Projects
Far North District Council project work
Paihia Wastewater Treatment Plant
Marshall Projects was contracted to deliver an upgrade to the Paihia Wastewater Treatment Plant using Bio-Shell®bioreactor technology. The project was designed to remove up to 120 kg/day of ammonia using 552 Bio-Shell®bioreactor units installed into an existing oxidation pond at the Paihia site. The Bio-Shell®bioreactors were fabricated locally and the oxidation pond remained in service during Bio-Shell® bioreactor installation.
The Paihia WWTP is the largest Bio-Shell®bioreactor installation in the world for nitrification. The project was commissioned during Oct – Dec 2020.
Performance monitoring over more than 1 year of operation has demonstrated that ammonia concentrations have been reduced from typically 50 mg/L to less than 2 mg/L. Total nitrogen has been reduced by 40% along with significant additional benefits to BOD, TSS and E. coli concentration.
As well as the Bio-Shell®bioreactor units, Marshall Projects installed 7,000 m² of Hexa-Cover®Floating Cover. Hexa-Cover®Floating Cover is manufactured of recycled Polypropylene and is solid and robust, offering a long lifespan free of maintenance, service and repair. The cover distributes itself on the fluid surface, automatically adapts to changes in the level and fits all shapes and geometries. Paihia is the largest Hexa-Cover® Floating Cover installation in NZ.
The Paihia WWTP was the subject of the 2021 Water NZ Conference paper, Paihia WWTP, Innovative In Pond Removal Of Ammonia Using Bio-Shells®, Andrew Springer (Wastewater Specialist, WSP) and William Down (Project Manager, Far North District Council). Additionally, the project won the “Excellence in Project Innovation” prize at the coveted 2021 IPWEA NZ Asset Management Excellence Awards held in March 2022 and then on the international stage at the 2022 IPWEA Australasia Excellence Awards.
Key outcomes of the Bio-Shell®bioreactor upgrade were:
- Ammonia of 2 mg/L can be achieved from an existing pond based system by retrofitting with Bio-Shell®bioreactors
- Bio-Shell®bioreactors are an affordable technology where tighter effluent standards are required; the Paihia project offered an $18m saving compared to conventional solutions
- Bio-Shell®bioreactors provide a suitable habitat for nitrifying bacteria that normally cannot be established in pond systems
- Bio-Shell®bioreactors provide a suitable habitat for filter feeding protozoa that contribute to solids and bacterial reduction
- Additional benefits achieved include:
- TSS reduced by 71%
- BOD reduced by 69%
- TN reduced by 42%
- E. coli reduced by 95%
These benefits are exciting and we look forward to applying the Bio-Shell®bioreactor technology to other existing pond-based treatment systems.
Contract value $5.5 Million
Custom-designed and manufactured barge to allow for installation of Bio-Shell®bioreactor units into a functioning oxidation pond
Completed Bio-Shell® bioreactors after fabrication at Marshall Projects temporary workshop at Haruru Falls waiting for transport to site within the nearby Waitangi Forest.
Bio-Shell®bioreactors during installation within the existing oxidation pond
Bio-Shell®bioreactors loaded and ready to be lowered into the oxidation pond
Bio-Shell®bioreactors in place prior to Hexa-Cover® Floating Cover installation
Bio-Shell®bioreactor zone with Hexa-Cover Floating Cover. A curtain was installed across the oxidation pond to direct effluent flow through the Bio-Shell®bioreactor zone and contain the Hexa-Cover® Floating Cover above the Bio-Shell®bioreactors.
South Taranaki District Council project work
Kapuni Water Treatment Plant
Marshall Projects and Pall formed the South Taranaki Water Consortium to deliver a 13,000 m³/day drinking water treatment system for the Kapuni Water Treatment Plant. The project was a design and construct contract and included the supply and installation of microfiltration equipment and associated supporting infrastructure. The project was undertaken to ensure that the drinking water supply to Hawera and the surrounding townships met the requirements of DWSNZ 2005 (2008).
The process plant consists of three Pall Aria Custom 8” microfiltration units with common reverse filtration, cleaning, heating and chemical neutralisation resources. Provision was made for an additional Pall Aria Custom 8” unit and a backwash recovery system in the future if required to increase capacity to 19,000 m³/day and overall feedwater recovery of >99%.
