Water Reuse 2024
Envisioning reuse: The next chapter in the story of industrial water Are you ready to reuse water at your industrial facility? Barr can help you begin by identifying and evaluating reuse options that make industrial processing more resilient and water-efficient.

Envisioning reuse: The next chapter in the story of industrial water

Looking to explore industrial water reuse but unsure where to begin? Watch our water reuse webinar recording that will equip you for your next chapter.

We can’t undo many of the forces that threaten our water resources. But we can make more efficient use of what we have. Water reuse—capturing wastewater or stormwater, treating it, and applying it locally for other needs—will be a key piece to the supply puzzle by reducing demand on municipal and natural sources. For industrial operators experiencing rising water costs, facing potential shortages, or lowering environmental impacts, reuse is an effective way to reduce water withdrawals and diversify available sources to reach a more resilient future.

Despite its many benefits and enabling technologies, water reuse remains an emerging practice. Bluefield Research estimates that in the United States, only 6.4 percent of discharged wastewater is currently reused for industrial, irrigation, or municipal purposes. One reason is that conventional water management infrastructure was designed for discharging wastewater, not recycling it. And while water reuse is generally encouraged federally by the U.S. Environmental Protection Agency, current state-level guidance and regulations vary widely. Reusing industrial water therefore requires innovative ideas, new infrastructure, and a water management strategy tailored to location- and industry-specific constraints of regulation, space, and funding.

Where to begin

Water is critical to virtually any industrial process; these processes often involve many applications of water at multiple stages that produce wastewater of varying quality. Knowing when water can be captured and reused, how much, and for what purpose raises further questions of appropriate treatment standards and technologies, permitting, infrastructure needs, and—importantly—economic feasibility. To sort through this complexity, Barr helps industrial operators visualize their options through a critical exercise known as a water balance.

A water balance reveals the story of water as it flows through an industrial facility. It quantifies how much water enters the facility, how much is used in the industrial process, and how much leaves through evaporation and discharge. It also tracks water-quality changes along the way. The resulting story shows operators where in their process—whether it’s paper manufacturing or metal recycling or agricultural processing—water may be captured, treated, and used again.
 

This conceptual water balance depicts example volumes (in million gallons per day or MGD) of water used at an industrial facility that draws from municipal and natural (groundwater) sources. Once used, either in manufacturing or cooling, water is discharged off site.
 

This is a collaborative exercise, with Barr’s water and wastewater treatment experts working with facility staff to collect and evaluate available water-use information from record drawings, operating procedures, water quality data, and flow data. If necessary, we help fill data gaps by installing temporary water meters to measure flows or conducting water-quality testing.
 

A reliable water balance requires reliable data. Barr begins by working closely with facility staff to gather and review available data on water supply, use, and quality before helping them collect any additional data necessary to complete a water balance.

Options will surface

A complete water balance reveals opportunities for reuse. Perhaps wastewater from one process can be treated, then used in another. Perhaps enough condensate from steam can be captured and reused in a boiler for power generation. The water balance provides clarity that can allow us to dream big: We’ve helped clients see the possibility of capturing, treating, and reusing enough water to eliminate or significantly reduce the wastewater discharge from their facilities.
 

Incorporating reuse lowers a facility’s demand on their water sources and potentially the volume of water discharged off site. In this conceptual, revised water balance, the industrial facility accomplishes both by treating cooling water and reusing it in an industrial manufacturing process.

From opportunity to decision: Understanding feasibility

As possibilities emerge, we examine each from the perspectives of necessary treatment technologies and implementation costs—known as a technoeconomic analysis or TEA—helping operators understand what returns on their investment they could expect. Will reduced water withdrawal and/or discharge fees resulting from reuse yield long-term savings, considering the costs of implementation? Even if savings are minimal, some industrial users are motivated by environmental, social, and governance (ESG) goals. Will these options help them reach those goals? We also investigate regulatory implications, particularly if reusing water changes the quality of wastewater discharged from a facility, which may trigger additional treatment and permitting.

Having navigated the complexities and made a fully informed decision to pursue reuse, industrial operators can continue to look to Barr for everything from bench testing treatment options to full-scale design, start-up, and permitting for new water reuse systems.

