El  Paso, Texas

 Ardurra partnered with Total Process Systems (equipment supplier), World Water Works (equipment supplier) and GSE Construction (construction contractor) on a design-build project to provide Eagle Family Foods with a wastewater pretreatment system to meet new, stricter discharge requirements instituted by the City of El Paso.  To meet the City’s aggressive discharge limit deadline and the client’s budgetary constraints, Ardurra proposed a phased approach, with Phase 1 focusing on solids reduction and Phase 2 on biological treatment.    

The Eagle Family Foods facility primarily processes and packages dairy products resulting in a maximum of 720,000 gallons per day of wastewater averaging over 100°F with an average TSS of 3,000 mg/L, BOD of 3,500 mg/L, and FOG of 1,000 mg/L.  Primary goals of the project were a low maintenance, relatively simple, and operator friendly system capable of flow equalization, neutralization of pH swings, TSS reduction to <200 mg/L, BOD reduction to <200 mg/L, and FOG reduction to <50 mg/L.    

Phase 1 included installation of a 250,000-equalization tank, dissolved air flotation skid, 10,000-gallon sludge storage tank, sludge dewatering screw press, and associated chemical/electrical systems to reduce solids and flow surges to the POTW.  Design and construction of Phase 1 was completed in under a year.  

Design of Phase 2 began immediately after startup of Phase 1 and consisted of two lift stations, two 370,000-gallon MBBR tanks, blower building, chemical/electrical building, two pre-engineered equipment canopies, cooling tower, heat exchanger, solids conveyor, and associated chemical/electrical systems.  Phase 2 also included migration of all chemical and electrical systems from their temporary Phase 1 locations to permanent locations in the chemical/electrical building.  

All work was designed to be phased and constructed with minimal impacts to the production facility and all tie ins were completed during previously scheduled plant shutdowns.    

Through both phases, Ardurra’s scope included:  

• Coordination of site survey and geotechnical investigations  

• Mechanical design of the entire treatment system including two lift stations and all interconnected piping systems consisting of air, potable water, chemicals, and process wastewater, and sludge handling  
  
• Structural design of foundations, pipe support systems, and incorporation of two new pre-engineered metal buildings   
• Civil design including grading, drainage, and stormwater management  
• Electrical design plans of power distribution, building electrical, and lighting  
• Permitting through the City of El Paso  

• Construction support through the duration of the project  
• As-built drawings  
• Computerized maintenance management system data entry support for all wastewater process equipment