The plant undergoes a mild chemical clean daily and recycles the chemical cleaning solutions up to four times before neutralising and discharging to the waste settling ponds. A more intensive chemical clean is performed at around monthly intervals.
Water is sourced from the Kapuni Stream and is supplemented by an on-site bore. Removal of colour and organics was achieved by coagulation upstream of the microfiltration units using PACl. The source water is subject to high turbidity fluctuations as a result of rainfall in the catchment on Mt Taranaki.
The site works commenced in August 2009 and the project was completed on time and on budget producing water to the distribution network on 17 December 2009.
Contract value $3.2 Million
Opunake Water Treatment Plant
Marshall Projects and Pall working together as the South Taranaki Water Consortium delivered a 2,000 m³/day drinking water treatment system for the Opunake Water Treatment Plant. The project was a design and construct contract and included supply and installation of microfiltration equipment and associated supporting infrastructure. The project was undertaken to ensure that the drinking water supply to the Opunake township met the requirements of DWSNZ 2005 (2008).
The process plant consists of two Pall Aria AP-4 microfiltration units with common cleaning, heating and chemical neutralisation resources. The source water is subject to high turbidity fluctuations as a result of rainfall in the catchment area. The microfiltration system is also used to remove iron from the source water.
This project was commissioned in 2014 and was completed on time and on budget.
Contract value $1 Million
Southland District Council project work
Edendale Water Treatment Plant
Marshall Projects constructed the UV disinfection unit, pH correction, chlorination and all monitoring for the Edendale Water Treatment Plant to meet the requirements of DWSNZ 2005 (2008).
This plant uses a Wedeco UV unit with cleaning system, soda ash dosing for pH correction together with CO₂ stripping in the first reservoir and a chlorine gas system. Plant monitoring includes turbidity, free available chlorine and pH.
The plant was completed on time and on budget in 2010. The project required a close working relationship with a number of separate contractors to ensure successfully delivery. The Edendale plant was a milestone project for the Southland District Council as it introduced a municipal drinking water supply to Edendale and Wyndham for the first time.
Contract value $200 k
Ohai Nightcaps Water Treatment Plant
Marshall Projects and Pall formed the Southland Water Consortium to deliver a 1,200 m³/day drinking water treatment system for the Ohai Nightcaps Water Treatment Plant. The project was a turnkey design and construct contract and included all civil, building, process, electrical, instrumentation and telemetry works. The project scope included all design, construction, commissioning, operator training and handover to Southland District Council. The project was undertaken to ensure that the drinking water supply to the Ohai and Nightcaps areas met the requirements of DWSNZ 2005 (2008).
The process plant consists of a Pall Aria AP4 microfiltration unit fitted with duty/standby feed and reverse filtration pumps. Water is sourced from a nearby stream with removal of colour and organics achieved by coagulation using PACl. The treated water pH is adjusted with NaOH and dosed with gaseous chlorine.
The site works commenced in February 2011 and the project was completed on time and on budget producing water to the distribution network on 31 July 2011. The plant has not had a single microfilter hollow fibre breakage since installation.
Contract value $1 Million
Clutha District Council project work
Heriot & Kaitangata Wastewater Treatment Plants
Marshall Projects and Pall together as the Pall Marshall Water Consortium were contracted to deliver two wastewater treatment system for the Clutha District Council at Heriot and Kaitangata. The project was a design and construct contract and included supply and installation of Bio-Shell®bioreactors and microfiltration equipment and associated supporting infrastructure. The project was undertaken to comply with new Resource Consent requirements..
The process plant consists of 7 Bio-Shell®bioreactors and a Pall Aria AP-2 microfiltration unit at Heriot and 21 Bio-Shell®bioreactors and a Pall Aria AP-4 microfiltration unit at Kaitangata.
The project was completed on time in 2018.
Marshall Projects have formed a partnership with the Clutha District Council to oversee operation at both sites.
