Chemical-physical treatment plant malfunction In an industrial chemical-physical treatment plant, the malfunctions are often the same. A common fault is that the limit values (or monitoring values from the indirect discharger permit) are exceeded in the wastewater from the chemical-physical wastewater treatment, but it can also be a matter of simpler problems, such as a float switch or limit value transmitter that no longer works or a pump that fails. Typical reasons for chemical-physical treatment plant failure
- Are qualified personnel on site or were they on site at the time? Due to the lack of skilled workers, it is often difficult to find staff with the appropriate training and previous experience. Career changers must receive regular internal and/or external training.
- If the limit values, or better monitoring values, are exceeded in the wastewater from the chemical-physical wastewater treatment, post-treatment is first required when a batch is released and, if this is not possible, blending with other wastewater should be considered, e.g. 1:10.
- If a selective exchanger is installed, check whether it still has sufficient capacity or whether it is already in the discharge phase again, i.e. “overrun“, and thus a selective exchanger fault may be occured.
- Any dosing devices must be checked for their actual functionality. Is sufficient supply medium available, are the pumps working and is the required quantity actually being dosed? It can sometimes happen that an air cushion has formed in the pumps or that dosing devices are sticky or encrusted and therefore the required chemicals cannot be added.
- Are the pH/redox probes functional and calibrated? Does the pH or redox value always show a constant value? This would be a typical sign that the probe still has the transparent silicone cap on and is therefore not in contact with the media.
- In the case of chromate reduction, the redox jump may be shadowed by the reduction of other substances to such an extent that it is either no longer recognizable as a jump or there is a redox jump, but it is not the chromate that has been reduced, but another substance.
- Are the pH/redox probes temperature-compensated? Sometimes the temperature compensation is not taken into account in the software and deviations may occur in the event of atypical temperature changes.
- Has the inlet changed? It is possible that the inlet cannot be fully controlled and that cleaning agents or residues may enter the waste water system via a laboratory sink, for example, and complicate or prevent waste water treatment there.
- Has the correct chemical been delivered or is it possible that the correct chemical has been delivered but has been mixed up, resulting in an incorrect dosage in terms of type, quantity or time?
- Has the agitator in the waste water system failed? The problem can often be solved temporarily with a so-called air lance (expensive regarding the of follow-up costs). Compressed air is connected to a pipe and inserted into the container for stirring or whirling. However, bear in mind any outgassing, the oxidation potential of oxygen and the subsequent costs.
- When entering a tank in the waste water system, think about any carbon dioxide or gas sinks. When working on a tank in the waste water system, remember to wear the necessary height safety equipment or life jackets in the event the cover breaks through.
- Is there an atypical odour in the waste water system? In this case, think about your own protection against theoretically conceivable gases escaping from an industrial waste water system, such as chlorine gas, ammonia, nitrous gases, hydrogen sulphide or hydrogen cyanide. Stop the process immediately and initiate countermeasures in accordance with your operating instructions (often: neutral points). A new ion exchanger can also cause unpleasant odours.
- Are the electrical transmission paths within the sensor system of the wastewater system ok? With analog signals (and also some digital signals), humidity can play a role during signal transmission. Newly added cables (especially heavy current) can also cause problems. Are the analog lines set to 4-20 mA or still to 0-20 mA (no safety against cable breakage).
Do you have a malfunction in the chemical-physical treatment plant or do you need external maintenance or an audit of the chemical-physical wastewater treatment plant? Please do not hesitate to contact us.