Case Study: Municipal Wastewater Treatment Plant (Webster, Texas, USA)
MODEL OF DEHYDRATOR – MDQ-354 C START OF OPERATION – 2018 August
Issue
The customer had an interest in reducing sludge disposal costs in their municipal wastewater treatment plant by obtaining lower maintenance costs and lower energy consumption. The plant treats wastewater from nearby residential areas and numerous local restaurants and generates about 120 gallons of aerobically digested sludge from their digesters per minute.
Solution
On-site pilot tests were carried out, using mobile dewatering unit MDQ-201, to find the best dewatering technology. According to the test results Esmil offered sludge dewatering complex based on Multidisc Screw Press Dehydrator MDQ-354 C. The complex includes – macerator, polymer feeder and service platform.
MODEL OF DEHYDRATOR – MDQ-353 C START OF OPERATION – 2020 February
Issue
Soapberry WWTP located near Kingston Harbour has been operated since 2004. Biological wastewater treatment process is based on wetland lagoons. The WWTP has not previously had any sludge processing equipment, therefore since the start-up of the plant lagoons have been gradually filled with dry solid particles. As a result, sludge accumulation had impact on biological process efficiency, because of the reduced effective volume of the lagoons. For this reason, customer was looking for the solution to clean the bottom of the lagoons and process the sludge.
Solution
The lagoons cover an area of nearly 6 km2. Bottom sludge from the lagoons is removed by remote controlled dredger supplied by Dragflow. For this reason, Esmil offered Mobile dewatering complex based on Multi-disc Screw Press Dehydrator MDQ-353 C. The complex includes mechanical screen, sludge tank, influent sludge feed pump, polymer solution preparation unit, polymer dosing pump, water tank, water pump and screw conveyors. All the equipment is mounted on the common platform. The complex can be fitted in a standard 40’ container or on a trailer, which allows an easy relocation.
Case Study: Municipal Wastewater Treatment Plant (Argentia, Newfoundland, Canada)
MODEL OF DEHYDRATOR – MDQ-102 C START OF OPERATION – 2019 November
Issue
The customer was looking for a low-cost, yet reliable and easy to operate solution for sewage from a construction site of an offshore platform treatment.
Solution
Project was carried together with our partner MABAREX. Esmil offered Multi-disc Screw Press Dehydrator MDQ-102 C, which is the part of the containerized wastewater treatment plant.
TYPE OF INDUSTRY – Renewable energy MODEL OF DEHYDRATOR – MDQ-354 CL START OF OPERATION – 2020 January
Issue
The customer was looking for a solution to replace one of the three existing centrifuges as well as to increase dry solid content, reduce energy consumption and improve operation.
Solution
On-site pilot tests were carried out, using mobile dewatering unit MDQ-201, to find the best dewatering technology. According to the test results Esmil offered sludge dewatering technology based on Multi-disc Screw Press Dehydrator MDQ-354 CL together with service platform.
Case Study: Guggisberg Cheese (Sugarcreek, OH, USA)
TYPE OF INDUSTRY – Dairy products MODEL OF DEHYDRATOR – MDQ-353 C START OF OPERATION – 2018 December
Issue
The customer had an interest in reducing sludge disposal costs in their industrial wastewater treatment plant by obtaining lower maintenance costs and lower energy consumption. The plant treats industrial wastewater from a nearby cheese factory and generates about 15,000 gallons of activated sludge from their MBR system per day.
Solution
On-site pilot tests were carried out, using mobile dewatering unit MDQ-201, to find the best dewatering technology. According to the test results Esmil offered sludge dewatering technology based on Multi-disc Screw Press Dehydrator MDQ-353 C.
Case Study: Modernization of the clarifiers (Awgustow, Poland)
PROJECT – Modernization of the secondary clarifier CUSTOMER – Wodociągi i Kanalizacje Miejskie Sp. z o. o. w Augustowie OBJECT – Wastewater Treatment Plant in Augustów COMMISSIONING – October, 2018
Introduction
Wastewater Treatment Plant is located in the South part of the Augustów city. It is a mechanical-biological type of plant adapted for deep removal of the biogenic compounds. Water needs to pass several steps and once purifi ed, it is drained to the Netta river. The maximum capacity of the plant is 10 000 m3/day. In June 2018 PRODEKO-EŁK Sp.zo.o. (Esmil Industrial Group) has been chosen as a main devices and technology supplier to accomplish the task of secondary clarifi er modernization at the Wastewater Treatment Plant in Augustów.
Modernization purpose
The main goal of the modernization was to:
ensure the stable work of the secondary clarifier
increase the removal effi ciency of the fl oating parts and the sludge
decrease the operating costs
Initial stage
As part of the signed contract a radial sludge scraper ZGRwt-25 type and the penstock SGSM type have been supplied. The scope of work carried out included preparation of the documentation to fabricate the devices and necessary parts properly adapted to the dimensions of the clarifi er and the sewage disposal channel, as well as assembly and technological commissioning of the supplied devices.
