For some years the process industry has not benefited as much as it might have done from the application of control technology. The twin pressures of the economic situation and environmental concerns have focused company attention at all aspects of their operations and, in particular, on cost-effective ways of maximising the return from existing assets. This, together with the emergence of some robust control techniques and the power of modern computing systems, has resulted in some spectacular operational improvements. This is resulting in increased management awareness of the power of control techniques to provide a high return on investment. The background to this change of perception is presented together with the description of an industryproven approach to highlighting profit opportunities and quantifying the benefit of investment in process control improvement before a commitment to expenditure is made. Recent developments and established control techniques that are effective in recovering these predicted benefits are described with reference to other papers in this issue of the transactions.

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A unique combination of primary treatment using oily waste ultrafiltration to reduce oil and metals concentrations followed by a membrane bioreactor (MBR) to treat BOD and Nitrogen has been installed and is now meeting effluent limits at the Ford Engine Plant in Romeo Michigan. Daily flow rates range up to above 120,000 GPD from the facility making it one of the larger MBR facilities at an engine plant.The process consists of: • Equalization • Controlled rate of coolant bleed-in • Free oil removal via a Corrugated Plate Interceptor (CPI) • UF for emulsified oil removal • Membrane Bioreactor using jet aeration • Nitrification/Denitrification Previous batch physical/chemical treatment at the plant was able to adequately treat metals and oils before discharging to a local POTW. In addition, a change in coolants at the facility increased organic loads, especially nitrogen, to much higher levels than previously treated. The system was a design/build contract supplied by Dynatec Systems Inc. of Burlington, N.J.The MBR process provides benefits over conventional activated sludge systems including a small footprint, high effluent quality, reduced wasting and sludge production, reduced vulnerability to upsets, and improved biological degradation. In addition, the Primary UF enhances operational performance of the system and allows recovery of the waste oils as compared to the MBR process currently being used in the automotive industry. This presentation will discuss start-up experience as well as report on treatment results from this unique treatment facility.

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