Manufacturers Offer Innovations in Biosolids Management

Many products to manage biosolids

Greener solution

Byo-Gon from Byo-Gon Inc. is a blend of natural plant alkaloids that accelerates the wastewater treatment process using existing bacteria. The alkaloids lower BOD and TSS, reduce oil, grease, and sludge, eliminate odors, and reduce sludge volume in ponds and lagoons.

Xeronine, the cell growth accelerator alkaloid, restarts enzymatic processes and promotes more rapid cell growth, overcoming limiting conditions. Injecting the alkaloid causes a shift from anaerobic fermentation to anaerobic respiration with more rapid growth and activity of facultative anaerobes. It also increases the activity of anaerobic and aerobic organisms.

Using advanced second-generation adenosine triphosphate measurement technology to confirm increased biological activity, operators can customize application dosages and treatment protocols depending on biological health. The product requires no special handling or equipment. It is nontoxic, nonflammable, noncorrosive, organic and biodegradable. 888/296-4661;

Isolated solenoids

Rotary shaft style valves from Clark-Cooper isolate the solenoid components from the process fluid, enabling them to handle extremely corrosive dirt, or viscous fluids. The valves, available in stainless steel, hastelloy, and monel, can be custom built to pipe sizes from 1/2-inch NPT to 6-inch 150 number flanges. Solenoid enclosures are rated NEMA 4X and explosion proof. Options include position switches, manual override, and emergency trip with manual reset. 856/829-4580;

Waste disposal

The Level Lodor from JDV Equipment Corp. covers standard dumpsters used for hauling processed material. The unit helps contain odors and facilitates even distribution, which increases the fill percent without manually leveling the waste. When stored outdoors, enclosed dumpsters control pests better, protect the contents from the environment, and free critical or limited indoor square footage. 973/366-6556;

Complete system

The ISAM (integrated surge anoxic mix) sludge reduction system from Fluidyne Corp. has a constant level anaerobic basin, surge-anoxic-mix (SAM) tank, and aeration basin. The basin, with BOD, TSS, and nitrogen removal, reduces sludge as much as 85 percent in integrated systems.

Wastewater enters a covered anaerobic reactor for pretreatment, sludge thickening and sludge destruction. Complex organic solids undergo hydrolysis to simpler soluble organics, which pass to the SAM tank. It regulates flow and provides an anoxic environment for rapid denitrification. The conditioned mixed liquor then passes to the final aerobic tank for completion of BOD and nitrogen removal and solids separation. A proprietary control system paces the operation, producing tertiary water quality. 319/266-9967;

Solar drying

Once unloaded in the greenhouse, the automated Soliamix system from Kruger Inc., a Veolia Water Solutions and Technologies company, forms dewatered biosolids into triangular windrows, maximizing the drying surface area. The mechanism turns the windrows at regular intervals, aerating the biosolids and promoting fermentation, which generates a high temperature increase (122 to 140 degrees F) to accelerate the drying. The system produces 45- to 90-percent dry solids content, or a 3-to-5-fold reduction of final to initial quantity. 919/653-4574;

Rotary fan press

Available in four sizes, the rotary fan dewatering press from Prime Solution Inc. operates continuously at 1 rpm. Totally enclosed compact skid and mobile models are cost effective, space saving, simple, and efficient. Operators have total control of the process flow inside the press. Automated cleaning and minimal parts expedite maintenance. 269/673-9559;

Faster digestion

BIO ENERGIZER biostimulant from Probiotic Solutions accelerates the digestion of organic matter in wastewater sludge. The product is a scientific formulation of organic acids, buffers, natural biological systems, nutrients and energy systems that balance the natural microbial ecosystem. It increases the bio-oxidation of wastewater, creating a “wet burn” that reduces sludge and odor levels in wastewater treatment plants and lagoons. The product can be used to break down sludge while the lagoon stays online. Reduced sludge volume means lower mechanical handling and hauling costs. The formulation also reduces grease problems in sewer lines and lift stations. 800/961-1220;

Mixing system

The Rotamix process mixing system from Vaughan Co. combines uniform and vertical rotation mixing assemblies to optimize solids contact. The dual-zone mixing pattern vertical-axis vortex improves volatile solids reduction, assures uniform mixing velocities, increases gas production, reduces sludge volume, and saves energy during non-peak hours. A chopper pump prevents clogging.

The system allows continued mixing until the tank is empty, and reduces maintenance by eliminating all rotating equipment within the tank. It also allows the use of a single mix pump for multiple tanks and transfer. Computational fluid dynamics analysis confirms optimum mixing performance before the installation, while process testing reaffirms an even distribution of solids once the installation is complete. 360/249-0722;

Polymer blending systems

The dynaBLEND pre-engineered liquid polymer blending system from Fluid Dynamics Inc. has diaphragm metering or progressing cavity pumps. Hydrodynamic or mechanical mixing provides polymer activation technology paired to particular process and flow demands. Simple manual systems to fully instrumented PLC-based units introduce activated polymer solution from 30 to 21,000 gph. Standard or custom dry preparation systems with capacities to 2,200 pounds per day are available. 888/363-78863; www.

