Case Studies

June 14, 2016

Our new 60 gpm nozzle and trolley assembly
Our new 60 gpm nozzle and trolley assembly

Problem: A mining company was washing and de-icing their large mining equipment with a 150-200 gpm water cannon monitor system. In the summer, washes typically averaged 1-2 hours, using 9,000 to 24,000 gallons per vehicle.

In the winter months, however, the company used the same water cannon monitor system to defrost the equipment and then wash it. Defrosting in the depths of winter could often take up to 10 hours which added an additional 90,000 to 120,000 gallons per vehicle!

The company called Wash Bay Solutions and asked us to develop a heavy-duty washing solution that would greatly reduce their water usage.

Solution: With input from the client, our engineers enhanced our existing demucking system with a new nozzle design to produce our 60 GPM @ 1000 PSI Mighty Monitor system.

The key to this system is our specially designed, multi-directional, 60 gpm @ 1000 psi nozzle. These nozzles are trolley-mounted so they can ride along I-beam systems, immediately adjacent to the vehicle. Specialized hose trolley systems attached to the nozzles allow the operator to wash the 60-ton mining vehicles almost single-handedly!

These nozzles are trolley-mounted so they can ride along I-beam systems, immediately adjacent to the vehicle.
These nozzles are trolley-mounted so they can ride along I-beam systems, immediately adjacent to the vehicle.

Results: The client is very happy the ease-of-handling, range of movement, and washing power of the new design. They are able to wash their large trucks quickly and effectively, using less time and about 1/10 of the amount of water than they did with the water cannons.


September 4, 2015

Oil Water Separator
The system removes the floating oils from the top of the water surface and directs the water continuously into the oil water separator.

“Our washing operation used to dump 3,000 to 5,000 gallons of process water down the sewer each day because it was contaminated with petroleum oil and wax. Not only did we lose this water in the middle of the worst drought in history but the heat energy it contained as well. We also risked plugging up the city sewer system.

With the help of Wash Bay Solutions, we designed a system using a floating oil skimmer on a hose, a non-emulsifying air pump, and a coalescing stainless steel oil water separator.

The system removes the floating oils from the top of the water surface and directs the water continuously into the oil water separator. The unit produces water so clean that we can use it in our boilers and cooling towers. Zero water is now sent down the sewer.”

John
California

Oil Water Separator Design


November 14, 2013

Clarifier Oil Water Separator in Mexico
The clarifier oil water separator used for the mining company in central Mexico.

Problem: A gold mine in central Mexico was modifying their vehicle maintenance facility and adding a wash bay for their heavy mining trucks and vehicles covered with solids, dirt, oil, and grease. The mining company contacted an engineering firm in Arizona who then contacted us for our wash bay expertise.

Solution: We worked with the engineering firm to help design the wash bay with the proper pad layout to accommodate the enormous vehicles, substantial wash water volumes and large amounts of solids. We also had to account for rainwater volumes since their wash bay was uncovered.

Our SPT-50 Clarifier Oil Water Separator System was a perfect fit since it was designed for treating wash water from industrial washing operations with large solids concentrations. It includes a stainless steel clarifier oil water separator that has both a clarifier section, which will remove all settable solids and an oil water separator section, which will remove all non-emulsified oil from the waste stream.

During construction of the wash pad and installation of the SPT-50, we continued to work with the engineering company so insure all tasks were completed properly. We provided all manuals and documentation in both Spanish and English so that as little information as possible was lost in translation. The client has reported that the SPT-50 has been working very well since installation.


November 8, 2013

DM 1000 Demucker
Featuring the DM 1000 Demucker (Low Flow Water Cannons) used by a Canadian worker washing huge mining trucks.

Problem: A mining company in western Canada was using a traditional 150-200 GPM @ 200 psi water cannon system to wash large mining trucks and loaders.

Because of the size of the vehicles, which can measure over 40 feet long and 12 feet high, the average wash time was lasting one to two hours in normal weather conditions, and 10-12 hours in winter conditions. That is a water volume of between 9,000 and 140,000 gallons per vehicle!

The company called Wash Bay Solutions seeking a solution that would save them both labor and water while at the same time providing a quality wash.

Solution: For testing purposes, we rented them our revolutionary DM 1000 demucker, which provides 20 GPM @ 1000 PSI of cold, fresh or recycled wash water.

The testing only lasted a short time. Within days, they determined that it worked perfectly for them – cleaning their large trucks quickly and effectively, and using about 1/10 of the amount of water used in their traditional water cannons.

Results: The client remains very happy with the demucker efficiency and ease of use, and the fact that it saves them time and water in an environmentally effective way.


May 30, 2011

Originally, the first stage of the locomotive wash system consisted of three different wash arches.  Circa 1970, this wash system included a wetting system to wet the locomotive, a second arch to apply soap and finally, an acid wash to serve as a surface brightener.  The second original stage was a rinse arch system that included a 10,000 gallon storage tank, a 100 HP rinse pump, a rinse arch with galvanized nozzles and a 1970‘s vintage process controller.

