When rising sludge disposal costs began to spiral out of control and place a serious strain on the operating budget of a chemical production plant in Charleston, North Carolina (USA), a fast and effective solution was urgently needed. The company began an intensive search for a modern sludge dewatering technology that would not only reduce expenses but also improve overall process efficiency. The plant turned to ESMIL, which quickly delivered the perfect answer – a mobile sludge dewatering system.
About the Facility
The plant in question is one of the leading producers of specialty chemicals used in the manufacturing of asphalt, adhesives, industrial coatings, and printing resins. Its production processes generate significant volumes of wastewater, which, during treatment, produce sludge that requires further disposal.
Until recently, the sludge was transported off-site. However, due to its large volume, the rising transportation costs began to put a considerable strain on the plant’s operating budget. This prompted the search for a more efficient sludge dewatering technology.
Sludge Characteristics
The production processes at the plant result in a mixture of chemical sludge and biologically activated sludge. The dry solids content of this sludge is approximately 8%.
Process Requirements
According to operational requirements, the new dewatering system needed to be capable of processing around 7 m³ of sludge per hour.
Implementation Goals
The decision to implement a new dewatering solution was directly driven by existing operational challenges. The project identified three key goals:
- Achieve a dewatered sludge content of 20–25% dry solids,
- Reduce the frequency of sludge disposal, thereby lowering operational costs,
- Minimise the need for operator involvement, limiting manual handling to only essential tasks.
A Practical Approach to Operational Challenges – ESMIL Mobile Sludge Dewatering System
To meet the project’s requirements, ESMIL specialists proposed the use of a mobile sludge dewatering system based on the MDQ-503CS multi-disc screw press. The entire system is mounted on a trailer, ensuring full mobility, easy transport, and fast implementation without the need for complex on-site installation work.
The mobile dewatering unit is a complete, self-contained solution equipped with:
- Sludge feed pump with flow meter
- Polymer preparation and dosing system, including a tote-type storage tank
- Macerator for homogenising the sludge prior to dewatering
- ESMIL MDQ-503CS mulit-disc screw press, the core dewatering component
- Screw conveyor for collecting and transporting the dewatered sludge
- Centralised control panel enabling automated, stable operation with minimal operator involvement
This flexible and efficient setup allows the plant to address its sludge challenges quickly, without disrupting ongoing operations.
