Solids Management

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High-quality cake

The Prime rotary fan press from Prime Solution Inc. produces cakes averaging 18 to 24 percent solids for a range of applications. The unit, with a slow rotational speed of 1 rpm, has a continuous dewatering process that is totally enclosed, eliminating odor and reducing corrosive exposure to nearby equipment.

 

Self-contained skid, mobile and modular units require little supervision and have a semi-automated self-clean cycle. Units are compact with footprints from 40 to 70 square feet. Varying models produce 100 to 2,000 pounds of dewatered biosolids per hour. Single or dual presses are available with 18-, 24-, 36- and 48-inch screens.

 

The process flow is controlled from inside the press. Material moves slowly toward the outlet, forming a cake. An adjustable two-piece pneumatic restriction plate controls pressure at the outlet. The frictional force of the slow-moving filter plates and controlled outlet restriction produces cakes as dry as 60 percent solids. 269/673-9559; www.psirotary.com.

 

Sludge reduction

The ISAM sludge reduction system from Fluidyne Corporation incorporates a constant-level anaerobic basin, followed by a surge/anoxic/ mix (SAM) tank, and an aeration basin that incorporates BOD, TSS and nitrogen removal along with sludge reduction in an integrated system.

 

Complex organic solids undergo hydrolysis to simpler soluble organics, which pass to the SAM tank. In addition to flow regulation, the SAM tank provides an anoxic environment for rapid denitrification of recycled nitrates and concurrent stabilization of the soluble organics from the

 

I-Tank. The conditioned mixed liquor then passes to the final aerobic tank for completion of BOD and nitrogen removal and solids separation. 312/266-9967; www.fluidynecorp.com.

 

Bagging compost

Compost manufacturer McGill Environmental Systems has added compost bagging service. Residuals are transported to a composting facility and, at the customer’s option, bags of EPA Class A compost suitable for unrestricted end use are returned. Lime stabilization is not required for materials accepted for processing. The company has computer-controlled indoor facilities. 910/532-2539; www.mcgillcompost.com.

 

Real-time odor measurement

OdoWatch software from Kruger Inc. provides continuous, real-time odor measurements. The electronic nose (e-nose) is calibrated to quantify site odors in odor units. The system is comprised of one or more e-noses, a weather tower, a wireless communications system, and a computer preconfigured with the software.

 

The e-noses are positioned near the odor sources. Using weather data, the system performs real-time dispersion modeling using AERMOD and displays the results as a color-coded plume on an aerial view of the site. The system alerts operators when odors begin to reach threshold values. The device can distinguish between the odors generated at the site and those originating from other sources. The sensors in the e-noses are calibrated based on data from an odor panel. 919/653-4574; www.krugerusa.com.

 

Shaftless conveyors

The integrated sludge-handling system from SPIRAC includes a receiving bin with a shaftless screw live bottom and 19 other shaftless conveyors, including two trains of vertical shaftless screw conveyors to convey biosolids with 80-foot vertical lift into a storage silo. The design provides redundancy and the ability to move more than 1,600 tons of biosolids per day. 770/632-9833; www.spirac.com.

 

Repair-in-place housing

The Double Disc pump from Penn Valley Pump Co., incorporates a repair-in-place hinged housing design for complete servicing without disturbing the piping. With flow rates to 1,400 gpm, the pumps are used for sludge handling applications such as belt press feed, centrifuge feed, rotary press feed, thickener feed, thickened sludge, digested sludge, primary sludge, scum and septage. The pumps are self-priming and able to handle high suction lifts. They can run dry without damage. 800/311-3311; www.pennvalleypump.com.

 

Remote-controlled dredge

The Pit Hog dredge from Liquid Waste Technology is an electrically powered, remote-controlled unit available with a standard 40 hp high-efficiency, high-chrome pump. A Bottom Sense feature minimizes damage to lined ponds by following the bottom contours automatically. The stainless steel unit has higher-horsepower models. Dredging depths of 15 feet are standard, with options up to 30 feet. 800/243-1406; www.lwtpithog.com.

 

Single-pass dryer

VOMM sludge dryer thin film technology from Drycake uses convection and conduction heat transfer to enable Class A drying from and to any desired dryness up to 98 percent. The system has low energy cost and safe and simple operation in a closed loop with no odor emissions and up to 50 percent heat recovery. More than 150 systems are installed worldwide. 877/379-2253; www.drycake.com.

 

High efficiency

The 2G Agenitor cogeneration plant from CENERGY Power Systems Technologies Inc. is a biogas powered, thermodynamically output-optimized combined heat and power module offering 40.6 percent electrical and 85.5 percent overall power plant efficiency. The generating system is connection-ready, is factory tested, and comes as a complete module for quick installation.

 

The unit has an electronically controlled ignition system with bus coupler to the master control and optimized gas mixer for improved startup, minimization of pressure and high efficiency. Other features include oversized generator for extended operating life and automatic tracking of gas qualities and heat value fluctuations. 904/579-3217; www.2g-cenergy.com.

 

Complete dredge package

The remote-controlled Flump dredge from SRS Crisafulli Inc. is an integrated system comprised of major standard and optional components including flotation system, primary and secondary motors, hydraulic and electrical systems, cutterhead, pump, ladder, manual or programmable computerized skills, cabled traverse system, and Crisafulli Integral Floating Discharge System. The unit is fabricated in a variety of materials, including special metals for abrasive or corrosive sludges. All four models are powered with electric motors and have standard dredging depths to 12 feet (custom depths to 30 feet). 800/442-7867; www.crisafullipumps.com.

