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Publication
Identificação de medidas para reduzir o consumo de água
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| 4.56 MB | Adobe PDF |
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Abstract(s)
O presente estudo foi desenvolvido no âmbito de um estágio de seis meses no Departamento
de Energia e Infraestruturas da Continental Mabor – Indústria de Pneus, S.A., com o propósito de
identificar e aplicar ações que visem reduzir o consumo de água tratada com origem no Rio Ave e
melhorar a eficiência hídrica na unidade de produção.
Com a entrada em funcionamento da Estação de Tratamento de Água 2 (ETA 2), foi possível
atingir uma redução de aproximadamente 22 % na captação de água do rio. Esta unidade trata, em
média, 7,7 m³/h (cerca de 185 m³/dia), permitindo a recirculação de correntes internas anteriormente
descartadas. Como resultado, o consumo específico de água foi reduzido para cerca de 1,33 m³ por
tonelada de pneu produzido, valor significativamente inferior ao registado em 2024 (1,6 m³/t), o que
evidencia a melhoria real na eficiência hídrica da unidade. A poupança anual estimada ronda os 50.000
euros, e o investimento apresenta um período de retorno de aproximadamente cinco anos, evidenciando
a eficácia técnica e a viabilidade financeira da solução adotada.
Adicionalmente, foram analisadas outras soluções técnicas com potencial de aplicação futura.
Entre estas, destaca-se a integração de um segundo estágio de osmose inversa para o reaproveitamento
do rejeitado da osmose inversa (RO) existente, com elevada eficiência de remoção e um payback
estimado de cerca de 3 anos. Foi igualmente avaliada a recuperação dos condensados industriais
gerados no setor CST (vulcanização), cujo período de retorno se encontra igualmente na ordem dos
três anos. A instalação de sistemas WSAC (Wet Surface Air Cooler), em substituição de torres de
arrefecimento convencionais, revelou igualmente potencial de poupança de água significativa,
sobretudo no caso da Torre N2, onde o payback projetado ronda os 6 anos. Já as alternativas,
envolvendo o reaproveitamento das purgas das torres de arrefecimento ou a eletrodiálise inversa
(EDR), apresentam limitações técnicas e económicas que inviabilizam, por ora, a sua implementação.
Os resultados obtidos comprovam o potencial das soluções estudadas em promover uma
utilização mais eficiente da água na indústria de pneus. A experiência com a ETA 2 demonstrou que
intervenções bem direcionadas podem gerar benefícios ambientais e económicos relevantes. Face a
este enquadramento, propõe-se a gradual integração das restantes soluções analisadas, de forma
seletiva e sustentada, reforçando o compromisso da empresa com a gestão responsável dos recursos
hídricos.
This study was conducted as part of a six-month internship within the Energy and Infrastructure Department at Continental Mabor – Indústria de Pneus, S.A., with the primary objective of identifying and implementing measures to reduce the consumption of treated water originating from the Ave River and enhance water efficiency in the manufacturing facility. Following the commissioning of Water Treatment Station 2 (ETA 2), the plant achieved an approximate 22 % reduction in river water intake. This facility processes an average of 7.7 m3/h (about 185 m3/day), enabling the recirculation of previously discarded internal streams. As a result, the specific water consumption was reduced to approximately 1.33 m3 per ton of tire produced, significantly lower than the 1.60 m3/ton recorded in 2024, clearly demonstrating a real improvement in the plant’s water efficiency. The estimated annual savings amount to roughly 50,000 €, with a payback period of approximately five years, thus confirming both the technical effectiveness and economic feasibility of the implemented solution. Additionally, several other technical alternatives with potential for future application were evaluated. Among them, the integration of a second reverse osmosis (RO) stage to recover the reject stream from the existing RO system stands out, offering high removal efficiency and an estimated payback period of about three years. The recovery of industrial condensates from the CST (curing) sector was also analysed, revealing a payback period of approximately three years. The implementation of Wet Surface Air Cooler (WSAC) systems as a replacement for conventional cooling towers also demonstrated significant potential for water savings, especially in the case of Tower N2, where the projected payback is approximately 6.3 years. Conversely, alternatives involving the reuse of cooling tower blowdown or reverse electrodialysis (EDR) currently present technical and economic limitations that hinder their immediate implementation. The results obtained confirm the potential of the studied solutions to promote more efficient water use in the tire manufacturing industry. The experience with ETA 2 has shown that well-targeted interventions can yield meaningful environmental and economic benefits. Based on this context, the progressive and selective integration of the remaining analyzed solutions is recommended, reinforcing the company’s commitment to the responsible management of water resources.
This study was conducted as part of a six-month internship within the Energy and Infrastructure Department at Continental Mabor – Indústria de Pneus, S.A., with the primary objective of identifying and implementing measures to reduce the consumption of treated water originating from the Ave River and enhance water efficiency in the manufacturing facility. Following the commissioning of Water Treatment Station 2 (ETA 2), the plant achieved an approximate 22 % reduction in river water intake. This facility processes an average of 7.7 m3/h (about 185 m3/day), enabling the recirculation of previously discarded internal streams. As a result, the specific water consumption was reduced to approximately 1.33 m3 per ton of tire produced, significantly lower than the 1.60 m3/ton recorded in 2024, clearly demonstrating a real improvement in the plant’s water efficiency. The estimated annual savings amount to roughly 50,000 €, with a payback period of approximately five years, thus confirming both the technical effectiveness and economic feasibility of the implemented solution. Additionally, several other technical alternatives with potential for future application were evaluated. Among them, the integration of a second reverse osmosis (RO) stage to recover the reject stream from the existing RO system stands out, offering high removal efficiency and an estimated payback period of about three years. The recovery of industrial condensates from the CST (curing) sector was also analysed, revealing a payback period of approximately three years. The implementation of Wet Surface Air Cooler (WSAC) systems as a replacement for conventional cooling towers also demonstrated significant potential for water savings, especially in the case of Tower N2, where the projected payback is approximately 6.3 years. Conversely, alternatives involving the reuse of cooling tower blowdown or reverse electrodialysis (EDR) currently present technical and economic limitations that hinder their immediate implementation. The results obtained confirm the potential of the studied solutions to promote more efficient water use in the tire manufacturing industry. The experience with ETA 2 has shown that well-targeted interventions can yield meaningful environmental and economic benefits. Based on this context, the progressive and selective integration of the remaining analyzed solutions is recommended, reinforcing the company’s commitment to the responsible management of water resources.
Description
Keywords
Water consumption water efficiency water reuse industrial sustainability Consumo de água Eficiência hídrica Reutilização de água sustentabilidade industrial