Problem: The whole system was out-dated, expensive to run and maintain, and no longer performing efficiently.  Many of the parts were hard to locate and expensive, while environmental issues long ago decommissioned the acid arch.  The wetting portions of the wash performed very poorly.  And the dated pumps were simply worn out.  Finally, 1960’s vintage control panels were outdated and hard to maintain.

Solution:

  • A comprehensive study was conducted of existing wiring in order to integrate the new control panels into the system
  • New stainless steel control panels were installed with new conduit and heavier wire to supply the proper amperage needed for the new pumps.
  • New high efficiency pumps were installed with new Schedule 80 PVC piping tied into the existing PVC pipe.
  • The existing nozzles were removed and replaced with re-engineered nozzles.
  • Due to budge and time constrains, this entire project, from initial engineering investigation to design to construction to start-up, was completed in just 90 days.

    During that time, the maintenance personnel were able to continue working. The client reports that the locomotives washing is much more thorough and efficient.


    April 22, 2009

    New Wash Bay updates for truck wash
    Wash Bay updates for automated truck wash tunnel.

    PROBLEM: A new municipal waste management truck wash facilities needed several large water recycling systems to handle the high volumes of water needed for their automated truck wash tunnels. The new facilities required up to 600-gpm of recycled water.

    In addition, the systems needed to collect and isolate heavy solids loads, provide strong disinfection for odor and bacteria/BOD control, and filter the water adequately for reuse.

    SOLUTION: Washbaysolutions provided 600-gpm engineered systems for each location to collect, treat, disinfect, and store clean recycled water for reuse. Large conical-bottom tanks assisted with the extensive solids removal required, along with screen and basket systems and in-line filters. A large ozone disinfection system was utilized to control the odors and organic contamination.

    Automated solids transfer pumps, programmable controllers, and an automated fresh water makeup system enabled the equipment to treat and maintain sufficient clean recycled water for continuous truck wash operation.

    DATE INSTALLED: April 2009

    RESULTS:The initial two locations have operated successfully since 2003 without any major problems. As the facility maintenance personnel became familiar with the operation of the system and its capabilities to handle the large solids loads, the quality of the recycled water soared above their initial expectations.


    April 13, 2009

    Marina Water Recycling
    Water Recycling Units for new Florida Marina.

    PROBLEM: A large new Florida marina needed to provide clean recycled water to 18 boat wash hose locations for hull cleaning. Since no city sewer was available, all water had to be captured and recycled.

    The marina wanted the system to operate 24/7 with minimal maintenance and constant exposure to the heat, sun, humidity, and salt air.

    SOLUTION: Washbaysolutions designed a 200-GPM closed-loop reclaim system to capture, treat, store, and deliver clean recycled water to the hose bibs.

    The system incorporated a large ozone disinfection system, fully automated filter valves for filter backwashing, PLC control of all filter functions, and all non-ferrous components and hardware.

    The system also incorporated a rain detection system to manage excess rainwater in the collection system, and a fresh water makeup system to compensate for evaporation losses.

    DATE INSTALLED: April 2009

    RESULTS:The customer is very happy since the system has operated continuously since start-up with no downtime. It continues to deliver extremely clean recycled water. Average maintenance time is minimal.


    February 20, 2009

    Location: Eastern Tennessee

    PROBLEM: A rural large distributor of construction and mining equipment was cleaning their equipment on an uncovered wash pad. The combination of the equipment washing and rain water accumulation often caused the pad to overflow into a nearby canal, creating environmental concerns. The company was seeking a solution that would eliminate the overflow problem, completely recycle all their wash water, and require minimal new site construction. They also needed a system that would be easy to move since their corporate officials were looking at new facilities.

    The customer needed two types of cleaning systems – high volume washdown for heavy solids removal and hot water pressure cleaning for grease and oil removal. The facility also needed a completely self-contained water recycling system since there was no sewer connection and rainwater detection and water level controls to eliminate the wash pad overflows.

    SOLUTION: The site was an excellent candidate for the WWMI TWP System – a transportable equipment room containing all washing and recycling equipment needed to completely collect, store, treat, and redeliver the water for all cleaning requirements.

    The 40-foot modular equipment room contained a 20 GPM, 300 psi Demucking System, a 4 GPM, 3000 psi electric hot water pressure washer, closed loop recycling system with 1500 gallons of processed water storage, and a Rain Detection System (RDS). The entire Transportable Wash Bay (TWB) System was shipped intact and pre-tested, enabling the client to rapidly put it into operation. The integrated RDS System provided for the capture of all contaminants in the water during a rain event, and allowed only clean storm water to divert to the adjacent canal.

    DATE INSTALLED: February 2009

    RESULTS: The client has utilized the system without any environmental or operation problems for over 1500 hours/year. They use the Demucking System 80-85% of the time to clean their equipment, minimizing the need for high pressure. The adjacent canal is now clear and pollution-free.


    North Carolina

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    At WashBaySolutions.com, we have been specializing in high tech, custom-engineered solutions to complex washing and wastewater issues since 1991.
    + 1 800-453-8639

    WashbaySolutions.com

    info@washbaysolutions.com

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