In September 2018 a paper written by Tom Marshall (Marshall Projects) titled “Keep Your Effluent Pond – Bio-Shell®bioreactors/MF – Case Study to Improve Quality” was presented at the Water NZ conference highlighting the new approach to pond treatment used at these sites.
Also in 2018 a paper written by Peter Ross (CDC) titled “Something New with Townie Poo” was presented at the Institute of Public Works Engineering Australia conference discussing the procurement process used to meet their KPIs.
Contract value $2 Million
Taupō District Council project work
Taupō Water Treatment Plant
Marshall Projects and Pall formed the Taupō Water Consortium to deliver a 25,000 m³/day drinking water treatment system for the Taupō Water Treatment Plant. The project was a design and construct contract and included the supply and installation of microfiltration equipment and associated supporting infrastructure. The project was undertaken to ensure that the drinking water supply to the Taupō township met the requirements of DWSNZ 2005 (2008).
The process plant consists of four Pall Aria Custom 8” microfiltration units with common reverse filtration, cleaning, heating and chemical neutralisation resources. The plant undergoes a mild chemical clean every 2-7 days and recycles the chemical cleaning solution up to four times before neutralising and discharging to sewer. A more intensive chemical clean is performed at around 6 monthly intervals.
The project required considerable coordination with civil and electrical contractors as the site area between Lake Taupō and (at the time) SH1 was extremely limited. The work involved installation of the microfiltration process plant within a multi-level building across three levels.
Water is sourced from Lake Taupō and removal of arsenic and colour is achieved with coagulation upstream of the microfiltration units using ACH.
This project was commissioned in October 2013 and was completed on time and on budget.
Marshall Projects also completed additional mechanical installation work for Fulton Hogan, the main civil & construction contractor for the project.
Contract value $4.24 Million
Taupō Water Treatment Upgrade
Marshall Projects and Pall as the Taupō Water Consortium are undertaking an expansion of the existing Taupō Water Treatment Plant to process 30,000 m³/day. The project is a design and construct contract and includes an air compressor upgrade, additional feed pump, strainer and treated water pump.
The upgrade consists of two additional Pall Aria Custom 8” microfiltration units to process the existing lake water source. The ultimate plant capacity will be 35, 000 m³/day with the simple addition of further microfiltration modules.
The project is due for completion in 2019.
Contract value $1.7 Million
Fonterra Co-operative Group project work
Te Rapa Water Treatment Plant
Marshall Projects and Pall formed the Pall Marshall Water Consortium to deliver a 9,500 m³/day potable water treatment system for the Fonterra Te Rapa site. The project was a turnkey design and construct contract including all design including geotechnical reports, building and resource consents along with a full structural and architectural package for the building. The building work consisted of setting out, construction of a precast panel building along with a light steel framing PAC building. Civil works included connecting into existing storm water and site sewer drains. The project was undertaken to ensure that the potable water supply to the Te Rapa site met the requirements of DWSNZ 2005 (2008).
The process plant consists of two Pall Aria Custom 8” microfiltration units with common reverse filtration, cleaning, heating and chemical neutralisation resources. Wastewater from backwashing the microfiltration units is processed with a lamella clarifier to reduce the load on the site wastewater system and increase the overall recovery to >98%.
Water is sourced from the Waikato River and removal of arsenic and organics is achieved with coagulation upstream of the microfiltration units using ACH. The plant also has a PAC system which can be used as required.
The project was awarded in October 2013 and commissioned on time and on budget in August 2014.
Fulton Hogan Civil South project work
Akaroa Water Treatment Plant
Marshall Projects and Pall formed the Pall Marshall Water Consortium to deliver a 2,000 m³/day drinking water treatment system for the Akaroa Water Treatment Plant. The project was a design and construct contract and included the supply and installation of microfiltration equipment and associated supporting infrastructure. The project was undertaken to ensure that the drinking water supply to the Akaroa township met the requirements of DWSNZ 2005 (2008).
The process plant consists of two Pall Aria AP-4 microfiltration units with common cleaning and heating resources. Water is sourced from multiple locations and backwash waste is processed with a clarifier and recovered to the plant feed. Scope also included a steel framed building with colorsteel exterior cladding and plywood internal lining. The project also included pre-membrane coagulation and post-membrane treatment including pH correction and chlorination, a new 100 m³ raw water tank, upgrading the existing power supply and provision of electrical, control and instrumentation systems.
