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

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

EKOTON 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 EKOTON 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

Type of sludgeMixture of waste activated sludge
and DAF sludge
Unit Sludge Supply10.8 m3/h (47.6 GPM)
216 kg DS/h (476 lb DS/h)
Feed Sludge DS Concentration1-2 % (up to 4 %)
Cake DS Concentration16-17 %
Operation Time16-20 h/d
Average Polymer Dose5 g/kg DS (20 lb/ton DS) of liquid
polymer

Case Study: Municipal WWTP (Ozd, Hungary)

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, EKOTON specialists actively assisted in the development of sludge dewatering scheme.

Results

Type of sludgeThickened waste activated sludge
Unit Sludge Supply7-7.5 m3/h (31-35 GPM)
140-150 kg DS/h (309-331 lb DS/h)
Feed Sludge DS Concentration2 %
Cake DS Concentration18-20 %
Operation Time6-7 h/d
Average Polymer Dose4-6 g/kg DS (8-12 lb/ton DS)
Unit Daily Power Consumption9-11 kW*h

Case Study: Municipal WWTP (Medgyesegyháza, Hungary)

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, EKOTON specialists actively assisted in the development of sludge dewatering scheme.

Results

Type of sludgeMixture of primary sludge and
waste activated sludge
Unit Sludge Supply0.5-1.3 m3/h (2.2-5.7 GPM)
16-18 kg DS/h (35-40 lb DS/h)
Feed Sludge DS Concentration2 %
Cake DS Concentration18 %
Operation Time5-6 h/d
Average Polymer Dose3.5-4 g/kg DS (7-8 lb/ton DS)
Unit Daily Power Consumption4-5 kW*h

Case Study: Municipal WWTP (Karád, Hungary)

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, EKOTON specialists actively assisted in the development of sludge dewatering scheme.

Results

Type of sludgeThickened mixture of primary
sludge and waste activated
sludge
Unit Sludge Supply0.5-1.3 m3/h (2.2-5.7 GPM)
18-20 kg DS/h (40-44 lb DS/h)
Feed Sludge DS Concentration1.5-4 %
Cake DS Concentration18-20 %
Operation Time6-8 h/d
Average Polymer Dose3.5-4 g/kg DS (7-8 lb/ton DS)
Unit Daily Power Consumption5-6 kW*h

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

EKOTON 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.

ekoton multi-disk Screw press Kanev

Results

Type of sludgeDAF sludge
Unit Sludge Supply6-7.5 m3/h (26-33 GPM)
700-750 kg DS/h (1540-1650 lb DS/h)
Feed Sludge DS Concentration8-12 %
Cake DS Concentration33-40 %
Operation Time14-18 h/day
Average Polymer Dose2.2 g/kg DS (4.4 lb/ton DS)
Unit Daily Power Consumption35-45 kW*h

ekoton multi-disk Screw press Kanev

Case Study: Gorno-Altaysk Municipal WWTP

SIZE OF WWTP 10 000 m3/day (2 641 000 GPD)
END USER Water and wastewater utility provider, OAO Vodokanal
CUSTOMER OOO SibKapStroy
START OF OPERATION August, 2017

Issue

In Gorno-Altaysk WWTP, instead of mechanical sludge dewatering, sludge was dewatered in outdated sludge drying beds. Malodor from sludge drying beds disturbed residents from nearby leaving area, therefore regional authorities made a decision to fund the construction of a new sludge dewatering facility.

Solution

Based on national requirements, 3 units (2 duty and 1 stand-by) of MDQ-352 C were installed.

