Fleischmann’s Yeast Selects Yardney Water Filtration Systems
to Design and Fabricate a 1,000 GPM
Well Water Treatment System for the Removal of Iron (Fe)
This food processing plant located in Memphis, TN was unable to use the water from a newly
drilled well for boiler and cooling tower make‐up due to the high level of iron (Fe) in the water.
This resulted in higher than expected plant operating costs since the company had to purchase
water from the city for these uses.
During the testing period, Yardney Water Management Systems, Inc of Riverside, CA teamed
with Sparkling Clear Industries of Houston, TX (SCI) for a field trial at the plant using DMI‐65, a
revolutionary new filtration media manufactured by Quantum Filtration Medium in Western
Australia. DMI‐65 is a silica sand based filtration media that will remove iron, manganese and
arsenic when operated in the presence of chlorine (sodium hypochlorite). The purpose of the
trial was two-fold: to determine the effectiveness of the iron removal properties of the DMI‐65,
and to ascertain the appropriate hydraulic flow rate (in gpm/ft2) for the sizing and design of the
required filtration equipment.
System Design and Fabrication
After the successful completion of testing, and with the DMI‐65 media approved for the
application based upon the testing, the design and fabrication of the treatment system moved
forward. Yardney has over 40 years of experience in system design and vessel fabrication and
has provided many different types of systems for all types of applications. One of the main
advantages of the vessels produced by Yardney is the ability to utilize many different types of
specialty medias without having to make significant modifications to the vessel design. The
result is additional technical and economic benefits realized for the client.
The client requested a completely automatic system that would provide variable flows from 200
gpm to 1,000 gpm. This requirement was an ideal application since it allowed for one of the
many standard designs offered by Yardney to be utilized. The system utilized a total of twelve
54" diameter x 60" side shell, fusion epoxy lined, carbon steel vessels. Yardney has
determined, from many years of experience and hundreds of system installations, that this
diameter of vessel provides a high degree of flexibility and ease of operation when dealing with
applications requiring variable flows. This size vessel is also more cost effective than using
larger diameter vessels and can achieve a complete backwash within 3‐5 minutes while
requiring less water during the backwash cycle.
System Automation and Operation
The client’s main desire was to have a system that would be effective in removing the iron
contaminant, but also require little operator involvement with regards to operation and
maintenance. With this in mind, Yardney proposed an automatic system with a control package
utilizing a free chlorine residual monitor, an electronic flow meter and a programmable logic
controller (PLC). The final design of the system was composed of twelve 54" filter vessels
in four banks of three vessels.
As the flow varies, the flow meter sends a signal to the PLC, which then sends a signal to the
control valves on the individual filter vessels. This allows either more vessels to be put on-line or
taken off-line so that the hydraulic flow in gpm/ft2 remains within the design range of the
The PLC also receives a signal from the free chlorine residual monitor, which then controls the
chlorine‐metering pump. The result is that the proper hypochlorite feed and free chlorine
residuals are monitored and maintained without operator attention regardless of the service flow
through the treatment system.
The system was installed and commissioned in mid-2009. Since start-up, the quality
of the water being supplied by the Yardney system utilizing the specialty iron removal media has
met and exceeded the client’s expectations. This has allowed the plant to use the well water
treated by the Yardney system for make-up to the boilers and cooling towers. Additionally, they
have found other uses in the plant due to the high quality of the water produced. In terms of cost
savings, the client is realizing over $9,000/month on water savings since the installation and
start-up of the treatment system. Additional savings, yet to be quantified, are in natural gas and
chemical savings due to the significant reduction of boiler and cooling tower blow down.
Download PDF version