Site work commenced in August 2014 and the project was completed on time and on budget.
Marshall Projects also completed additional mechanical installation work for Fulton Hogan, the main civil & construction contractor for the project.
Tauranga District Council project work
Waiāri Water Treatment Plant
Marshall Projects and Pall together as the Pall Marshall Water Consortium have been contracted to deliver a 20,000 m³/day drinking water treatment system for the Waiāri Water Treatment Plant. The project is a design and construct contract and includes supply and installation of microfiltration equipment and associated supporting infrastructure. The project is being undertaken to ensure that the drinking water supply to Tauranga and the wider area meets the requirements of DWSNZ 2005 (2008).
The process plant consists of six Pall Aria Custom 8” microfiltration units with common reverse filtration, cleaning, heating and chemical neutralisation resources. The ultimate plant design capacity will be 60,000 m³/day. The plant will have a high feedwater recovery due to careful management of solids at the site.
The project is due for completion in March 2021.
Contract value $5.6 Million
Westland District Council project work
Hokitika Water Treatment Plant
Marshall Projects and Pall formed the West Coast Water JV in 2007 to deliver a 7,000 m³/day drinking water treatment system for the Hokitika Water Treatment Plant. This project established a partnership between the two companies that continues today. The project was a turnkey design and construct contract which included underground pipework, foundations, building, process, electrical, instrumentation and telemetry works. The scope included all design, construction, commissioning, operator training and handover to Westland District Council. The project was undertaken to ensure that the drinking water supply to the Hokitika township and Westland Milk Products met the requirements of DWSNZ 2005 (2008).
The process plant consisted of two Pall Aria AP-6 microfiltration units with common cleaning and heating resources. An additional Pall Aria AP-3 microfiltration unit was used to filter the concentrated backwash and chemical waste from the two primary units ensuring an overall feedwater recovery of 99.97%. The treated water from the AP-3 unit was directed to supply via a UV treatment unit to provide an additional safeguard.
This contract was awarded in September 2007 and commissioned in April 2008. The project was completed on time and on budget.
In September 2009 a paper written by Tom Marshall, Tony Foskett (Marshall Projects), Ben McSweeney (Pall) and Peter Anderson (WDC) titled “Approaching Zero Discharge at a Modern Microfiltration Facility in New Zealand” was presented at the NZ Water and Wastewater Association highlighting the overall feedwater recovery achieved by the process.
Contract value $3 Million
Hokitika Water Treatment Plant Expansion
Marshall Projects and Pall formed the West Coast Water Consortium to undertake an expansion of the existing Hokitika Water Treatment Plant to process 15,000 m³/day. The project was a turnkey design and construct contract and included an extension to the existing steel-framed building, upgraded chemical storage, chemical dosing, compressed air supply, power supply, electrical, control and instrumentation. The scope included all design, construction, commissioning, operator training and handover to Westland District Council. The project was undertaken to provide additional drinking water capacity for the Hokitika township and Westland Milk Products.
The new process plant consisted of one Pall Aria Custom 8” microfiltration unit to process the existing lake water source. The existing Pall Aria AP-3 microfiltration unit was reconfigured to also process lake water to provide additional capacity. The existing Pall Aria AP-6 units were reconfigured to process a new river water source.
The project also included pre-membrane coagulation of the river water and post-membrane treatment including pH correction and chlorination.
The project was completed on time and on budget in 2015.
Contract value $1 Million
Harihari Water Treatment Plant
Marshall Projects and Westroads formed the Harihari Water Consortium to complete the new Harihari Water Treatment Plant and rising main.
This project required a new bore, building, cartridge filtration, UV disinfection, pH correction, all monitoring and controls and 3 km of rising main. The project was undertaken to ensure that the drinking water supply to Harihari met the requirements of DWSNZ 2005 (2008).
Treated water is conveyed to a remote reservoir with radio telemetry back to the treatment plant together with remote access to the HMI and PLC.
The project was completed in 2009 on time and on budget. The plant provides the community with safe water removing the requirement to boil drinking water.
Contract value $700k