Reference groups: Mechanical dewatering

PURCHASER Nijhuis Industries Central Europe Sp. z o.o.
OBJECT Meat factory, poultry slaughterhouse
SEDIMENT TYPE Excessive activated sludge, initial flotation sludge
DESIGNED CAPACITY 5000 m³/day

Objective

Sludges coming from the treatment of wastewater from meat processing services show specific parameters for this type of industry. They contain increased fat amounts and generally understood animal protein, which in turn requires use of dedicated technology for dewatering of this type of industrial sludge.

The sewage treatment plant is located around 20 km from Kutno, in the Łódź province. The initial entering sewage is a mixture of industrial wastewater from the production lines and biological wastewater which is formed as a result of the daily work of the plant.

The main goal of the investment was the construction of the wastewater treatment plant at the newly built production factory and as part of that the supply and commissioning of two independent and fully automated sludge dewatering complexes.

Work Progress

To determine the efficiency of sludge dewatering, first laboratory tests were performed. Because the plant in which this technology meant to be implemented was still under construction, the tests were carried out in another plant, which had an identical production line and purification technology to the built one. When selecting the device, the experience of Esmil Prodeko-Ełk was used as a supplier of comprehensive solutions based on modern technologies.

The analysis of advantages and disadvantages of the use of various sludge dewatering devices at a given facility has led to the selection of the multidisc screw dehydrators (MDQs), whose main advantages are:

• simple operation,
• low energy, flocculant, water consumption,
• very low noise,
• the ability to work in automatic mode

The scope of delivery included two independent drainage lines. Each of them consisted of a multidisc screw press, an automatic polymer preparation station, a sludge feed pump and a polymer dosing pump.

Multidisc screw dewatering units and the other supplied devices work efficiently and reliably. The
operating parameters of the sludge treatment units in both lines enable them to obtain sludges with the
level of DS up to 34%. Equipped with full automation, it allows the user to optimalise the dewatering process and meakes the sludge management much easier.

ESMIL- Case Study - Multi Disc Screw Press_Poultry slaughterhouse (Kutno, Poland)

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TYPE OF INDUSTRY Food and beverage industry
PLANT CAPACITIES 1,3 million litres per year
START OF OPERATION October 2018

Issue

The Beverage Factory has been treating their wastewater using an external company. Due to high transportation costs, a decision was made to build their own wastewater treatment plant on-site. The full technology was developed for technological and domestic wastewater treatment to safely discharge treated water to the environment. The problem was only in utilization of generated sludge, as its transportation by an external company was of high cost. Hence, Esmil was invited to develop the technology and supply the equipment for sludge dewatering.

Solution

Aſter receiving the enquiry, Esmil professionals began calculations and selected the best dewatering equipment for the sludge regarding its fl owrate and composition. The flocculant solution preparation station was also adjusted to provide fully automatic operation of dewatering facility. Soon aſt er multidisc screw press MDQ-102C and solution preparation station SMART Mix 2100 was successfully installed and commissioned at the site. Multidisc screw dehydrator was selected considering its advantages before other equipment. With much more lower footprint compared to a decanter centrifuge and a belt fi lter press, it ensures silent and trouble-free operation with no need of periodical maintenance. Additionally, the power consumption is reduced significantly comparing to the centrifuges, and the water consumption – comparing to the belt-filter presses. What is more, even if to compare with other modern dewatering equipment such as screw press, the multidisc screw press still allows achieving of lower flocculant consumption with easier maintenance. Aſter commissioning, the complex operation was synchronized and adjusted to work automatically together with other technological equipment for wastewater treatment. Whenever DAF sludge is collected in the sludge tank, the facility starts the dewatering process that shows high effi ciency regarding to equipment capacity and a moisture content of the dewatered cake, which is then periodically taken and utilized by the external company at a greatly reduced volume achieving low operational costs.

Results and Efficiency

ESMIL - Case Study - Multi Disc Screw Press_Beverage factory (Romania)

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Aim of work:

The studied municipal wastewater treatment plant is located in Biskupiec, Warmian-Masurian voivodship, Poland. It serves Biskupiec city and Rukławki village. Inlet wastewater consists of household, industrial sewage from nearby meat plants and rainwater. The average capacity is 1 450 m3/d, with the maximum of 1 725 m3/d.