Wherever you are in writing the next chapter of your industrial water story, we’ll meet you there, leveraging more than 50 years of experience to help you find and implement reuse solutions that meet your economic, regulatory, and ESG goals. Contact us to get started.

About the authors

Chad Haugensenior process engineer, has over 10 years of experience in process engineering and a background in process safety management, water and wastewater treatment, mining, and energy audits. His expertise includes project management and process engineering support for existing and new systems. His work has varied from water and wastewater treatment system design and mine tailings system design to piloting projects, CAPEX & OPEX cost estimating, and R&D projects.

Bailey Hadnott, former environmental engineer at Barr, assisted organizations with environmental compliance, bench testing, technical analysis, and system design. She evaluated new or existing water and wastewater treatment systems, performed bench testing to model water and wastewater treatment systems, calculated mass balances, and performed feasibility studies. Her services also included preparing plans for compliance, spill prevention, and stormwater monitoring. Bailey also participated in preparing applications for new and reissued NPDES permits.

 

Chad Haugen, Senior Process Engineer
Chad Haugen
Senior Process Engineer

 

Bailey Hadnott, Environmental Engineer
Bailey Hadnott
Environmental Engineer
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In This Issue

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Envisioning reuse: The next chapter in the story of industrial water

Envisioning reuse: The next chapter in the story of industrial water

Hear more about water reuse from Barr's experts

Hear more about water reuse from Barr's experts

Project: Turning a facility’s wastewater into process water

Project: Turning a facility’s wastewater into process water

Project: System evaluation to achieve zero liquid discharge

Project: System evaluation to achieve zero liquid discharge

Navigating the storm: Effectively managing industrial stormwater

Navigating the storm: Effectively managing industrial stormwater

Seeing the picture below ground

Seeing the picture below ground

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Stormwater O&M: When construction ends, the work begins

Over the last two decades, innovative stormwater management practices have been implemented by cities, watershed organizations, and developers throughout the country. These practices include rain gardens, infiltration and filtration basins, detention basins, bioretention cells, proprietary underground treatment systems, and more. But, over time, these systems have been strained by aging infrastructure, deferred maintenance, and climate change and may no longer be performing as designed.

The fact is a lot of money goes into stormwater best management practices (BMPs) that reduce runoff volumes, improve water quality, and mitigate flood risk. Whether you’re using capital-improvement money, grants, or cost-share funds, it’s important to remember that the work—and the costs—don’t end when construction is finished. Proper maintenance is critical to the long-term performance of stormwater management systems; without it, you’ll be risking your investment. The potential costs to fully repair or reconstruct a system can far exceed routine maintenance.

Incorporating maintenance into project design

Ideally, maintenance should begin with project design. Planning access for inspection and maintenance is critical. Private development projects often rely heavily on below-ground systems to maximize the developable space. Underground systems are also used for retrofit projects in fully developed watersheds where space is limited. The downside of underground systems is that they can be more challenging to inspect and maintain than surface systems due to lack of visibility and limited access.

Designing practices without involving the staff who will be responsible for their long-term function can also result in systems that cannot be properly maintained. If possible, we recommend involving maintenance staff early in the design process—not only those staff members responsible for structural cleanouts but also vegetation maintenance and even forestry staff.

Ongoing maintenance considerations

Beyond upfront preparations for maintenance during the design process, there are a number of approaches to keep stormwater management systems working as intended. Here are a few:

Underground filtration/infiltration system inspections

Underground stormwater treatment systems can be effective at protecting water quality and mitigating flood risk, but only when maintained properly. Unfortunately, these underground systems are too often out of sight, out of mind. These systems should be inspected at least a couple of times a year, including after rain events, to confirm that they are functioning as the manufacturer intended. Barr’s NASSCO-certified (the industry standard in underground inspection) staff regularly inspect underground filtration/infiltration systems, as well as storm sewers and tunnels, to confirm they’re operating correctly and to catch any problems early.

Green stormwater infrastructure inspections

Green stormwater infrastructure practices (rainwater gardens, tree trenches, swales, filter strips) capture and treat stormwater at its source. The benefits of these practices include enhancing biodiversity in urban areas, managing stormwater flows, treating stormwater before it permeates groundwater, reducing urban temperatures, and improving air quality. To provide these benefits, on top of water quality performance, a well-thought-out inspection, operations, and maintenance program is critical. This helps to ensure the practices function as designed and remain beautiful and evolving spaces that offer habitat. We also assist clients in hiring contractors to maintain green infrastructure features and make necessary repairs to preserve their function.
 

