The wastewater treatment plant in Madisonville, located in Kentucky (USA), processes waste activated sludge (WAS) with an initial dry solids content of 3–5%. Recently, the facility began facing increasing loads, which prompted the search for a new, more efficient sludge dewatering technology.
An Operational Challenge that Became a Catalyst for Change
As the load continued to increase, the wastewater treatment plant faced a serious operational challenge. In order to maintain process continuity, the facility was forced to rent additional equipment and introduce a second shift to relieve the existing, worn-out machinery. While this temporary solution kept the process running, it came with high costs and failed to deliver the expected results. Over time, it became clear that a technology was needed that could ensure stable and efficient operation while optimising operating costs.
It was at this point that the plant team recalled the pilot tests previously carried out together with ESMIL specialists. During these trials, the MDQ series multi-disc screw press was tested under real operating conditions and delivered very strong results – both in terms of dry solids content in the dewatered cake and polymer consumption. Over 16 test cycles, the unit achieved an average dry solids content of 21.2%, with peak results exceeding 25%.
These outcomes confirmed the effectiveness of the ESMIL solution in practice and prompted the plant to contact our team again for support in addressing the growing operational challenge.
Rapid Response to an Operational Crisis: The Mobile ESMIL Module D Dewatering Unit
It was at this point that the containerised ESMIL Module D dewatering station came into action – a solution designed for flexibility, rapid deployment and reliable support in emergency situations. The entire system is housed in a 40-foot sea container adapted for HVAC installation, allowing it to operate in various climates and locations.
Inside, the unit is fully equipped and includes:
- an MDQ-503CL multi-disc screw press with three dewatering drums,
- a polymer preparation and dosing system (with space for a tote container),
- a sludge pump and flow meter,
- a macerator,
- an ESMIL screw conveyor for transporting dewatered sludge.
Just a few days after the request was received, the Module D station was delivered and commissioned at the treatment plant. Installation and start-up were carried out by ESMIL’s service engineering team, who also provided on-site operator training, enabling the plant staff to independently operate the system.
Implementation results
Immediately after installation, the Module D mobile sludge dewatering station began operating at full capacity. The results significantly exceeded expectations – the ESMIL unit not only improved dewatering efficiency but also outperformed the combined capacity of the previously used equipment and the temporarily rented solution.
Cost efficiency proved to be an additional advantage. Renting the ESMIL mobile system accounted for only a fraction of the weekly expenses previously incurred for rented equipment.
As a result, the plant not only restored stable dewatering operations but also significantly reduced operating costs.
The Madisonville case is another example of how Module D supports facilities in crisis situations – delivering efficiency, flexibility and uninterrupted operation wherever time is critical.
