Reference of Astrvodokanal MUE about the Operation of the EKOTON Slide Gates

From reference Astrvodokanal MUE:

The slide gate of stainless steel with the dimensions of 2330*2200 mm was installed on the distribution bowl of primary clarifiers of the Northern sewage treatment facilities in May 2009. For the time of operation, the personnel has noticed such features as ease of installation, ease of the manual operation, resistance of the material of the gate to corrosion, compaction equipment  ensuring the leak-free shutoff of the channel, ease of maintenance and operational reliability.

CASE STUDY. Catenary Screen. Olecko, Poland

Installation of a Catenary Screen and a Screenings’ Wash Press at the Sewage Pumping Station (Olecko, Poland)

PROJECT Modernization of the sewage pumping station in Olecko
INVESTOR Przedsiębiorstwo Wodociągów i Kanalizacji Sp. z o. o. in Olecko
OBJECT Sewage pumping station at Batory street
STARTING December 2018 – June 2019

Plans and Modernization Goals

According to the modernization plan of the pumping station building located at Batory street in Olecko delivery of equipment was divided into two stages:

  1. December 2018 – delivery and installation of the mechanical catenary screen bar type RKC 0827 with
    6 mm clearance.
  2. June 2019 – delivery and installation of SCP 2020 type screenings wash press with Q = 2 m3/h capacity along with the necessary supporting structure.

The purpose of the modernization of the main pumping station was to increase the efficiency of
removing solid parts from inflowing sewage, as well as to reduce the amount of generated screenings
and their hydration.

State from before the Modernization

City’s sewage is directed to the pumping station’s main collecting chamber, and then goes to the grate, which is mounted in a channel with dimensions Bk = 950 mm, Hk = 2000 mm. Before the project, problems related to the presence of the wet wipes occurred, which caused diffi culties in normal gate operation and its blocking. Screenings collected on the grating were transported to the screw conveyor, through which they were transported to the collecting container. The shiſt operator then had to transport the container outside of the building and load it onto the removal vehicle. The main problems associated with the operation of the old devices were:

  • large costs related to the handling and cleaning of the grate from wet wipes and the removal of screenings with a high water content;
  • problems related with stopping the grate too oſten;
  • pump failure and operational problems at further stages of purifi cation that were caused by insufficient efficiency of solid impurities removal.

Results

Aſter analyzing the situation at the pumping station, specialists from EKOTON Industrial Group have decided to install a grid prototype to check the efficiency increment comparing to the old device. The RKC 0827 catenary screen bar has been installed at the pumping station, the very first to be produced at our plant. Aſter three months of operation, the management of the plant has decided to buy back the installed device and order SCP 2020 screenings wash press.

As a result of installation of the new equipment, the following results were obtained:

  • Thanks to the use of an innovative chain mechanism that allows efficient collection and extract of a various types of wastes and wet tissues from sewage, the number of failures associated with grid jams has been reduced;
  • The number of removed screenings has doubled due to the use of a grid with a clearance of s = 6 mm within the strainer;
  • The weight of removed screenings has been reduced over three times, thanks to the pressing and rinsing them on the SCP wash press;
  • The time necessary to operate the equipment has decreased by over 95% due to the use of a full automatic mechanical treatment line.

In addition, the following upsides related to equipment replacement should be noted:

  • A significant decrease in the number of failures and repairs at further stages of wastewater and sludge treatment;
  • Total elimination of the need to work in a manual mode when removing screenings from grates.

Conclusions

The modernization of the mechanical sewage treatment system at the pumping station allowed the organization of an effective treatment system for large and medium solid wastes, using a special construction of the grid chain. Screenings, removed from the sewage, are washed to reduce their organic content and pressed on a wash press to reduce their volume and weight.

The installed mechanical cleaning line works fully automatically and does not require constant presence of a personnel. The work of the mechanical wastewater treatment complex has fully met the requirements and ensured stable and trouble-free operation at subsequent stages of treatment.

 

CASE STUDY. Mechanical treatment. Augustow, Poland

Project brief

PROJECT – Modernization of the mechanical wastewater treatment facility

CLIENT – Wodociągi i Kanalizacje Miejskie Spółka z o. o. w Augustowie

OBJECT – Augustów WWTP LOCATION Augustów, Poland

COMMISSIONING – January 2017.

The Municipal Wastewater Treatment Plant is situated in the southern part of Augustów. Its capacity is 10 000 m3/d.

In 2016 EKOTON Company was chosen to implement investment project for the modernization of the main sewage pumping station which located at the Augustów WWTP. Within the project, the following equipment for mechanical wastewater treatment facility was produced, installed and commissioned:

  1. Rake bar screen RKE;
  2. Screw compacting press SCP;
  3. Slide gates of ZSg type;
  4. Facility control system.

The aim of the pumping station modernization was to increase the efficiency of mechanical impurities removal and waste thickening with full automation of the process.

Initial state:

In accordance with initial project, wastewater was fed via two collectors into the pumping station, where it was mechanically treated on the screens with 25 mm mesh.