After mechanical and biological treatment, an excess sludge with humidity of approximately 99.7 – 99.8% is generated in amount of approximately 360 m3/d, which is then gravitationally thickened to a dry solids content of 1.0 – 2.0% in an amount of approximately 60 – 120 m3/d. Earlier, the sludge was dewatered on the belt filter press and then utilized partially for agriculture needs as well as distributed to the sludge plots.

The necessity of reconstruction was caused by poor dewatering process efficiency which affected in high humidity of dewatered cake (approx. 10 %). Additionally, existed belt filter press capacity of approx. 60 m3/d was insufficient to process the entire amount of sludge even beside the fact it was operating with high accident rate.

As the company with rich experience in municipal sludge dewatering technology, Esmil IG was able to offer an appropriate solution and accepted this project for work.

Progress of work:

To get acquainted with the case, laboratory and pilot studies were carried out. First of all, flocculation tests were conducted and the optimal process parameters were obtained. Further pilot scale tests allowed to find the optimal dewatering process parameters in real conditions. The results were analyzed and necessary calculations were done which gave Esmil constructors opportunity to fit and design the best appropriate dewatering technology.

After the old dewatering complex was removed, the new equipment were installed with respect to all client and labor protection requirements. Then it was commissioned and all technological parameters were adjusted to meet the best dewatering efficiency for this kind of sludge.

The reconstruction of the sludge dewatering facility at Municipal Wastewater Treatment Plant in Biskupiec allowed to increase its capacity from 60 to 120-150 m3/d.

Despite of extremely low dry solid content in initial sludge caused by its specific composition and poor thickening process efficiency, installed equipment managed to obtain dewatered cake of transportable consistence and allows ta save expenses on further transportation and utilization due to its quantity reduction. The new technology allows to obtain higher dry solids content in cake (up to 17 %) and cleaner filtrate (60-260 mgTSS/l) with fully automatic and reliable operation of Esmil equipment even in such complicated case, when average dry solids content in inlet sludge is only 1,5 %.

Moreover, implemented technology leads to additional operating costs decreasing due to water, electricity and reagent consumption reduction.

ESMIL - Case Study - Multi Disc Screw Press (Biscupiec, Poland)

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SIZE OF WWTP 700 m³/day (184 900 GPD)
END USER Northern Hungary regional water and wastewater utility provider, ÉRV Zrt.
CUSTOMER Northern Hungary regional water and wastewater utility provider, ÉRV Zrt.
START OF OPERATION December, 2016

Issue

The client was not satisfied with the existing belt-filter press because of high repair and maintenance costs, therefore they decided to change it during the general reconstruction of WWTP. The client was looking for sludge dewatering solution with low power consumption as well as small footprint to be installed in place of the existing filter press.

Solution

After the detailed analysis and comparison with other manufacturers, the client chose our dehydrator. The client was impressed by reliability, low wash water consumption and negligible odour emissions due to the enclosed design of our dehydrators operating in Scécsény and Ózd WWTPs, Hungary. Based on the required dewatering capacity, one unit of MDQ-351 C was installed, while previously installed belt-filter press is stored as a metal scrap in the territory of WWTP. Esmil specialists actively assisted during all project steps – starting from the development of new sludge dewatering scheme, ending with the replacement of existing facilities with new equipment and pipework installation – making it virtually a turnkey project.

Results

ESMIL - Case Study - Municipal WWPT (Sentishtvan, Hungary)

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SIZE OF WWTP 2000 m³/day (528 300 GPD)
END USER Northern Hungary regional water and wastewater utility provider, ÉRV Zrt.
CUSTOMER INWATECH Kft.
START OF OPERATION December, 2014

Issue

The client had frequent maintenance issues with their belt-filter press, therefore they decided to change it during the general reconstruction of WWTP. However, no belt-filter press manufacturer could guarantee more than 18 % DS content of sludge cake.

