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Solving Brownfield Site Challenges with Advanced Ultrafiltration (UF) System Design

3D Render of Advanced UF System Design for Industrial Water Treatment

BHF is currently in the design review phase of a technically complex ultrafiltration (UF) and recovery project for a leading global beverage manufacturer, involving the installation of a 240 m³/hr Ultrafiltration system and an accompanying 16 m³/hr Recovery UF unit. This state-of-the-art UF system is part of our broader suite of filtration solutions designed to support efficient and sustainable water treatment. Sustainability is a key focus of the project – with the goal of achieving measurable water, energy and cost savings for a more sustainable treatment process.

Brownfield Design Challenges and Engineering Strategy

The brownfield nature of the project presents a number of technical hurdles:

  • Limited footprint for new equipment, requiring custom skid configurations and spatial modelling to maximise use of available real estate.
  • Hydraulic integration with existing pre-treatment and post-treatment processes, ensuring a seamless flow balance across multiple system loops.
  • Electrical and control system compatibility, where new PLCs and instrumentation must communicate effectively with existing SCADA architecture.

Our engineering team has taken a modular, service-friendly design approach, ensuring ease of maintenance and scalability while complying with site-specific HAZOP and WHS requirements.

Process Benefits: Efficiency, Longevity, and Sustainability

The system is designed to pre-treat feedwater prior to activated carbon filtration, using ultrafiltration membranes rated for sub-micron removal of suspended solids, colloids, and organics. This configuration provides several technical and operational benefits:

  • Reduction in Fouling Load: By removing fine particulates, the UF system reduces the rate of carbon bed fouling, extending the operational lifespan of the GAC media.
  • Reduced Backwash Frequency: Minimising solids ingress into downstream filters leads to significantly fewer backwash cycles, translating into water savings and lower operational expenditure.
  • Improved System Availability: With optimised flow distribution and a robust cleaning-in-place (CIP) system, the plant is designed for high uptime, ensuring process continuity even under variable loading conditions.
  • Energy and Chemical Efficiency: Fewer CIP cycles and reduced regeneration events result in lower energy and chemical consumption, supporting site-wide ESG and decarbonisation targets.

In addition, the 16 m³/hr Recovery UF system is engineered to reclaim and treat waste streams generated from filter backwashing and other intermittent processes. This reclaimed water is recirculated for non-potable uses, further improving overall water recovery rates and minimising discharge volumes to trade waste.

 

Delivering Custom Solutions for Complex Water Treatment

At BHF, we specialise in fit-for-purpose filtration and water treatment systems tailored to each site’s technical, operational, and regulatory requirements. From pharmaceutical-grade ultrapure water to industrial-scale reuse systems, our strength lies in delivering sustainable, reliable, and compliant outcomes in both greenfield and brownfield environments.

Let’s Talk Water

If you’re planning a water or wastewater upgrade and need a partner with technical depth and a track record of innovation, contact us to learn how BHF can engineer a smarter, more sustainable future for your facility.

Learn more about our filtration and purification systems designed for industrial applications.