Results

Type of sludgeMixture of primary sludge and
waste activated sludge
Unit Sludge Supply3-3.5 m3/h (13-15 GPM)
150-160 kg DS/h (330-350 lb DS/h)
Feed Sludge DS Concentration4-6 %
Cake DS Concentration23-27 %
Opetarion time10 h/d
Average Polymer Dose3.5-4.5 g/kg DS (7-9 lb/ton DS)
Unit Daily Power Consumption18 kW*h

ekoton multi disk screw press gorno-altaysk

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

EKOTON 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 sludgeMixture of waste activated sludge
and anaerobically digested DAFsludge
(nearly 50:50 %)
Unit Sludge Supply0.10–0.22 m3/h (0.44–0.97 GPM)
3–6 kg DS/h (6.6–13.2 lb DS/h)
Feed Sludge DS Concentration2.86–2.99 %
Cake DS Concentration16.3–19.5 %
Average Polymer Dose4.0–8.4 g/kg DS
(8.0–16.8 lb/ton DS)
Filtrate SS Concentration40–500 mg/l (40–500 ppm)
Solid Capture97.3–99.9 %

ekoton multi disk screw press cebrob

Case Study: Herzliya WWTP, Israel

SIZE OF WWTP 22 000 m3/d (5 812 000 GPD)
START OF OPERATION November, 2013

Issue

Soon after the reconstruction of WWTP and launching a new biological reactor with EPDM membrane disc diffusers in 2009, the aeration system appeared to be highly uneconomical. In order to keep the constant dissolved oxygen DO concentration of 1.5-2.0 mg O2/l in the reactor, three blowers with capacity of 4500 m3/h each had to work continuously almost all the time.

Solution

Because of its low economic efficiency and tearing of some diffusers noticed at the beginning of 2013, it was decided to replace the existing aeration system. EKOTON company installed 600 m (1970 ft) of highly efficient PE tube air diffusers with high mechanical strength and longevity. Previously installed air diffusers were replaced gradually section by section.

Results

Bioreactor Size3 sections, 6000 m3 (1,6 MG) each
with an operating height
approx. 6 m
Type of biological treatment processAerobic suspended growth
DO concentration2.0 mg O2/l
Supply air flow rate4500-9000 m3/h (2650-5300 cfm)

End User’s Comment

After we launched the first section of the reactor with EKOTON tube air diffusers, the quantity of consumed air as well as the energy was significantly reduced. Wastewater saturation with oxygen became more stable and uniform throughout the whole basin. After the old aeration system in all reactor sections was replaced with EKOTON air diffusers, the quantity of consumed air was reduced up to 3
times. From November 2013 so far there has been no diffuser breaking detected or any other problems occurred.

 

Case Study: Modernization of the Primary and Secondary Clarifiers (Slupsk, Poland)

PROJECT Modernization of the primary and secondary clarifi ers
CUSTOMER Wodociągi Słupsk Sp. z o.o.
OBJECT WWTP Slupsk, Poland
COMMISSIONING March, 2017

Introduction

The wastewater treatment plant is located in the northern part of the Słupsk city, on the right bank of the Słupia River. It is a mechanical-biological treatment plant, adapted for deep removal of biogenic compounds in a threephase, modified Bardenpho process, supplemented with a predenitrification chamber. The capability of the treatment plant corresponds to 200,000 population equivalent, and the average daily fl ow of about 19 647 m3/day.

In November, EKOTON PRODEKO-EŁK Sp. z o.o. has been selected as a General Contractor and signed an agreement with Słupsk Waterworks for the task: “Delivery of a dewatering centrifuge and scrapers to the municipal sewage treatment plant in Słupsk at ul. Sportowa 73 – task no. 2 – Delivery of the scrapers along with the performance of necessary construction, assembly and installation works.

As part of the contract, the following facilities were modernized:

  • Preliminary settling tanks with a diameter of D = 34m – 2 sets
  • Secondary clarifiers with a diameter of D = 40m – 2 sets

The modernization included dismantling of the old scrapers, delivery, assembly and kick-start of the new ones and also commissioning and warranty tests.

Initial Stage

The preliminary settling tanks were built in the first stage of construction of the wastewater treatment plant in 1986 and equipped with radial scrapers according to the solutions used in the 1970s. As a result of the modernization of the sewage treatment plant in 2006-2009, one of the primary settling tanks has been adapted to the retention and overflow function. The technical condition of the scrapers at the initial stage of the project was very poor and qualified them for replacement. In case of secondary clarifiers,
the situation was similar, with the diff erence that the facilities were built in 1978 and modernized in 2001.

Project Goals

The main goal of the signed modernization project was to improve the efficiency of sludge removal from both primary and secondary clarifiers.