Screen cloth cleaning was carried out manually by the personnel as it became clogged. The removed waste was fed into the container for its further lifting by means of lifting device to a zero mark (ground surface) into a receiving tank.

The main problems which were occurring during operation of the old equipment are following:

  • The need of constant monitoring of the screen cloth to prevent pump station flooding and emergencies;
  • High cost of the screen cloth cleaning and further waste transportation into receiving tank;
  • Pumping equipment and further stages emergencies occurring due to insufficient removal of mechanical impurities.

ekoton rake bar screen augustow poland

Project implementation:

One of the key complication during the project implementation was installation of equipment in existed pumping station among which:

The building was not designed for installation of equipment with length of more than 2,5 m, thus there was a requirement to produce rake screen with 6 m length from separate parts with length of 2 m max. Every part was mounted on supporting structure which were brought together inside the pumping station for further parts assembling inside the building.

Results:

The modernization project allowed to achieve the following results:

  1. After the new rake screens installation with 5 mm mesh, the amount of removed waste was increased by 2 times.
  2. Due to the partial waste dewatering with screw compacting press SCP, its overall mass has decreased more than 3 times.
  3. The necessary time for equipment maintenance reduced more than by 95 % due to its replacement on the new one which operates in fully automatic mode.

It should be also noted the additional advantages achieved by mechanical wastewater treatment equipment replacement:

  • Considerable decreasing of emergencies and scheduled repairs on the next stages of wastewater treatment technological process.
  • Full elimination of the need for manual labor which were necessary for waste removal earlier. It has significantly improved not only the sanitary condition at the pumping station, but also the labor conditions of the personnel.

The quantity and mass data of the waste removal from the screens in period from 2015 to 2017 is given below in figures. The pumping station modernization was carried out in the fourth quarter of the 2016 and in January 2017, the new mechanical treatment facility was launched; the data from that year indicates significant treatment parameters improvement.

Reliable screen and screw press design provide the treatment facility with a possibility of round-the-clock and trouble-free operation of equipment in automatic mode. Daily maintenance and inspection requires no more than 15 min.

ekoton rake bar screen augustow poland

The amount and mass of wastes removed from the screen in the period from 2015 to 2017

ekoton rake bar screen augustow poland

Time for equipment maintenance in minutes per day

Conclusions:

The mechanical treatment facility modernization at the sewage pumping station allowed to organize efficient wastewater treatment from large and average impurities. Removed wastes are rinsed for organic part reduction and are thickened on the screw press for its volume and weigh reduction. Installed mechanical treatment facilities operate in fully automatic mode and do not require constant personnel presence. The mechanical treatment process improvement allowed to solve all of the set challenges and assured stable and uninterrupted wastewater treatment process operation.

Case Study: Radevormwald Municipal WWTP

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

EKOTON 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.

ekoton multi disk screw press radevormwald

Results

Type of sludgeThickened and anaerobically
digested mixture of primary and
waste activated sludge
Unit Sludge Supply0.09–0.26 m3/h (0.40–1.15 GPM)
2.4–6.8 kg DS/h (5.3–15.0 lb DS/h)
Feed Sludge DS Concentration2.60–2.70 %
Cake DS Concentration19.1–25.0 %
Average Polymer Dose5.5–9.7 g/kg DS
(11.0–19.4 lb/ton DS)
Filtrate SS Concentration60–700 mg/l (60–700 ppm)
Solid Capture97.9–99.8 %

ekoton multi disk screw press radevormwald

Reference of Wastewater Treatment Plant, Mezdra, Bulgaria

Industrial Parts Ltd., with address South Industrial Zone, P.O. 24, 6100, Kazanlak, Bulgaria, issued this Reference to EKOTON Industrial Group for successful and professional cooperation with this company.

In March 2015 at the Wastewater treatment plant in Mezdra (Bulgaria) EKOTON Industrial Group delivered and commissioned the following equipment:

  • Rake type bar screen RKE with double level sensor in the channel – 1 pcs
  • Combined mechanical treatment module M-Comby (600 m3/h) – 1 pcs
  • Sludge scraper for secondary sedimentation tank – 2 pcs
  • Central driven picket type stripper – 1 pcs
  • Slide gates (manual) – 5 pcs • Slide gates (with electric drive) – 2 pcs
  • Mechanical sludge dewatering belt filter-press – 2 pcs
  • Dewatering sludge screw conveyer KVE – 1 pcs

Since the launch of this complex all kind of equipment works stably providing a high degree of wastewater treatment. With insure qualitatively affected on the operation of wastewater treatment plant in general.

Installation of the mechanized screen allowed to increase the efficiency of the deterrence of waste and their extraction from wastewater.

The complex shows high reliability and minimum maintenance costs.

This equipment is well designed and convenient to operate. Also on the stage of mechanical sludge dewatering we used two belt filter press PL-06C with capacity 6 m3/h. For all operation period equipment under trademark EKOTON showed effective and reliable work, high corrosion resistance, low energy consumption.

