A BL BioDisc wastewater treatment plant from Kingspan Water & Energy was installed at a major ammonia plant in Karratha, WA to replace a failing sewage treatment system. One of the world’s largest ammonia product manufacturing facilities, the Karratha plant produces approximately 850,000 metric tons annually. Kingspan carried out the manufacturing and installation of the replacement wastewater treatment system.

Working in partnership with ABCO Water Systems, Kingspan manufactured and supplied a BL BioDisc wastewater treatment plant that met the challenging requirement for a controlled flow rate due to the fluctuating seasonal demand at the processing plant. The BioDisc was installed with the existing pumping stations on the site.

The flow rate was controlled by using a gravity return line, which ensured the primary settlement tank of the BioDisc remained at a constant level while inflow was available. A complex flow system between the pump stations and the BioDisc was managed carefully by the ABCO installers with technical support from the Kingspan team.

The existing individual pumping stations were connected to the primary pumping station, which pumped the influent to a below ground 19KL balance tank; this waste was then pumped to the Kingspan treatment plant. The treated effluent was discharged by gravity into a pumping station where it was pumped to an evaporation pond for disposal.

Due to seasonal low population at the production plant, two of the bailing buckets were removed to allow maximum time within the BioDisc for biological treatment.