In order to solve the problems and ensure stable and proper conducting of the technological process in both the sewage and sludge part, it was necessary to replace the scrapers in two primary settling tanks with models ensuring greater efficiency and reliability. Ultimately, this meant to improve the balance of the initial and excessive sludge, and thus increase the biogas production and reduce the operating costs of the treatment plant. Also the scrapers had to be replaced on the two existing secondary clarifiers. Part of the modernization was to supply the equipment with so-called side scraper, similar to ones mounted on two clarifiers that were built in 2008-2009.

Project Implementation

The modernization project of the preliminary and secondary clarifiers has been carried out between 15th of October 2018 and 28th of March 2019 and consisted of:

  • disassembly of the old (existing) scrapers and placing them in the containers provided by the INVESTOR,
  • preparation and delivery of the new scrapers made entirely from AISI 304 (1.4301) steel, sized to existing facilities,
  • installation of the new scrapers in an alternating system, i.e. first preliminary, then secondary, then again preliminary and finally secondary clarifier
  • technological start-up of each of the settlers and putting them into operation.

Results and Conclusions

As a result of modernization of the preliminary settling tanks, by installing new scrapers, problems related to ensuring stable and correct conducting of the technological process in both the sewage and sludge part were solved. The new scrapers are characterized by greater efficiency and operational reliability, which significantly contributed to the improvement of the initial and excessive sludge balance, and thus to increased biogas production and reduction of the operating costs of the treatment plant.

However, as a result of replacing scrapers in the existing secondary clarifiers with the devices equipped with so-called side-scraper, the removal of activated sludge excess to the surface of the settling tank in relation to normal operating parameters has been eliminated. This, in turn, resulted in a decrease of the total suspended solids discharged with sewage,and with it the load of carbon, nitrogen and phosphorus in the treated sewage to the Słupia river.

By replacing scrapers with ones equipped with the catching scrapers, the duration of active sludge retention within the secondary clarifiers has been shortened, which has prevented the formation of anaerobic conditions and secondary biological dephosphorization, and as a consequence – the process of secondary release of the orthophosphates into the wastewater from the activated sludge accumulated at the bottom.

Case Study: Modernization of Sewage Treatment Plant (Myszkow, Poland)

PROJECT Modernization of the secondary clarifier
CUSTOMER Schumacher Packaging Zakład Grudziądz Sp. z o.o.
OBJECT Local WWTP, The Paper Factory in Myszków
COMMISSIONING January, 2019

Introduction

The Paper Factory in Myszków was founded in early 1894 year, where at the time it was the largest paper production plant in Poland. In 2016, the factory became part of the Schumacher Packaging group. To ensure high quality standards and increased paper production plant modernization project has began. One of the main tasks of the project was to increase the throughput of the existing sewage treatment plant located on the production plant premises. In July 2018, PRODEKO-EŁK Sp.zo.o. (EKOTON Industrial Group) was chosen as the main contractor for the modernization of the secondary clarifi er at the Sewage Treatment Plant of the paper factory in Myszków.

Modernization Purpose

The aim of the project was to replace the existing radial sludge scraper and the drainage system of the secondary clarifier with a diameter of 39.4 m. The mounted device is designed to ensure high effi ciency of sludge and floating parts removal.

Initial Stage

The modernized secondary clarifi er was not exploited for many years. It was equipped with a radial sludge scraper made from black steel and also concrete drainage troughs. The plan was to remove the scraper with troughs, repair of concrete elements of the clarifier, assembly of a scraper along with the trough system made from stainless steel.

Project Implementation

As part of the contract, a ZGRwt-39.4 type of a radial scraper has been delivered with a drainage trough system. The scope of work included preparation of the documentation to fabricate the parts adapted to the size of the settling tank as well as assembly and technological commissioning of the supplied devices.

Results and Conclusions

The use of modern technological solutions in the sludge scraper designing ensured high work efficiency, energy efficiency and reliability. As a result of the installation of the new scraper hasthe following goals have been achieved:

  • ensuring effective removal of the sludge and floating parts;
  • reduction of electricity consumption;
  • ensuring stable and trouble-free operation.