Case Study: Modernization of Wastewater Treatment Facilities at the Decorative Printing (Poland)

The Case Study Describes Increasing of the Economic and Technological Treatment Efficiency of Wastewater Containing Dyes by Modernising the Wastewater Treatment Process Technology

SITE – Local wastewater treatment plant (WWTP) of the decorative printing plant
FLOWRATE – 25 m3/day
WW GENERATION SOURCES – Industrial wastewater from production machines and tank washing
YEAR OF COMMISSIONING – 2020

Introduction:

The local wastewater treatment facilities of the decorative printing plant included stages of buffering, physical-chemical and biological treatment. The treated wastewater was discharged to the municipal sewer system. Despite the diligent operation of WWTP and high operating costs of chemicals, the treatment efficiency often did not meet the requirements for its discharge. For example, according to the municipal wastewater treatment plant discharge requirements, the maximum allowed concentration of the chemical oxygen demand (COD) should not exceed 1500 mg/l, when in fact it could reach 2000-3000 mg/l. Realising the need for increasing the WW treatment efficiency, the printing plant appealed to PRODEKO-EŁK Sp. z o.o., the part of the EKOTON Industrial Group, with a request to carry out an inspection of existing process technology and a corresponding WW treatment study to make a conclusion on the required modernisation of the WWTP.

Project implementation:

Upon the appeal, EKOTON technologists visited the plant’s treatment facilities, inspected the wastewater treatment site and took wastewater samples in order to conduct a detailed study on the efficiency of their possible treatment method. During the inspection and study, it was found that the existing wastewater treatment process does not correspond to the wastewater composition, and therefore the process technology should be changed. The technologists have proposed to use a flocculation process with dosing of aluminium coagulants with low chloride-ion content and polyacrylamide-based anionic flocculant (PAA). Such treatment allowed to remove a significant part of all contaminants which were in colloidal form, leaving dissolved organic matter in the filtrate, which could then be safely transferred to the next stage of biological treatment without harming the activity of microorganisms.

The designed treatment technology was tested several times in the laboratory and then repeated as an industrial-scale study. After the experimental approval of its high efficiency, the representatives of both companies proceeded to a technical discussion regarding the modernisation of the treatment facilities with possibility of saving the existing equipment. As a result of individual approach to the project, it was succeeded to found the optimal solution and to implement it with the lowest capital costs. Representatives of both companies worked side by side to launch and adjust the process. All additional customer requirements and demands were fulfilled to make the operation process as easy and convenient as possible.

Results and conclusions:

Owing to the carried out comprehensive study of existing treatment facilities and individual approach to the client, the optimal technological solution for the modernisation of the WWTP was found giving high treatment efficiency with minimal capital expenses. After launching and setting up the whole process, it was possible to achieve the quality requirements for the discharge into the municipal sewer system. The modernisation included simplification and operation automation of the entire technological process; operating costs reduction; improvement of the chemical dosing system and implementation of the intelligent dosing and flocculation technology; customisation and automation of the chamber filter-press and the whole dewatering process; increasing the flexibility of regulating and adjusting of the overall treatment processes.

Case Study: Municipal Wastewater Treatment Plant (Bridge City, TX, USA)

MODEL OF DEHYDRATOR – MDQ-354(2) CL
START OF OPERATION – 2020 June

Issue

In the plant sludge drying beds for sludge dewatering were used. This method required lots of labor and constant maintenance. Due to this reason, the customer was looking for the efficient and minimal maintenance solution.

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 EKOTON offered sludge dewatering complex based on Multidisc Screw Press Dehydrator MDQ-354(2) CL. The complex includes – influent sludge feed pump, polymer feeder, three screw conveyors and service platform.

Type of sludgeaerobically digested excess sludge
Operating timeup to 8 h/day, 3 days/week
Unit sludge capacityup to 9 (18*) m3/h
up to 320 (400*) kg DS/h
Inlet sludge DS content3.5 %
Cake DS contentapprox. 22-23 %
Polymer consumption14.6 l/tonDS
TSS concentration in filtrate200 ppm
DS capture rate99.4 %
*in case of adding two additional dewatering drums.

 

 

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 EKOTON offered sludge dewatering complex based on Multidisc Screw Press Dehydrator MDQ-354 C. The complex includes – macerator, polymer feeder and service platform.

Type of sludgeaerobically stabilized excess sludge
Operating time9-10 h/day, daily
Initial sludge capacity20 m3/h
310 kg DS/h
Inlet sludge DS content1.3-1.5 %
Cake DS content16-18 %
Polymer powder consumption8.8 g/kgDS
TSS concentration in filtrate70 ppm
DS capture rateup to 99.7 %

 

 

Case Study: Soapberry WWTP (Kingston, Jamaica)

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, EKOTON 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.

Type of sludgebiologically digested lagoon sludge
Operating timeup to 23 h/day
Initial sludge capacity10-15 m3/h
Inlet sludge DS content2-3 %
Cake DS contentapprox. 23-26 %
Polymer powder consumption1-2 kg/tonDS
TSS concentration in filtrate100 ppm
DS capture ratemore than 99 %

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. EKOTON offered Multi-disc Screw Press Dehydrator MDQ-102 C, which is the part of the containerized wastewater treatment plant.

Results

Type of sludgeexcess activated sludge from MBR
Operating time6-10 h/d
Unit sludge supply0.5-1 m3/h
Inlet sludge ds content0.5-1 %
Cake DS content15-17 %
Polymer consumption5 kg/ton DS
TSS concentration in filtrate20-100 ppm
DS capture ratemore than 98 %

Case Study: KB Bioenergy, inc. (Akron, OH, USA)

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 EKOTON offered sludge dewatering technology based on Multi-disc Screw Press Dehydrator MDQ-354 CL together with service platform.

Results

Type of sludgeanaerobically digested sludge
Operating time23 h/day, 6 days/week
Unit sludge supplyup to 78 gpm
up to 3,276 lbDS/h
Inlet sludge ds content8.4 %
Cake ds content26.5 %
Polymer consumption16.5 lb/ton DS
Tss concentration in filtrate350-500 ppm
Ds capture rateup to 99.4 %

 

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 EKOTON offered sludge dewatering technology based on Multi-disc Screw
Press Dehydrator MDQ-353 C.

Results

Type of sludgeaerobically stabilized MBR sludge
Operating time8 h/day, up to 5 days/week
Unit sludge supplyup to 12 m3/h
up to 230 kgDS/h
Inlet sludge ds content2%
Cake DS contentapprox. 18-20%
Polymer consumption4.0 g/kg DS
TSS concentration in filtrate50 ppm
DS capture rate99.7%

 

 

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. (EKOTON 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 EKOTON 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 Ekoton 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 Ekoton 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 EKOTON 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 EKOTON 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 Ekoton 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.