Barr helped an existing retail property—Maplewood Mall in Maplewood, Minnesota—redesign its parking areas and pedestrian plazas to both improve stormwater quality and enhance the user experience. The design includes 375 trenched trees that clean rainwater (as shown above), a rainwater cistern to collect and store rainwater for future use, and a rainwater garden, among other unique features.

Pond cleanouts and dredging

Stormwater ponds are designed to capture runoff from impervious surfaces. They not only decrease downstream flooding but also prevent polluted runoff (runoff that contains sediment, oil, salt, and nutrients from plant materials) from contaminating lakes and rivers. The pond works by allowing sediment and associated pollutants to settle and remain until they can be removed and properly disposed of. Like other stormwater practices, stormwater ponds must be inspected and maintained to work effectively. Ponds also need to be dredged periodically (usually once every 10–20 years).

Stormwater operation and maintenance plans

Stormwater management systems that function effectively protect water quality, offer environmental benefits, and protect public safety. Operation and maintenance (O&M) plans for those systems not only help yield those benefits but also protect your infrastructure investment. Stormwater management systems should be inspected every year (often a few times a year) to look for sediment and debris accumulation, clogging, weeds, and damage. We recommend that clients take advantage of technology to make their O&M plans “living” documents.

Barr developed custom tools for the City of Edina, including an iPad checklist for use during inspections and an online GIS database and tracking tool to manage inspection progress and maintenance recommendations. The tool is optimized for MS4 tracking and reporting, streamlining the annual reporting process.
 

Barr staff inspect an underground stormwater treatment system in Edina, Minnesota.
 

Prioritizing stormwater infrastructure for maintenance

You establish priorities when you set your family’s budget. The same should be true when you consider maintenance for stormwater infrastructure. In either case, you need good data to make informed decisions.

Working with the Hennepin County Regional Railroad Authority (HCRRA), Barr developed a risk-based program to help manage its stormwater infrastructure. The risk assessment used spatial data of HCRRA’s stormwater infrastructure and other parameters such as topography, hydrology, soils, and information about county and public infrastructure (roads, trails, railroads, structures, etc.). Stormwater infrastructure condition and inspection data were used to evaluate the likelihood and possible consequences of infrastructure failure. A risk matrix was then created using the failure likelihood and failure consequence rankings to identify and prioritize actions related to ongoing inspection, maintenance, and replacement of HCRRA stormwater infrastructure.

Barr also helped the city of Calgary on a low-impact development assessment and monitoring and maintenance prioritization project to help evaluate the performance of their existing stormwater infrastructure and target efforts to improve and restore function.

Learn more

Well-maintained stormwater infrastructure is critical to our communities—preventing flooding and protecting water quality. A thoughtful inspection and maintenance protocol keeps it functioning and helps avoid unexpected, expensive repair or replacement costs. Whatever your operations and maintenance needs, Barr can help. Contact our team for help getting your stormwater management system on the road to better health.

Interested in learning more about watershed management? Join us at the 2023 Minnesota Watersheds Annual Conference and Trade Show in Alexandria, Minnesota, on November 28–December 1. Visit us at Booth #40 and attend the “Developing Strategies for Ecosystem Protection and Enhancement within Riley Purgatory Bluff Creek Watershed District (RPBCWD)” session on November 30, presented by Landscape Architect and Ecologist Fred Rozumalski and RPBCWD’s Terry Jeffery.

About the author

Nathan Campeau, vice president, senior water resources engineer, has two decades of experience in hydrologic and hydraulic analysis, flood-risk management, green infrastructure, and GIS. Nathan is a NASSCO-certified professional engineer (CO, MI, MN, WI) and an ENVISION-accredited professional. He works closely with watershed districts and cities on projects involving stormwater management, flood analysis and mitigation, and low-impact site design. Nathan has helped plan, implement, and maintain hundreds of green infrastructure practices.

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Nathan Campeau, Vice President, Senior Water Resources Engineer
Nathan Campeau
Vice President, Senior Water Resources Engineer
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