies in the site's existing water-softening plant. In order to take the opportunity during the planned downtime, we took the initiative to overhaul this unit, further enhancing the site's operational efficiency.Added value
Our initial assessment laid the groundwork for a cost-to-savings projection. According to our calculations and in collaboration with our partners, the system was on track to pay for itself in approximately two-and-a-half to three years. Almost two years post-installation, the RO plant has showcased its reliability with no reported failures, echoing our commitment to delivering lasting solutions. [caption id="attachment_9647" align="alignnone" width="1200"]
Courtesy of PBJ Engineering[/caption]
Paul Collins from Lubron echoed this stating;
“As a result and due to the success of this project, we are finding the business for boiler treatment increasing now due to sites wanting to eliminate some of the chemical treatment. Also the cost saving in water use and energy for blow downs significantly and quickly pays for an RO system”.
Such projects resonate with PBJ Engineering's ethos. Guided by Paul Johnson's expertise our team blends technical know-how with practical solutions, ensuring that clients reap the rewards of both immediate efficiency and long-term value.
For more information contact PBJ Engineering: +447758 120432 | http://www.pbjengineering.co.uk/
- Strongford STW
Strongford STWSevern Trent’s Strongford Sewage Treatment Works recently completed a major upgrade to improve wastewater processing for a population of around 350,000 people across Newcastle-under-Lyme and Stoke-on-Trent. A key part of the upgrade project was introducing Thermal Hydrolysis Process (THP) technology, a method that treats sludge (the solid byproduct of wastewater) so it is safer and more efficient to process. THP helps break down the sludge, making it easier to produce biogas — a renewable energy source — and improving the plant’s overall efficiency.
PBJ Engineering’s role
PBJ Engineering's team was on the ground at Strongford every day for around 18 months, running the steam boilers and training Severn Trent’s staff until they were ready to earn their Boiler Operations Accreditation Scheme (BOAS) certification. Our job didn’t stop there, though. During this period and beyond, we supplied boiler testing kits, managed stock resupplies, maintained detailed logbooks, and offered ongoing support, including coverage during management leave. We also provided and installed a hired reverse osmosis (RO) unit, currently still in operation on site. This unit improves boiler performance by reducing total dissolved solids (TDS), which lowers the frequency of boiler blowdowns and minimises operational issues. It was a proactive measure to help ensure smoother day-to-day operations while the client develops a permanent solution.Challenges and solutions
Keeping everything running smoothly meant being prepared for any unplanned downtime. The PBJ team provided round-the-clock support and quick-response services whenever needed. We supplied specialised testing equipment and designed a comprehensive logbook to track and simplify daily maintenance — making sure nothing slipped through the cracks. The reverse osmosis unit was also key to maintaining efficiency, preventing disruptions by improving boiler reliability and performance. This combination of technical expertise and ongoing support ensured that Strongford’s upgrades moved forward without a hitch. [caption id="attachment_18128" align="alignnone" width="1200"]
Boiler area - Courtesy of PBJ Engineering[/caption]
Value & impact
With our support, Strongford’s upgrades ran safely and efficiently, helping Severn Trent meet their environmental goals. By reducing downtime and boosting reliability, we contributed to a more sustainable treatment system that benefits the entire community. In the bigger picture, the THP technology has transformed Strongford into a central sludge treatment hub, now capable of handling up to 94 tons of sludge per day and supporting nearby sites by taking on additional processing. The upgrades also boost Severn Trent’s sustainability efforts: the plant now produces an extra 16.34 GWh of biogas per year, which improves energy self-sufficiency and reduces carbon emissions by 3,000 tons annually, alongside producing cleaner Class A sludge that’s safer for reuse or disposal. One thing to note: while our THP Operator services were not required on this project, it is an option we can offer in the future. If that’s something you’re considering for your next project, get in touch to discuss your requirements.
For more information contact PBJ Engineering: +447758 120432 | http://www.pbjengineering.co.uk/