Enhancing Water Filtration Efficiency at Layer Water Treatment Works

Overview

  • Client: Northumbrian Water Ltd (NWL)
  • Location: Layer Water Treatment Works, Essex & Suffolk Water
  • Project Start: 18 months ago (Fact check)
  • Completion: January 2025
  • Key Partners: Duo Group, Terex Washing Systems (TWS), Nexdorf Electrical, Pleshey Forge, Axon

Introduction

As part of a £30 million investment to ensure a sustainable and resilient water supply for over 300,000 residents in Essex, the Layer Water Treatment Works has undergone a significant upgrade. The goal is to enhance filtration performance and improve raw water quality by upgrading the sand washing system and installing a new Mecana filter block.

Duo Group, in collaboration with Terex Washing Systems, played a crucial role in supplying and installing the advanced FM120C sand washing system, ensuring the highest efficiency in filter media processing.

Challenges

  1. Aging Filtration System:
    • The existing sand washing system was outdated, affecting filtration efficiency.
  2. Raw Water Quality Decline:
    • Climate change-related factors were impacting raw water quality, increasing the need for a pre-treatment solution.
  3. Operational Efficiency:
    • The need for a chemical-free solution to improve sustainability and reduce maintenance costs.

Solution

The project was executed in two key phases:

Phase 1: Sand Washing System Upgrade

  • Installation of a new Terex Washing Systems FM120C plant to improve sand cleanliness and optimize filtration.
  • The plant includes:
    • H12 Feeder – Handles feed material efficiently.
    • 12x5 Double Deck Static Rinsing Screen – Removes unwanted fines and debris.
    • Prewash System & Cyclones – Ensures optimal sand classification.
    • Radial Product Conveyor & Dewatering Screen – Improves sand recovery and water efficiency.
    • Freshwater Tank & Pumps – Maintains consistent water supply for operations.

Phase 2: Mecana Filter Block Installation (Planned for Summer 2026)

  • This chemical-free pre-treatment system will improve raw water quality before it enters the main filtration process.
  • Designed for off-site construction, minimizing disruption to ongoing operations.

Process Breakdown

  1. Sand Removal & Transport:
    • Contaminated sand from filtration beds is removed using dump trucks and fed into the H12 Feeder.
  2. Screening & Prewashing:
    • Oversized materials and debris are removed using a double-deck rinsing screen.
  3. Sand Classification & Recovery:
    • Fine sand is separated using cyclones, reducing material loss and improving sand reuse.
  4. Dewatering & Storage:
    • A high-frequency dewatering screen ensures minimal residual moisture in the final product.
  5. Water Treatment & Recycling:
    • Variable Speed Pumps (VSPs) manage water flow, while a settling pond system ensures sustainable water use.

Challenges & Solutions

  1. Break Tank Resealing:
    • Addressed water leakage by applying Sika Sealant and installing a rain protection system.
  2. Pipework Modifications:
    • Reoriented non-return valves to prevent backflow.
    • Extended VSP pipework to fully drain water tanks, improving system efficiency.
  3. Logistics & Installation:
    • Equipment was pre-assembled at the TWS factory in Northern Ireland, ensuring a smooth on-site installation.
    • Mobile cranes and telehandlers were used for precise placement of large components.

Results & Impact

✅ Improved Filtration Performance – Cleaner, more efficient sand washing enhances water treatment.
✅ Sustainable & Chemical-Free Processing – Reducing environmental impact while maintaining high-quality water standards.
✅ Increased Operational Efficiency – Modern equipment reduces maintenance downtime and improves output.
✅ Reliable Water Supply for 300,000+ Residents – Ensuring long-term water security in Essex.
✅ Cost Savings & Resource Efficiency – Recycled sand minimizes the need for purchasing new material.

Conclusion

The Layer Water Treatment Works upgrade sets a new benchmark in sustainable water filtration. By integrating advanced Terex Washing Systems technology and innovative engineering solutions from Duo Group, the project enhances water quality, supports climate resilience, and improves long-term operational efficiency.

With Phase 2 on the horizon, this collaboration between Northumbrian Water Ltd, Duo Group, and Terex Washing Systems continues to drive progress in innovative water treatment solutions.

Associated Businesses

  • BT71 4DR