In mid-October, the commissioning of local wastewater treatment facilities was completed at the “Akvaizol” plant in Kalush, Ukraine, the largest producer of bitumen-polymer roofing materials in Ukraine and Eastern Europe. The Esmil equipment-based treatment complex has a capacity of 15 m³/h (up to 360 m³/day). The installation of Esmil’s comprehensive equipment simplifies engineering and design processes by offering a single source of high-quality equipment. Esmil representatives oversaw the system’s commissioning, enabling effective wastewater treatment with the possibility of water reuse.
Challenge and Task
“Akvaizol” LLC approached Esmil Group with the task of improving wastewater treatment following the washing of PET containers and recycling the treated water. One of the main challenges was that the plant’s wastewater sludge contained a high percentage of solids, fats, petroleum products, and abrasive particles. This made the dewatering process significantly more difficult, as most conventional equipment cannot handle such complex sludge without rapid wear or high maintenance costs.
Solution from Esmil Group
Esmil Group proposed pilot testing of the JD-500 roller press—the best available technology for handling abrasive sludge. This modern equipment demonstrated its ability to efficiently process sludge without abrasive wear or blockages. During the tests, optimal operating modes were determined, allowing the selection of the most suitable equipment model for the “Akvaizol” plant. Additionally, the proposed system included an Esmil DAF unit, which ensures highly effective removal of fats, petroleum products, and suspended solids, leveraging the superior performance and reliability of Esmil’s flotation technology.
Esmil Group also provided an integrated control system for the equipment, ensuring seamless coordination and optimization of all processes. The use of equipment from a single manufacturer significantly simplifies engineering and design tasks, as all system components are perfectly aligned, reducing the risk of incompatibility, simplifying installation and commissioning, and providing a single point of contact for technical support and maintenance.
Project Implementation
In October 2024, a fully operational wastewater treatment complex was commissioned at the company’s local treatment facilities. The system included the following key components from Esmil:
- Drum Screen outside-in RMB TP 3/6;
- Tangential grit chamber PT-25;
- DAF unit FT-10L with flocculator KF10;
- Roller press JD-750;
- Supporting equipment, including pumps, mixers, flow meters, pH meters, and chemical dosing systems.
Esmil Equipment Advantages
The equipment installed at the “Akvaizol” plant’s local wastewater treatment facilities was carefully selected to ensure maximum efficiency in wastewater treatment and sludge dewatering. Each system component plays a crucial role in achieving high-performance results, combining technological excellence with economic efficiency.
The Drum Screen outside-in RMB TP 3/6 serves as the first stage of fine treatment, effectively separating solid particles and debris from the wastewater. This reduces the load on subsequent treatment stages, such as the grit chamber and the flotation unit, enhancing their efficiency and extending their service life. The screen operates continuously, automatically removing solids to ensure uninterrupted system performance.
The Tangential Grit Chamber PT-25 is designed to remove abrasive particles, such as sand and gravel, from wastewater. Eliminating abrasives early in the treatment process protects downstream equipment, including the DAF unit and sludge dewatering system, from premature wear. The grit chamber provides reliable protection against the settling of heavy particles, which is especially crucial for systems handling wastewater with a high content of solid materials, as is the case at the “Akvaizol” plant.
The DAF unit FT-10L with Flocculator KF10 plays a crucial role in removing fats, petroleum products, and other suspended particles that complicate further treatment processes. This high-tech DAF unit effectively separates and removes contaminants from water using dissolved air flotation technology. The use of flocculants significantly improves treatment efficiency and reduces the amount of suspended solids entering subsequent processing stages. As a result, the DAF unit greatly reduces the load on the dewatering system and provides clean water that can be reused in the production process.
Key Advantages of Esmil DAF Units:
- Precision in Every Detail – All components are meticulously engineered for maximum cleaning efficiency.
- Custom System Design for Each Client – Unlike the common practice of offering standard tanks with fixed capacities of 10, 20, 30, or 50 m3/h, we tailor the tank size, lamellas, and recirculation system to match specific loads.
- Advanced Reagent Treatment Technology – This optimizes the cleaning process, ensuring superior performance.
- Innovative Solutions – Includes a “white water” feed system, an innovative tank configuration, and an advanced scraper mechanism.
- Top-Brand Components – Featuring parts from renowned brands such as EDUR, E&H, Siemens, and others.
The Roller Press JD-750 serves as the final stage in sludge dewatering, demonstrating high performance and reliability even when handling challenging sludges containing abrasive particles, fats, and petroleum products. Thanks to its innovative design, the roller press ensures efficient sludge dewatering with minimal energy consumption and wear. A key feature of this dewatering press is its resistance to abrasive wear, which significantly reduces maintenance costs and extends its operational life. The JD-750 not only delivers high sludge dryness but also helps reduce the volume of wastewater requiring further treatment, thereby lowering the operational costs for the facility.
Comprehensive Approach
The combination of Esmil equipment, from fine drum screens and grit chambers to DAF units and roller presses, provides comprehensive wastewater treatment and sludge dewatering. The unique advantages of Esmil equipment include tailored component selection for each project, high reliability and durability, innovative solutions, and the use of top-brand components.
With a unified control system, all processes are integrated and coordinated, providing easy management and control over every stage of treatment. This approach allows enterprises not only to improve water treatment quality but also to significantly reduce water supply and wastewater treatment costs. Recycling treated water enables a substantial reduction in the use of fresh water resources and lessens the burden on municipal wastewater systems.
Conclusion: Environmental and Economic Benefits
The use of industrial water recycling systems is not only an environmentally responsible choice but also an economically beneficial solution. Enterprises that adopt such systems can significantly reduce water supply costs and minimize the volume of wastewater requiring treatment. Thanks to high-tech equipment such as the Esmil FT-10L DAF unit and the JD-750 roller press, companies gain reliable, efficient, and durable solutions for their production processes. Collaboration with a single manufacturer streamlines design, simplifies commissioning, and provides a single point of contact for maintenance, greatly enhancing efficiency and reducing costs.