Results and conclusions
The use of modern technological solutions in the design of devices ensures high work efficiency, energy efficiency and reliability. As a result of replacement of the existing sludge scraper at the Wastewater Treatment Plant in Augustów the following were achieved:
increase in the efficiency of floating parts and sludge removal due to the special design of the scraper elements;
high level of energy efficiency of the device due to the use of energy saving trolley drive with the gearbox embedded directly within the wheel;
lowered operating costs of the device related to maintenance and repair.
Case Study: The Practice of operating the Esmil Catenary Screen at Wastewater Treatment Plants (Budapest, Hungary)
It is no secret that the industry market leader is the most prestigious customer for any supplier of specialized equipment in any given country. In Hungary such customer is certainly the Budapest Waterworks, FCSM Zrt., who provides wastewater treatment in Budapest. Moreover, we feel especially proud of those projects implemented in this city as they received positive professional assessment from the specialists of FCSM Zrt.
One of such projects is the project of manufacturing and installation of a unique Esmil catenary screen for rough wastewater treatment at Angyalföld pumping station that became a substitute to an older coarse screen. In the channel, 6 mtr deep and 3 mtr wide, with the existing transporting conveyor for the wastes from the screen, a new screen had to be installed as soon as possible. Our designers had to focus on the installation and commissioning procedure of the finished product, which was to be delivered from the Esmil plant in Poland.
We can rightfully consider this project as a special operation – due to its non-standard dimensions (3.2 mtr wide, 9 mtr long, weight 2,890 kg), the screen required the use of an escort vehicle; its installation into the channel required high-precision work by the Hungarian team of crane operators and installers. Under the guidance of an Esmil commissioning expert, this operation was performed with surgical precision. Almost 3 hours after the channel had been closed, a penstock was reopened, and the KR 2853 catenary screen was put into operation. The flow rate supplied for this screen ranges from average values of 5-6 thous. m3/hour to 12 thous. m3/hour.
The screen was put into operation in the middle of June of 2020 and during the past six months the operation has clearly demonstrated its efficiency and reliability. The article, published by Waterworks in a professional publication in October 2020, notes the following:
“The Esmil screen, installed in the summer, passed a successful initial inspection. The rakes, located at a distance of about 1 meter from each other, prevent the screen filtering mesh from clogging. Collected wastes remain on the screen filtering mesh for a much shorter period of time compared to the previous one. Consequently, the period of time, when wastes on the filtering mesh can be pressed through by water, is much shorter. Another advantage that could be observed is that the wastes is collected from a screen not with a help of a steel cord, but with a chain made of the same material as the screen itself. This eliminates the possibility of rupture of the steel cord and further interruption in screen operation due to the need of steel cord replacement”.
The article also states that the high efficiency of sewage treatment from all kinds of fibrous and rag materials ensures the stable operation of pumping equipment, which is the most important economic factor. The experts of the Esmil company, together with the employees of the Budapest Waterworks, continue to constantly monitor the operation of the installed catenary screen to control the effectiveness of the applied solutions and their further improvement.
Case Study: Esmil diffusers at Tesla (Shanghai, China)
SITE – Tube Air Diffusers EQUIPMENT – Tesla (Shanghai) Co., Lingang Development Zone, Pudong New Area, Shanghai YEAR OF COMMISSIONING – May 2019
Introduction:
On May 10th 2018 Tesla (Shanghai) Co., Ltd. was established in Lingang Development Zone, Pudong New Area, Shanghai. The company is engaged in technology development, technical services in the fields of electric vehicles and parts, batteries, energy storage equipment and photovoltaic products. Electric vehicles, technology, wholesale, consulting, commissioning as well as import and export business of the above-mentioned products and supporting services constitutes the business of the company.
Tesla Gigafactory is the largest foreign manufacturing project in Shanghai to date, and it is also Tesla’s first Gigafactory outside of the United States. Tesla has invested over 2 billion USD in the components plant in China in order to localize the supply chain and is preparing to expand the factory’s production capacity.
As Esmil diffusers has the advantages of stable performance, strong aeration capacity and low energy consumption, the owner decided to use Esmil tube air diffusers for the local WWTP.
Esmil diffuser parameters
Outer diameter
120 mm (Threaded to DN100)
Total length
1020/2025 mm
Model
APKV-1 / APKV-2
Disperser length
940/1945 mm
Dry weight
4/8 kg
Design air flow
8-25/16-50 Nm3/h
On-site
After detailed investigation of the on-site data, aeration tank conditions and blowers, we recommended arrangement of the diffusers accordingly. The installation of Esmil tube air diffusers was completed on the 30th of May 2019. The equipment operates smoothly since then.
Aeration system length
64 r.m.
