Efficient Mechanical Dewatering for Sludge Management

Case Study: Industrial WWTP (Kanev, Ukraine)

SIZE OF WWTP 6000 m3/day (1 585 000 GPD)
END USER Poultry slaughterhouse, PrAT Myronivska Poultry Farm
CUSTOMER PAT Myronivsky Hliboproduct
START OF OPERATION December, 2015

Issue

Increased capacity of a slaughterhouse resulted in an increased amount of sewage sludge. An existing dehydrator was not able to handle this increase alone, therefore a call for bids was issued.

Solution

ESMIL submitted a lowest priced bid for a modern complex sludge dewatering solution with a state-of-the-art automation system based on PLC and HMI and won the bidding. One unit of MDQ-353 C was installed in parallel with an existing dehydrator from other manufacturer. Having similar nominal capacity, our MDQ achieves higher cake DS content compared to an existing dehydrator.

Results

Type of sludge	DAF sludge
Unit Sludge Supply	6-7.5 m3/h (26-33 GPM) 700-750 kg DS/h (1540-1650 lb DS/h)
Feed Sludge DS Concentration	8-12 %
Cake DS Concentration	33-40 %
Operation Time	14-18 h/day
Average Polymer Dose	2.2 g/kg DS (4.4 lb/ton DS)
Unit Daily Power Consumption	35-45 kW*h

ESMIL - Case Study - Multi Disc Screw Press_Poultry slaugherhouse (Kanev, Ukraine)

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Case Study: CEDROB S.A. (Ciechanów, Poland)

TYPE OF INDUSTRY Poultry slaughterhouse and meat processing plant
MODEL OF DEHYDRATOR MDQ-101
DATE OF PILOT TESTS August, 2016

Issue

The client could not achieve high DS content of sludge cake with the existing centrifuges (barely 13.5 % was achieved with the polymer dose of nearly 19 g/kg DS (38 lb/tonDS). Due to high operation and sludge disposal costs, the client wanted to find a more effective solution and for that was looking for other types of dewatering equipment.

Solution

Esmil brought the MDQ-101 dehydrator with ancillary equipment to the WWTP to perform on-site pilot tests. During the tests, optimum polymer type and operating parameters were determined which resulted in 30 % higher cake DS concentration and consequent reduction of sludge disposal costs as well as reduction of polymer consumption by more than 50 % compared with the existing centrifuges. The client also noted the very low energy consumption of the MDQ dehydrator and low rotation speed of its screw which resulted in slower wear and tear processes compared with the centrifuges.

Results

Type of sludge	Mixture of waste activated sludge and anaerobically digested DAFsludge (nearly 50:50 %)
Unit Sludge Supply	0.10–0.22 m3/h (0.44–0.97 GPM) 3–6 kg DS/h (6.6–13.2 lb DS/h)
Feed Sludge DS Concentration	2.86–2.99 %
Cake DS Concentration	16.3–19.5 %
Average Polymer Dose	4.0–8.4 g/kg DS (8.0–16.8 lb/ton DS)
Filtrate SS Concentration	40–500 mg/l (40–500 ppm)
Solid Capture	97.3–99.9 %

ESMIL - Case Study - CEDROB S.A. (Ciechanów, Poland)

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Case Study: Radevormwald Municipal WWTP

Esmil multi disk screw press radevormwald

MODEL OF DEHYDRATOR MDQ-101
DATE OF PILOT TESTS June, 2017

Issue

R&W Filtertechnik GmbH (Wuppertal, Germany) as a company that specializes in the field of filtering and dewatering of sludges and slurries was interested in onsite testing of a multi-disc screw dehydrator to verify its dewatering efficiency and operation parameters at the real facility as this kind of equipment is not widespread in Germany.

Solution

Esmil company together with R&W Filtertechnik GmbH performed on-site pilot tests of multi-disc screw dehydrator MDQ-101 in municipal WWTP in Radevormwald. The object of the study was the mixture of primary and excess activated sludge after anaerobic digestion and thickening. Initially, selection of optimum polymer type and dose was carried out and then optimal operating parameters of dewatering process were adjusted. The unit showed high process efficiency with high automation level along with its simplicity and was jointly recommended for the sludge treatment. At the same time, dewatering process based on multi-disc screw technology allowed to reduce electricity, polymer and water consumption compared with the existing chamber membrane filter presses assuring all requirements for further cake transportation and disposal.

Results

Type of sludge	Thickened and anaerobically digested mixture of primary and waste activated sludge
Unit Sludge Supply	0.09–0.26 m3/h (0.40–1.15 GPM) 2.4–6.8 kg DS/h (5.3–15.0 lb DS/h)
Feed Sludge DS Concentration	2.60–2.70 %
Cake DS Concentration	19.1–25.0 %
Average Polymer Dose	5.5–9.7 g/kg DS (11.0–19.4 lb/ton DS)
Filtrate SS Concentration	60–700 mg/l (60–700 ppm)
Solid Capture	97.9–99.8 %

ESMIL - Case Study - Municipal WWTP (Ragevormwald, Germany)

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Reference of WWTP, Scécsény, Hungary / Multi-Disc Screw Press MDQ

Northern Hungary Regional Sewage Plant ZRt.

Reference letter Equipment: Multi-Disc Screw Press MDQ-353C Esmil

Location: WWTP, Sechin, Hungary
Start-up date: December 2014

Since the Multi-Disc Screw Press MDQ-353C was launched by Esmil Industrial Group, the equipment performance is faultless, it works stably and without interruptions. During the operation of the equipment it turned out that:

inlet sludge with dry solids content of 1% after the Esmil dewatering Screw Press, becomes of 18-22 % while ensuring compliance with the filtrate quality regulations;
the equipment works completely in the automated mode, the control cabinet is equipped with a touch screen by means of which it is easy to set the operational parameters not only of the dehydrator, but also of the sludge pump;
the equipment works stably in automatic mode, without the need of operator intervention during operation; the equipment works noiseless;
the equipment works reliably and flawlessly: within 3 years of operation, only flexible hoses for rinsing water have been replaced.

13th November 2017, Kazincbarcika

Reference of WWTP, Ozd, Hungary / Multi-Disc Screw Press MDQ

Northern Hungary Regional Sewage Plant ZRt.

Reference letter Equipment: Multi-Disc Screw Press MDQ-352C Esmil

Location: WWTP, Ozd, Hungary
Start-up date: September 2015

Since two Multi-Disc Screw Presses MDQ-353C were launched by Esmil Industrial Group, the equipment performance is faultless, it works stably and without interruptions. Discharging the cake from dehydrators takes place by screw conveyors also produced by Esmil . During the operation of the equipment it turned out that:

inlet sludge with dry solids content of 1 % after the Esmil dewatering Screw Press, becomes of 18-20 % while ensuring compliance with the filtrate quality regulations;
the equipment works completely in the automated mode, the control cabinet is equipped with a touch screen by means of which it is easy to set the operational parameters not only of the dehydrator, but also of the sludge pump and screw conveyors for cake transporting;
the equipment works stably in automatic mode, without the need of operator intervention during operation; the equipment works noiseless;
the equipment works reliably and flawlessly.

13th November 2017, Kazincbarcika