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CASE STUDY
Electroplating Wastewater Treatment: Achieving Zero Liquid Discharge
How Memva's Advanced Evaporation System Solved Heavy Metal Contamination for a Major Automotive Parts Manufacturer
98%
Water Recovery
Zero
Liquid Discharge
40%
Cost Reduction
Client
Global Automotive Parts Manufacturer
Location
Midwest, United States
Industry
Automotive Electroplating
System Installed
Memva Triple Effect Evaporator with MVR
Project Overview
A leading automotive parts manufacturer specializing in chrome, nickel, and zinc electroplating faced significant challenges with their wastewater treatment system. With increasing environmental regulations and rising disposal costs, the company needed an innovative solution to manage their electroplating wastewater effectively.
Project Scope
- Treatment of 50 m³/day electroplating wastewater
- Heavy metals removal: Chromium, Nickel, Zinc, Copper
- Cyanide and complexing agent breakdown
- Achieve Zero Liquid Discharge (ZLD) compliance
- Maximize water recovery for reuse
Wastewater Characteristics
| Parameter | Concentration (mg/L) |
|---|---|
| Total Chromium | 250-350 |
| Nickel | 180-220 |
| Zinc | 120-150 |
| Copper | 80-100 |
| Cyanide | 15-25 |
| Total Dissolved Solids | 8,000-12,000 |
| pH | 2.5-4.5 |
Key Challenges
1
Regulatory Compliance
Strict EPA and local regulations for heavy metal discharge limits (Cr: 0.1 mg/L, Ni: 0.5 mg/L, Zn: 0.5 mg/L). Previous system failed to meet these standards consistently.
2
High Disposal Costs
Hazardous sludge disposal costs exceeding $450,000 annually. Transportation and landfill fees increasing by 15% each year.
3
Water Consumption
High freshwater consumption (1,200 m³/month) for rinsing processes. Water scarcity concerns in the region with increasing water costs.
4
Complex Chemistry
Presence of cyanide complexes and chelating agents interfered with conventional precipitation methods. Variable wastewater composition from batch operations.
5
Space Constraints
Limited space available in existing facility for new treatment equipment. Needed compact solution that could integrate with existing infrastructure.
6
Operational Complexity
Existing system required constant chemical adjustment and monitoring. High labor costs and risk of human error in manual operations.
Memva Solution
Integrated Treatment System
Memva designed and installed a comprehensive electroplating wastewater treatment system centered around our advanced Triple Effect Evaporator with Mechanical Vapor Recompression (MVR). The system was customized to handle the specific challenges of electroplating wastewater.
System Components
- Pretreatment: Cyanide oxidation, pH adjustment, chemical precipitation
- Primary Treatment: Memva Triple Effect MVR Evaporator (50 m³/day capacity)
- Post-Treatment: Heavy metals polishing, water conditioning
- Control System: Fully automated PLC with remote monitoring
Process Flow Diagram
1
Wastewater Collection
Equalization tank with mixing
2
Cyanide Destruction
Alkaline chlorination oxidation
3
pH Adjustment & Precipitation
Lime and coagulant addition
4
Solid-Liquid Separation
Clarifier and filter press
5
Memva Evaporation System
Triple effect with MVR
6
Product Recovery
Clean water reuse, metal concentrate
Key Technical Features
Corrosion Resistance
Titanium and high-grade stainless steel construction for acidic electroplating wastewater
Energy Efficiency
MVR system reduces energy consumption by 70% compared to conventional evaporators
Automated Control
PLC system with remote monitoring and automatic chemical dosing
Compact Design
Skid-mounted system requiring only 150 m² footprint
Project Results
98%
Water Recovery Rate
High-purity water recovered for reuse in plating rinsing processes
99.9%
Heavy Metals Removal
All heavy metals reduced to below detectable levels in treated water
Zero
Liquid Discharge
Complete elimination of wastewater discharge to environment
Performance Data
| Parameter | Influent (mg/L) | Treated Water (mg/L) | Removal Efficiency | Discharge Limit |
|---|---|---|---|---|
| Total Chromium | 300 | < 0.05 | > 99.98% | 0.1 mg/L |
| Nickel | 200 | < 0.1 | > 99.95% | 0.5 mg/L |
| Zinc | 135 | < 0.1 | > 99.93% | 0.5 mg/L |
| Copper | 90 | < 0.05 | > 99.94% | 0.3 mg/L |
| Cyanide | 20 | < 0.1 | > 99.5% | 0.2 mg/L |
| Total Dissolved Solids | 10,000 | < 50 | > 99.5% | 500 mg/L |
Economic Benefits
Cost Savings
- $450,000/year saved on hazardous waste disposal
- $180,000/year saved on freshwater purchase
- $75,000/year saved on chemical consumption
- 40% reduction in overall treatment costs
Operational Benefits
- 90% reduction in operator intervention
- 60% reduction in sludge volume
- 24/7 automated operation
- Remote monitoring capability
Environmental Benefits
- Zero wastewater discharge
- 98% water reuse
- Reduced carbon footprint
- Compliance with all environmental regulations
Client Testimonial
JD
"Memva's electroplating wastewater treatment system has transformed our environmental compliance and operational efficiency. We've achieved zero liquid discharge while significantly reducing our operating costs. The system has been running reliably for over two years with minimal maintenance."
John Davis
Environmental Manager, Global Automotive Parts Manufacturer
Need a Similar Solution?
Memva specializes in customized wastewater treatment solutions for electroplating and metal finishing industries. Contact us to discuss how we can help you achieve regulatory compliance, reduce costs, and implement sustainable water management.
Email Us
jiangmou2024@gmail.com
Response Time
Within 24 Hours