 

Isotropic mixing

The Linear Motion Mixer from Eimco Water Technologies produces isotropic mixing due to the combined effect of oscillating velocity and pulsating pressure waves. The motion is created by the controlled up-and-down movement of a thin, doughnut-shaped Hydro-Disk driven by a Scotch yoke and cam follower drive, which is powered by a gear motor. 512/834-6047; www.eimcowater

technologies.com.

 

Single skid

Centrifugal dewatering systems from Centrisys provide a complete dewatering process on a single skid. Systems range from 25 to 300 gpm. Low floor loadings and vibration eliminate structural issues. 262/654-6006; www.centrifuge-systems.com.

 

Inline heater

ProSonix offers the PSX inline sludge heater for biosolids heating and anaerobic digestion. The unit has no hot surfaces, eliminating plugging and fouling. Inline sludge and slurry flow is designed for high solids and large particulates. The system is designed to handle slurries and sludge that have high viscosities and are difficult to pump. A low liquid pressure drop across the heater, typically 1-2 psig, reduces energy demand and allows for smooth integration with the pumping system.

 

Steam injection via internally modulated steam control allows rapid and complete mixing and condensation of the steam for smooth and stable operation. The steam injector’s diffuser design produces 360-degree delivery of steam into the material for uniform heating. 800/849-1130; www.pro-sonix.com.

 

Easy grit handling

The Grit Classifier from Schreiber LLC is designed to wash and dewater grit slurry from grit removal systems, enabling easy handling and transfer of grit for final disposal. The system is effective over a wide range of grit particle sizes, including sugar sand.

 

The grit slurry is transferred to the grit classifier, where the inlet flow is directed downward. The grit settles into the bottom of the hopper. A shaftless screw rotates, lifting the grit from the bottom of the hopper up the trough, further washing and dewatering the grit. The decanted water flows over a weir and is returned to the waste stream, and the discharged grit is dewatered and ready for the landfill.

The system is fully enclosed and is made of 304 stainless steel. A hardened steel shaftless screw requires no submerged bearing, resulting in low maintenance. The system is available in 12-inch diameter for flow rates up to 150 gpm and 20-inch diameter for up to 300 gpm. 205/644-7466; www.schreiberwater.com.

 

Automatic re-priming

Gusher self-priming centrifugal pumps are completely interchangeable with similar pumps from other brands. Users can install new pumps or rebuild existing pumps using a replacement rotating assembly. The large-volute design allows the pumps to re-prime automatically without suction or discharge check valves.

 

Self-priming is achieved with the pump casing only partially filled with liquid and with a completely dry suction line. Pumps range from 2 to 10 inches. The line includes pumps that handle solids up to 3 inches and pumps made from ductile iron, 316SS or CD4M. All models come pre-assembled and ready to install. 800/548-1234; www.usabluebook.com.

 

Pre-piped and pre-wired

Skid-mounted dewatering systems from FKC Screw Press come with a screw press, flocculation tank, sludge pump, controls and polymer system. Everything is pre-piped and pre-wired. The systems are upgradeable to be used to dewater and produce Class A biosolids. 360/452-9472; www.fkcscrewpress.com.

 

Drying and composting

Brown Bear Corporation produces four sizes of self-propelled composting and sludge-drying machines. The four units range from Model 200 at 130 hp and 800 cubic yards per hour to the Model 500 at 350 hp and 3,000 cubic yards per hour. All units are used for composting of biosolids.641/322-4220; www.brownbear corp.com.

 

Knife Valve

A.H. Stock Mfg. Corporation offers the 12-inch-square Newton Knife Valve, designed for vehicles hauling biosolids to fields for land application. The air-operated valve uses a stainless steel knife edge to shear off foreign objects that may obstruct the seal area, thereby preventing leaks. During development, the valve was tested successfully in various conditions including sawdust, straw, sand bedding and municipal waste. 920/726-4211; www.ahstockmfg.com.

 

Alkaline stabilization

Cemen Tech Inc. offers mobile alkaline stabilization equipment available in sizes from 10 to 80 tons per hour. The units can be driven by utility power or by a diesel genset. The alkaline materials are fed to the units from low-profile silos that are provided. The machines can produce Class A or B biosolids. 800/247-2464; www.cementech.com.

 

Capable spreader

The Stoltzfus BMS 1516 spreader includes a hopper with 53-degree sides. At the bottom of the sides is a 4-inch-deep pan containing a 30-inch-wide, slat-type conveyor chain with exposed links that pull the material to the rear-metering gate. For dense, low-fiber materials, there is a low-rpm, flail-type agitator that runs the length of the hopper to slice the material and break up any bridging.

 

The shredder has a low-rpm, flail-type device that sets sideways outside the rear-metering gate and above the dual spinners. It shaves off a continuous flow of materials down to the spinners, eliminating gaps between large lumps in materials that do not flow evenly. 800/843-8731; www.stoltzfusmfg.com.

 

Biosolids drying technology

EcoWave 1000 Series drying technology dries municipal biosolids to produce a Class A product using a microwaveear-infrared process. The process is safe, energy efficient, and highly scalable. It produces little to no odor, has low operation and maintenance costs and minimizes emissions of secondary pollutants such as dust, CO, CO2, NOx and SOx, according to the manufacturer. The technology has a compact footprint — a 50-wet-ton-per-day machine has less than a 900 square-foot total recommended install area.

 

The technology combines the heating characteristics of microwave and near-infrared rays. The action of microwaves generating heat inside and the near-infrared rays heating the surface enhances heating and drying. The electric drying technology uses an agitator-equipped screw conveyor that agitates the material being moved in the dryer in order to apply heating evenly, for a uniformly dried product. EcoWave has a fully functioning pilot unit mounted to a truck available for demonstrations. 321/217-3181; www.ecowaveusa.com.



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