One-step process

Sludge Mate container filters from Flo Trend Systems dewater digester sludge, septic tank and grease trap waste, lagoon sludge, residual wastewater from manufacturing processes, sump bottoms, and industrial waste. Units, from 3 to 60 cubic yards, are permanently mounted on a tipping stand. A hydraulic cylinder raises the box and dumps the contents into a standard roll-off container. The process is controlled by a remote handheld device. 800/762-9893;

Ragless impeller

Lightnin, an SPX brand, has a Clean Edge impeller that remains free of fibrous debris while demonstrating steady power draw and delivering the required mixing performance. 888/649-2378;

Process control valves ­

Two-way stainless steel solenoid valves from Magnatrol Valve Corp. handle treated wastewater effluent at plants processing biosolids. Fitting 1/4- to 3-inch pipes, the valves are full port, require no differential pressure to open, and are serviced in the line. They have packless construction with continuous duty class-H high temperature coils for AC and DC voltages. The valves come normally open or normally closed with 150- and 300-pound flanged connections. 973/427-4341;

Biosolids pump

Piston pumps from Schwing Bioset Inc. pump dewatered biosolids from 10 to 50 percent solids at 1 to 300 gpm/1,800 psi. A pressure sensor in the transition between the screw feeder and pump, and a proprietary sludge flow measuring system, automatically synchronize operations regardless of pump speed and biosolids consistency. 715/247-3433;

Sludge conditioning

The FTXL belt filter press from Frontier Technology Inc. continuously dewaters using two porous belts threaded through rollers. Presses from 12 to 127 inches have a gravity sludge-conditioning zone, radial wedge section, and optimal pressure roll section. Standalone or skid-mounted units are made of 304 stainless steel. Auxiliary equipment includes nip rolls, polymerization systems, pH balancing systems, sludge infeed, and discharge with fully integrated controls. 269/673-9464;

Polymer blender

The Polyfeeder emulsion polymer blending system from Pulsafeeder Inc. handles the diverse mixing requirements of complex emulsion polymers. Its anti-siphon, anti-clog injection lance separates the polymer from the water flow, which helps close the valve on the lance, yet allows the membrane to accommodate the occasional solid.

A clear, high-energy mixing chamber lets operators monitor the polymer blending. From there, a diminishing energy-blending cascade hydrates the molecules without damaging the extending polymer chains. The blending system has a stainless steel frame and works with solenoid, gear pump, or progressive cavity pump configurations. 585/292-8000;

Reusing waste

Rectangular Square Cube heat exchangers from DDI-Heat Exchangers Inc. have compact, rectangular flow channels that minimize plugging. Sludge-to-sludge heat recovery exchangers, hot water-to-preheated sludge, and cold water-to-processed sludge heat exchangers are available. Systems using sludge-to-sludge heat recovery could see a payback in four to seven months.

The units have a large heat transfer surface, small footprint, more turbulence, 3-inch gaps to limit sludge blockage, full access to internals via doors, davit arms on swinging doors, optimum height for fast flow, realistic viscosity calculations, thick layers against abrasion (0.25- to 0.375-inch minimum), and a backup that uses the sludge-to-sludge heat exchangers for the water-to-sludge process. All are low maintenance. 514/696-7961;


Skid-mounted screw presses from FKC Co. Ltd. help smaller plants find simple and effective sludge dewatering solutions. The skids have a screw press, flocculation tank, control panel, sludge pump, and polymer system wired and piped for a true plug-and-play installation. The custom-designed skids dewater any type of sludge, septage, or grease trap waste. The Class A system simultaneously dewaters and pasteurizes biosolids. 360/452-9472;

Sludge heater

The PSX inline sludge heater from ProSonix has no hot surfaces, eliminating plugging and fouling. The steam, injected internally, assures rapid condensation for smooth, stable operation and complete mixing. The diffuser delivers 360 degrees of steam into the sludge for more uniform heating.

The inline sludge and slurry flow handles high volumes of solids, large particulates, and high-viscosity flows. A low liquid pressure drop of 1 to 2 psig across the heater reduces energy demand, enabling smooth integration with the pumping system. 800/849-1130;

Inclined press

The fully automatic, energy-efficient RoS3Q inclined screw press from Huber Technology has a slow rotating auger that handles thick, difficult sludge, producing the desired cake solids, polymer consumption, and capture rates. Intermittent wash cycles and frugal polymer dosing assure low cost of ownership. 704/949-1002;

Polymer saver

The Hi-Pass sludge mixer from Komax Systems Inc. mixes polymer solution into sludge flows before the dewatering process, resulting in polymer savings of more than 25 percent. The element is resistant to fouling or clogging, since its edges are smoothly contoured with a large radius, eliminating corners that trap solid or fibrous materials. The design passes individual solid items with a diameter of one-half the sludge mixer. The mixer is installed on the feed line to belt fiber presses, plate filter presses, gravity belt thickeners, centrifuges, and pressure or vacuum filters. 800/826-0760;

Improves performance

PolyClear CD5804, a cationic dry polymer from Clear-brook Inc., is a higher molecular weight, more structured product than previously offered. The free-flowing powder makes it down into solution faster with a better distribution of charge density for sludge dewatering, thickening, flotation, and clarification. 800/290-9331;

Headworks Offers BOD Removal Washer

The TurboWash screenings washer from Headworks Inc. allows biological material to be treated at the plant, not bagged as screened solids and taken to the landfill. The washer works best in cold climates, or where the collection system is a short distance from the screening process. The agitator creates a turbulent mixing zone in the channel or tank preceding the screening equipment. As wastewater enters and mixes in the turbulent zone, the agitator loosens and emulsifies the BOD material attached to the screenings, allowing soluble and fine particulates to pass through the openings and into the effluent stream. Additionally, the device intermittently runs in reverse, pushing retained solids back into the turbulent zones to dislodge more biological particles. 713/647-6667;

Lakeside Offers Septage Acceptance Plant

The self-contained, fully automated Raptor septage acceptance plant from Lakeside Equipment Corp. removes debris and inorganic solids passing through bar screens. A rotating rake on the heavy-duty, three-plane fine screen passes through the full depth of the basket bars, removing debris from the screening area. The rake deposits the material into the central screw conveyor hopper for washing, transport and dewatering. 630/837-5640;


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