Reference of Wabra Contractor, Zahran, Kingdom of Saudi Arabia

By here with we WABRA CONTRACTOR EST note that during the cooperation with the company EKOTON it has acquired a reputation as the organization of highly professional specialists, which knows subtleties of the operation of wastewater treatment facilities and develops technologies of the highest world level. We, as main contractor, are glad to work with products that are manufactured at this enterprise.

In July 2016, 2 ZSP sludge scrapers with the diameter of 10+8 m were delivered, installed and put into operation in wastewater treatment plant 1500 m3/day for Air Forces Defense in Zahran, Kingdom of Saudi Arabia.

All installed equipment has been operating stably and smoothly from 2016. One of the main advantages of this type of equipment is the serviceability and reliability, Sludge scrapers are structurally designed for a long-term trouble-free operation. No wear of moving parts are observed.

The suggested design is proved to be stable, rigid and reliable in operation. Bridge on the sludge scrapers has central drive and mounted on two independent supports that are placed out of the clarifiers. Such construction allows not carrying and weight on GLS tank where scrapers must operate.

The cleaners of walls and edges of sludge scrapers are well designed, convenient in adjustment and don’t cause dissatisfaction. All the electric part of the drive runs smoothly in various temperature conditions.

WABRA CONTRACTOR EST thanks the team of EKOTON for the high quality equipment and careful attention to the needs and requirements of our enterprise during the production, delivery and adjustment of sludge scrapers.

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 EKOTON

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

Since the Multi-Disc Screw Press MDQ-353C was launched by EKOTON 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 EKOTON 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 EKOTON

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

Since two Multi-Disc Screw Presses MDQ-353C were launched by EKOTON 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 EKOTON. During the operation of the equipment it turned out that:

  • inlet sludge with dry solids content of 1 % after the EKOTON 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

Case Study: Fish Processing Plant (Santiago, Chile)

In 2017 the dissolved air flotation complex for local wastewater treatment of fish processing plant in Los Lagos region had been installed by our partner Aguas Sipra S.A., including such equipment:

  • Fine drum screen RMB TP 6/6,
  • DAF unit FT-25,
  • Tubular flocculator,
  • Saturation system for white water preparing,
  • Pumps for the complex,
  • Automation system for the complex, including control system with sensors.

Ekoton DAF-Unit Flotator

Ekoton DAF complex has customized design for the particular application. The object’s features required high amounts of dissolved air to be fed into wastewater to tackle high loads of contaminants. The complex’s capacity is 18 m3/h.

The efficiency of the complex is as follows:

Los Lagos, Chilie Project Data

ParametersInput concentration, [mg/L]Efficiency, [%]Output concentration, [mg/L]
Total suspended solids (TSS)6,54195327
Biochemical Oxygen Demand (BOD5)10,696406,418
Nitrogen, Total Kjeldahi (NTK)72620581
Oil and Grace (O&G)9759098
Dissolved solids (DS)816032

In the result the customer got specially designed wastewater treatment system which is fully solves effluent requirements. In this project Ekoton confirms advantages if it’s developed DAF technology, as well as appropriateness of approach to use just the highest quality components available. Equipment operates steady well, which is really important for such a distant projects.

 

Reference of WWTP, Herzliya, Israel

During reconstruction of sewage treatment facilities in Herzliya in 2009 a new biological reactor, consisting of three sections of 6000 cubic meters each with an operating height about 6 m, was installed. Air is pumped by means of three air blowers of 6000 cubic meters each through disc diffusers.

Soon after launching it was obvious that all system is highly uneconomical. In order to keep oxygen concentration at 1.5/2 mg/l we had to continuously work with two-three air blowers (9000-13000 cubic meters) for the whole reactor and it was not always possible. After in the beginning of 2013 rupture marks were detected on some diffusers we decided that it is time to replace them by somewhat more effective. We issued a tender, and one of many offers we have received for consideration contained information about aerators of EKOTON Company.

There were a lot of cons: unknown company, lack of experience of work in Israel, disagreement of designers and technical advisors.

However, despite of some concerns and doubts we decided to install these particular aerators. This product attracted us by its simple and reliable design, price, mechanical strength, longevity, 8-year warranty, no need for service checks, easy and quick installation, and also a very tempting offer of company management: possibility to pay the most part of the amount only in case if we are fully satisfied by their operation, which can be done even in six months.

In November 2013 we launched the first section of the reactor with EKOTON tubular aerators.

Reality has exceeded our most optimistic expectations. Quantity of used air has significantly reduced as well as quantity of consumed energy.

Saturation of liquid with oxygen has become more stable and homogenous in the whole basin. In 2 months instead of previously agreed 6 months of observation of aerator performance it was decided to replace diffusers installed in two remaining sections by EKOTON aerators, which was done in stairstep order.

Today the whole reactor (3 sections) is functioning with installed EKOTON aerators, and we are extremely satisfied with obtained results. Required oxygen concentration (about 2 mg/l) is kept in all sections with much less energy consumption. The most part of a day (14-16 hours) we use one air blower (4500 cubic meters) and during peak hours (8-10 hours) two air blowers (instead of 2-3 air blowers used previously, before replacement of aerators). I send you the reactor operation schemes made before and after replacement of aerators.

ekoton tube air diffusers israel