FLI CAP Technology Meets Tank-in-Tank Challenge with CIRIA-Compliant Aeration Solution

Fifteen years after its first wastewater project with one of the UK’s leading providers of freshly prepared food, FLI CAP Technology has successfully delivered its latest bespoke installation for the same high-profile brand.

To support rising demand for the food producer’s products, FLI CAP Technology was commissioned to design and build a new above-ground effluent treatment tank. This tank not only needed to optimise wastewater management but also comply with CIRIA C736 guidelines on secondary containment for hazardous liquids.

The challenge of installing a tank-within-a-tank system was significant. Secondary containment around an inner vessel creates major access restrictions for maintenance and equipment servicing. 

Chris Woods, Divisional Director at FLI CAP Technology, explained:

“The best solution for aerating our customer’s tank was with submersible mixers, but we were keen to avoid the health and safety issues involved with working at height when removing the equipment for maintenance.

“Based on its quality, efficiency and longevity we specified Landia’s AirJet system which includes their proven chopper pump. We were able to install this 11kW system at ground level for the required tank-within-tank concept, with Landia assisting us in creating an elevated aspiration system so that the Venturi nozzles would create sufficient mixing for the glass-lined steel tank (inner diameter 6m, height 9.4m; with an outer bund of 7.9m diameter and a height of 7.9m).”

The Landia AirJet is a robust and simple aeration system that can be retrofitted into most tank types, often without needing to empty the vessel. It is an ejector aerator typically used for the aeration of wastewater or sludge. It thoroughly mixes and aerates the contents of a tank, eliminating odours and improving process efficiency. AirJet is also effective for supplementary aeration during peak loads and is suitable for flushing and cleaning equalisation tanks.

Chris Woods continued:

“As our customer expanded to create a fourth production line for a 35% increase in capacity, we needed to find an innovative design that greatly reduces residual risks with the project. Ensuring that our customer met CIRIA’s important C736 requirement was paramount, but keeping moving parts at ground level also makes maintenance significantly easier for them, greatly reducing health & safety issues, hassle and costs.”

In addition to the bunded balance tank and aeration system, FLI CAP Technology delivered a full turnkey effluent treatment solution. This included a solid screen, a chemical dosing system and a dissolved air flotation (DAF) system as the primary treatment stage.

Before commencing work, FLI CAP Technology undertook a detailed survey of the site’s existing effluent treatment plant. The assessment reviewed the condition, treatment capacity and environmental compliance of the plant in relation to the site's long-term discharge needs. The report concluded that a full replacement was necessary—despite the constraint of having no additional space available on-site.

As a result, the project was carefully phased to allow the plant to remain fully operational throughout the works. The full project took 18 months and covered all elements from design and supply to mechanical and electrical installation and final commissioning.

Phased Construction Overview:

• Phase One: Demolition of the existing chemical store and installation of a new final effluent sewer, a new ETP (Effluent Treatment Plant) building and DAF equipment fed by the existing balance tank and screen.
• Phase Two: Removal of the old ETP and DAF, followed by construction of new plinths to support the new screen and new balance tank in the footprint of the former ETP building.
• Phase Three: Removal of the old screen gantry and balance tank, replacement of ageing submersible pumps, and installation of new raw effluent suction pumps.

The new system is fully automated, monitored and controlled via a PLC with touchscreen interface. Treated effluent is safely returned to the sewer via a consent-compliant monitoring station.

Chris Woods concluded:

“This was our seventh project and perhaps the most challenging yet for this very important customer. Although their business has grown significantly during the past decade and a half, we’ve proved that we can continue to meet all their effluent treatment plant needs.

“We’re seeing more and more requirements for secondary CIRIA-compliant containment. By working with Landia we have, when required, the flexibility to introduce top quality ground-mounted pumps/mixers through the tank voids as part of our overall solution. The team at Landia are always quick to respond to our needs and we always have total confidence in their equipment.”

For more information:

www.fli-captechnology.com
enquiries@captechnology.co.uk

www.landiaworld.com
info@landia.co.uk

Contact Details

Landia Ltd

• 0194 8661 200
• info@landia.co.uk
• http://www.landia.co.uk
• Waymills Industrial Estate, Whitchurch, Shropshire, SY13 1TT GB
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Landia's headquarters are located in Lem, which is how it has been since 1933. Today, Landia has subsidiaries in England, Germany, Norway and the US, and a sales office in China. In addition, Landia products are sold in 45 countries worldwide. Landia supplies pumping and mixing solutions to many different industries, with the most important ones being agriculture, wastewater, biogas plants and the fish industry. In general, you will find Landia's products wherever there is a difficult medium to be pumped or mixed. Landia survives by selling quality solutions in close partnership with the customers.

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