Air volume of the blowers
1200 m3/h (2 blowers, each blower: 20m3/min)
Air volume per diffuser
18.75 m3/h/m
Tank bottom coverage
10.7% (percentage of the diffuser active area in relation to the bottom area of the tank)
Case Study: Esmil Tube Air Diffusers at Tianfu International Airport New City (Chengdu, China)
EQUIPMENT – Esmil Tube Air Diffusers SITE – International Airport New City, Chengdu Tianfu YEAR OF COMMISSIONING – 2021
Introduction
Chengdu Tianfu International Airport New City project is located in the Eastern New District of Chengdu, China. The Eastern New District was established on April 28, 2020. On March 4, 2020 Chengdu proposed 308.6 billion yuan (47.7 billion USD) to be invested in the construction of the Eastern New District of Chengdu within the next 10 years. Among them, the investment in 2020 will reach 28.9 billion yuan (4.4 billion USD).
By 2025 major infrastructure and public service facilities will cover the New District of Tianfu International Airport’s aviation hub is going to be completed by that time as well. Strategic emerging industries, modern service industries, legal governance will be established. The permanent population of the district is estimated to reach 800,000 and the regional GDP – 48 billion yuan.
Airport New City, relying on Chengdu Tianfu International Airport, gathers the functions of aviation economy, international finance, international trade, technological innovation, international education and cultural exchange. According to the development plan, 15 municipal WWTPs will be built in the Airport New City. Esmil tube air diffusers are used at No. 6, No. 9 and No. 15 water plants.
Esmil Tube Air Diffusers Parameters
Outer Diameter
120 mm (Threaded to DN100)
Total Length
1020/2025 mm
Disperser Length
940/1945 mm
Dry Weight
4/8 kg
Design Air Flow
8-25/16-50 Nm3/h
Project Overview
Chengdu Tianfu Airport New City WWTP no. 6 is located to the west of Jiangxi River and to the south of the New Airport Expressway. It’s estimated capacity is 40 000 m3/day. It is planned to serve mainly for innovative manufacturing, with the service area of about 1057 ha.
Aeration System Length
1 550 r.m.
Air Volume of the Blowers
14 040 m3/h (3 in use; 1 stand-by)
Air Volume per Diffuser
12 m3/(m3/h/m)
Tank Bottom Coverage
10.4%
Distribution of Aerators
0.6 m of Aerator per 1 m2 of the Tank Bottom
SOTE
47% (SSOTE 6.6% depth 7.2 m)
Pressure Loss
80 mm H2O
The 9th WWTP’s capacity is 32 000 m3/day. It is located in the Jiangxi Henan Group West Area on the south side of the Jiangxi River in the Airport Industrial New City. It is planned for economics, high-end industries, hotel services, medical education, administrative offices and residences. The service area is about 1450 ha.
Aeration System Length
1 190 r.m.
Air Volume of the Blowers
9 000 m3/h (3 in use; 1 stand-by)
Air Volume per Diffuser
9 m3/(m3/h/m)
Tank Bottom Coverage
13.1%
Distribution of Aerators
0.7 m of Aerator per 1 m2 of the Tank Bottom
SOTE
49% (SSOTE 6.9% depth 7.2 m)
Pressure Loss
75 mm H2O
The 15th WWTP has a design of 30,000 m3/day. It is located to the east of Jiangxi River in the starting area of the Airport Industrial New City, on both sides of the New Airport Expressway, and close to the new Chengdu Airport, which is currently under construction. It is planned for industrial and logistic purposes. The service area is about 581.6 ha.
EQUIPMENT Multi-Disc Screw Press Dehydrator MDQ-352C(1) TYPE OF SLUDGE Tannery wastewater treatment process INITIAL SLUDGE AMOUNT 12 m³/day DS LOAD 1200 kg DS/day DS CONCENTRATION 10% START OF OPERATION July 2019
Issue
Sludge from the tannery production waste water treatment plant was filtered with use of a chamber filter press. A large amount of lime used along with complex operation and low automatization level have led to dissatisfaction and search for another dewatering technology. Additional aspect to consider was the future plans for the tannery plant capacity increasement, that the new dewatering solution should be able to deal with.
Solution
Aſter pilot tests, which were performed in January 2019, Multi-Disc Screw Press dewatering technology was selected for renovation. MDQ unit showed high productivity and dewatering efficiency at the same time with good quality of the filtrate.
A unique feature of MDQ is the ability to increase productivity by installation of additional screws. Taking into account future increasement in productivity, the MDQ-352C(1) with one screw and a free slot for the second one was offered to the Customer with perspective extension to MDQ 352. This has allowed the Customer to reduce initial CAPEX.
In July 2019 the new dewatering system based on Multi- Disc Screw Press Dehydrator MDQ-352C(1) has been commissioned under Esmil expert’s supervision.
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Esmil Group stands as a premier global manufacturer, crafting cutting-edge equipment for wastewater treatment and sludge dewatering. Additionally, we specialize in delivering advanced membrane systems tailored to various industries.
