Advanced Dual Zone EC/EO Electrochemical Technology: A Case Study Industrial Wastewater Treatment at a U.S. Shipyard.

Valence Water recently completed a commercial pilot project at a U.S. shipyard on the West Coast, where we demonstrated the effectiveness of our electrochemical treatment system for managing complex industrial wastewater.

Like many shipyards, the facility deals with wastewater that contains a mix of heavy metals, hydrocarbons, COD and suspended solids—generated from maintenance, resurfacing, and hull washing operations. The shipyard was seeking a more reliable and cost-effective way to meet its wastewater treatment requirements, to replace an existing aging chemical treatment plant.

Project Overview

The objective of the pilot was to evaluate Valence Water’s dual-zone electrochemical treatment system in a commercial shipyard setting. Our patented system combines two electrochemical processes:

• Electrocoagulation (EC): Uses electric current and a sacrificial anode to generate a coagulant in situ, which binds with suspended solids and heavy metals.

• Electrooxidation (EO): Follows EC to break down hydrocarbons and complex organic compounds using oxidants generated at the anode surface.

Both processes occur within a compact, continuous-flow reactor designed for rapid treatment times with the most concentrated waste streams. The Valence platform also includes a sealed electroflotation clarification unit, real-time monitoring and automated controls to adjust performance based on water conditions.

Key Results from the Shipyard Pilot

Over the course of the trial, the system delivered consistent and significant reductions in key contaminants:

• Copper: Reduced by over 99% (from ~500 ppb to <5 ppb)

• Lead: Reduced by over 99% (from ~200 ppb to <1 ppb)

• Zinc: Reduced by over 98% (from ~800 ppb to <10 ppb)

• Hydrocarbons: Reduced by more than 99% (oil & grease from 25 mg/L to below detection)

• Total Suspended Solids: Reduced by over 99% (from 1000 ppm to <10 ppm)

The system also operated without chemical coagulants or pH adjustment chemicals, resulting in an estimated 90% reduction in consumable volume and operational costs compared to the shipyard’s current chemical treatment approach. The automated design reduced the need for constant operator oversight.

Operational and Environmental Benefits

The shipyard treatment team noted several advantages during the pilot:

• Compact footprint: The system was easy to install and operate on-site without major infrastructure changes, fully operational on first day.

• Low retention time: Treatment time is less than 10 minutes, compared to hours or days with traditional biological or chemical systems.

• Reduced sludge: 50% Less solids were produced, and the sludge was drier and easier to manage.

• No odor: The sealed system minimizes odor, improving working conditions for staff.

These improvements helped the shipyard meet compliance goals more efficiently, with the added benefit of lowering environmental impact and long-term treatment costs.

Looking Ahead

This pilot reinforces the potential for electrochemical systems in industrial wastewater treatment—particularly in sectors where space is limited, water quality varies drastically, and discharge standards are becoming stricter.

The Valence goal is to offer a superior alternative to traditional treatment methods that is both technically effective and operationally practical. We’re continuing to work with other shipyards and industrial facilities across North America to assess where this approach can be applied.

If you're exploring options to improve wastewater treatment performance or reduce wastewater treatment costs, contact Valence today.

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