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Industrial Case Studies

Stanwell Corporation – Australia


Veolia Water Technologies was contracted by Stanwell Corporation to provide the design, supply, construction, testing and commissioning of a new raw water treatment plant.

Project Background

Stanwell
The biggest Actiflo® plant for industrial process water in Australia - Design, supply, construction, testing and commissioning of a new raw water...

Rockhampton, Queensland - Stanwell Corporation is a power generator with a portfolio including coal-fired thermal, wind, hydroelectric, and bio- energy power generation facilities. Their operations supply electricity to satisfy the demand for energy from industrial and residential end users in Queensland and other Australian states, while demonstrating their commitment to the highest international environmental standards.

 

The Client’s Needs

Remove suspended solids from the make-up raw water coming from the nearby Fitzroy River.
Provide high quality clarified raw water to Stanwell Power Station cooling towers.
Prevent the build up of solids in the cooling system equipment, that had previously to be removed at regular intervals.

 

Project & Technology Solutions

  • Veolia Water Technologies was contracted by Stanwell Corporation to provide the design, supply, construction, testing and commissioning of a new raw water treatment plant.
  • The Stanwell Raw Water Pre-treatment Plant (RWPP) will be able to treat up to 80 Megalitres/day of raw water to provide the cooling towers with clarified raw water.
  • Veolia Water Technologies provided a complete solution including 3 Actiflo® ACP 750 clarification units, 3 clarified water storage tanks, micro-sand make-up system, coagulant & polymer storage and dosing systems as well as sludge thickening. The 3 trains of Actiflo® units, each rated for a flow of 307l/s are designed for treating the water to achieve suspended solids below 8 mg/L.
  • Clarified water from the Actiflo® units is stored in three clarified water storage tanks, one tank dedicated to each Actiflo® unit.
  • Three 50% duty water pumps draw clarified water from these tanks and direct clarified water at flows of up to 922 l/s to the Stanwell cooling towers.

     

Process Description

  • An 11m diameter sludge thickener further treats sludge from the Actiflo® system and returns supernatant to the Actiflo® feed stream. Polyelectrolyte is added to promote thickening of the suspended solids, which settle and are removed from the tank via a centre-driven rake assembly. The sludge generated by the plant will be pumped to the sludge drying beds.
  • New sludge drying beds are constructed as part of the expansion of water treatment facilities at Stanwell and handle the sludge generated by the new plant. The supernatant generated by the drying beds is then returned to the Stanwell Power Station cooling towers to maximise the raw water usage.
  • The plant and processes are designed for automatic operation with minimal operator input. The Siemens HMI (Human Machine Interface) allows for full remote operation and monitoring of the new plants.

     

Results

  • The plant will enable to remove suspended solids from the raw water, and provide clarified raw water for cooling tower feed, while preventing the build up of solids.
  • When the Stanwell Raw Water Pre-treatment Plant is completed in July 2005, it will treat 80,000 m3/day of raw water, which makes it the largest Actiflo® plant in Australia for industrial process water.
  • Following successful commissioning of the pre-treatment plant, a 3-monthly performance test was carried out to demonstrate that the specified plant performance is met.