How to reduce wastewater treatment operating costs

To reduce wastewater treatment operating costs, especially since wastewater treatment plants are essential for industries. They ensure that wastewater is safe to return to waterways or be reused in other business operations. Wastewater treatment plants are essential for preserving the environment and protecting human health. However, the cost of wastewater treatment operations can be high.

Wastewater treatment requires significant energy consumption, the use of chemicals and other materials, waste disposal, and a skilled and well-trained workforce. With budgets shrinking to cover necessities, many wastewater plants are seeking ways to reduce operating costs.

What is the average cost of operating a wastewater treatment plant?

The average cost of operating a wastewater treatment plant depends on several factors, including:

• How much water flows through the station daily?
• Sludge removal system at the station.
• What industry produces wastewater?

However, there are four main operational costs that every wastewater treatment facility will incur – manpower, waste disposal, and energy and material consumption. Each of these operating costs is necessary to operate the treatment plant.

Manpower costs

One of the highest costs of a wastewater plant is its workforce. Many sanitation facilities operate for long periods of time, and some even operate non-stop throughout the year. As a result, many processing plants require staff on call 24 hours a day to ensure smooth facility operation. Plant size and level of automation are two important factors that affect workforce costs.

Because employees are responsible for everything from leaking pipes to industrial and electrical equipment, they must also be trained and certified to work in wastewater treatment plants.

Waste disposal costs

Waste disposal is another major cost when operating a wastewater treatment plant. The plant must be able to dispose of wastes such as sand, screening and various types of sludge. Disposal costs vary depending on:

• Local and national regulations on disposal of organic and inorganic waste.
• Domestic waste disposal prices.
• Disposal method.

Energy costs

Many treatment plants operate for long periods and require significant energy to operate various equipment. As a result, energy is one of the highest operational costs for wastewater treatment plants. While the primary and secondary stages of water treatment are typically used the most, almost every process requires energy, including:

• Aeration tanks and sand traps for aeration.
• Pumping stations.
• Digestion facilities.
• Sludge screening.
• Primary and secondary sedimentation tanks.

Material costs

Wastewater treatment plants use chemicals and other substances to clean and stabilize wastewater. They often use large quantities to achieve the required level of cleanliness, making materials one of the major operational costs of any treatment plant.

The cost of chemicals and other materials will vary depending on the type and quantity used by the plant, which will depend on the type of wastewater and how clean it is. Global, local and national pricing structures and supply levels may also affect the cost of chemicals.

How to reduce the operational cost of a wastewater treatment plant

The rising costs of electrical energy and chemicals needed to treat wastewater are forcing many plants to find ways to manage expenses. There are various ways to reduce the average operational cost of a wastewater treatment plant, from equipment modernization to process automation. While some of these methods may require an initial upfront investment, they can provide significant cost reduction in the long term.

Here are 10 ways to reduce operating costs:

Upgrade pumping stations

Modern pumps, motors, and drives are more efficient than older pumps. Older pumps typically operate at one speed with an on-off cycle. Modern pumps and variable frequency drives can adjust pump speeds according to flow rates, which helps reduce energy consumption in the long term.

Improve ventilation

The plant can use the following methods to improve its ventilation:

• Consider upgrading older equipment such as blowers, distribution systems and air distribution components to newer, more efficient models.
• Use variable frequency drives to make older blowers more efficient rather than relying on adjusting the inlet valve to match demand.
• Reconfigure your aeration basin by switching to micro- or ultra-fine pore aeration systems that increase oxygen transfer efficiency while reducing energy use.
• Ensure that current ventilation systems are well maintained.

Improve sludge management

Improving sludge management in the primary treatment stages can significantly impact processes and equipment. Grit in the sludge damages equipment downstream, accumulates in areas where flow is slow and increases equipment wear. Removing as much granule as possible in early treatment can improve the life of the equipment and reduce the risk of sudden failure. Biogas from sludge can also produce electricity or heat water, reducing energy consumption.

Recover or recycle essential nutrients

Consider the feasibility of recovering and recycling phosphorus. Wastewater plants can recycle phosphorus and turn it into commercial fertilizers, providing an alternative source of revenue. Removing these nutrients can also improve sidestream performance by reducing nutrient load in recirculation streams.

Reduce chemical disinfection

Ultraviolet disinfection is becoming more popular in wastewater treatment. UV systems provide a high level of disinfection and reduce the need for expensive and dangerous chemicals such as chlorine. Processing plants that use UV disinfection systems can reduce chemical costs and create a safer working environment.

Updating lighting and air conditioning systems

Lighting, heating and cooling require significant energy. Upgrade your lighting, heating, ventilation, and air conditioning (HVAC) systems to newer, more energy-efficient models. Rebates may also be available for certain improvements.

Take advantage of gravity

Where possible, take advantage of gravitational forces. Look for areas where gravity can move the water instead of relying on electric motors.

Process automation

Automate as many processes as possible. Automated processes require less human intervention and provide in-depth data about treatment plant operations. Data from automated systems can help the plant:

• Improving processes.
• Reduce energy consumption.
• Reduce consumption of chemicals.
• Reducing manpower costs.

Adjust the size of installed equipment

Some equipment may be too large or too small for the flow the plant receives. Replacing oversized equipment with smaller, more efficient equipment can reduce costs. In other areas, replacing several smaller units with one larger, more efficient unit can significantly reduce energy consumption.

Diagnosis of costly operations

Before taking steps to reduce costs, wastewater treatment plants must identify and diagnose their most costly operations. Knowing which systems, processes, and equipment will cost the most will help determine next steps.

Here are some steps to properly diagnose and treat costly operations:

• Conduct a pilot study to collect operational efficiency and cost information.
• Use data analytics to analyze and interpret the results of a pilot study.
• Measure current costs and energy usage throughout the plant.
• Conduct forensic analysis to understand the life span of various equipment.
• Leverage AI to test potential changes and identify areas for improvement.
• Training employees to improve workflow and efficiency.
• Perform maintenance when required.
• Upgrade or replace systems and equipment.

Contact CareWater for solutions to reduce water treatment operating costs

Cutting costs has become crucial for all industries. Carewater has a team of experienced engineers working in the field of wastewater treatment plants to improve operations and reduce costs. Take advantage of a wide range of industry-leading wastewater treatment products to make your treatment more effective and efficient.