Solution

Esmil performed on-site pilot tests with a small MDQ model and achived 18.5-20 % cake DS content. The client was satisfied with the results and decided to purchase our equipment. Based on the required dewatering capacity, one unit of MDQ-353 C was installed. Previously installed belt-filter press is stored as a metal scrap in the territory of WWTP.

Results

End User’s Comment

Since the comissioning, the performance of Esmil multi-disc screw press dehydrator MDQ-353 C has been stable and with no issues. With an average feed DS content of 1 %, the cake DS content is 18-22 % while maintaining the required filtrate quality. Control cabinet is equipped with a touch screen which enables setting operational parameters both for the dehydrator and a sludge pump. Operation of the dehydrator is fully automatic, therefore it requires no attention of an operator. Besides beeing almost noiseless, the performance is also reliable and faultless. Over 3-year operation period, only wash water hoses have once been replaced.

ESMIL - Case Study - Scécsény municipal WWTP (Scécsény, Hungary)

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TYPE OF INDUSTRY Food and beverage industry
START OF OPERATION February, 2017

Issue

In this plant sludge from DAF-unit and MBBR reactor was stored on-site in tanks and its utilization was outsourced to an external company. Due to expensiveness of such service, it was decided to build a local dewatering facility to reduce sludge volume and its disposal cost.

Solution

Esmil company offered a sludge dewatering solution based on one multi-disc screw press dehydrator MDQ-353 C. Other auxiliary equipment including a polymer solution preparation unit and pumps as well as piping was supplied by our local partners, assembled by the customer and commissioned by Esmil representatives to meet the highest dewatering process efficiency.

End User’s Comment

Since the comissioning, the performance of the dewatering equipment has been stable, highly efficient and with no issues. High dewatering efficiency resulted in significant sludge volume reduction, so the construction of the local dewatering facility has paid off very quickly.

Results

ESMIL - Case Study - Industrial WWTP (Kerry Ingredients & Flavors, Savanah, GA, USA)

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SIZE OF WWTP 5400 m³/day (1 427 000 GPD)
END USER Northern Hungary regional water and wastewater utility provider, ÉRV Zrt.
CUSTOMER VEOLIA Water Solutions & Technologies Magyarország Zrt.
START OF OPERATION September, 2015

Issue

During the preparation of Ózd WWTP construction project, engineering department of one of the leading companies in the field of wastewater treatment was looking for an effective sludge dewatering solution with low power consumption as well as small footprint.

Solution

After the detailed analysis and comparison with other manufacturers, the client chose two MDQ-352 C units. During the design stage, Esmil specialists actively assisted in the development of sludge dewatering scheme.

Results

ESMIL - Case Study - Multi Disc Screw Press (Ozd, Hungary)

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SIZE OF WWTP 300 m³/day (79 250 GPD)
END USER Public utility provider, Gyulai Közüzemi Nonprofit Kft.
CUSTOMER Pure-Aqua Kft.
START OF OPERATION October, 2015

Issue

The client was not satisfied with the existing belt-filter press because of high repair and maintenance costs, therefore they decided to change it during the general reconstruction of WWTP. The client was looking for sludge dewatering solution with low power consumption as well as small footprint to be installed in place of the existing filter press.

Solution

After the detailed analysis and comparison with other manufacturers, the client chose our dehydrator MDQ-201. During the design stage, Esmil specialists actively assisted in the development of sludge dewatering scheme.

Results

ESMIL - Case Study - Medgyesegyhaza municipal WWTP (Medgyesegyhaza, Hungary)

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SIZE OF WWTP 380 m³/day (100 400 GPD)
END USER Transdanubian regional water and wastewater utility provider, DRV Zrt.
CUSTOMER KEVITERV PLUSZ Komplex Vaillakozasi Kft.
START OF OPERATION September, 2015

Issue

Prior to the construction of new wastewater treatment facilities in Karád, the client was looking for an effective sludge dewatering solution with low power consumption as well as small footprint.

Solution

After the detailed analysis and comparison with other manufacturers, the client chose our dehydrator MDQ-201. During the design stage, Esmil specialists actively assisted in the development of sludge dewatering scheme.

Results

ESMIL - Case Study - Karad municipal WWTP (Karad, Hungary)

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