When sludge disposal costs threatened to spiral out of control at a major chemical production facility in Charleston, South Carolina, the search for a better, more cost-effective dewatering solution led directly to Esmil — and to a high-performance mobile system that quickly delivered results.
Chemistry creates water challenges
The facility is a leading producer of specialty chemicals used in asphalt production, adhesives, coatings, and ink resins. These processes generate large volumes of wastewater — and as part of treatment, the site produces a significant amount of sludge that historically required offsite hauling.
Hauling costs, however, steadily increased, prompting the plant to explore onsite dewatering options that could reduce sludge volume and cut operational expenses.
Sludge characteristics and process goals
The sludge generated at the facility is a combination of chemical and biologically activated sludge, with an initial dry solids content of approximately 8%. The plant required a system capable of processing roughly 30 gpm of sludge continuously.
Primary goals:
- Dewater sludge to a target cake dryness of 20–25% dry solids
- Reduce sludge hauling frequency and costs
- Maintain minimal operator involvement in daily system operation
Esmil’s solution: Mobile multi-disk screw press system
To meet these goals, Esmil deployed its semi-trailer mounted mobile dewatering system, equipped with an MDQ-503CS multi-disk screw press.
This fully integrated system includes:
- Sludge pump with flowmeter
- Polymer preparation and dosing system (with tote storage)
- Macerator for sludge homogenization
- Esmil MDQ-503CS multi-disk screw press for sludge dewatering
- Shaftless screw conveyor for cake discharge
- Centralized control panel — enabling highly automated operation with minimal supervision
Consistent with all Esmil rental solutions, the setup required only three connections: stored sludge source, electrical supply, and water.
Once delivered and connected, the unit was quickly optimized for site-specific conditions. Within a short commissioning window, Esmil’s technicians trained plant operators on system control and basic maintenance.
Results: Rapid setup, superior performance
- Cake solids exceeded the 25% DS target, delivering immediate savings on hauling and disposal.
- System throughput comfortably exceeded 30 gpm, providing ample capacity buffer.
- Minimal operator attention required, freeing up plant resources.
- Fast implementation — the system was operational shortly after arrival on-site.
Another successful Esmil deployment — helping a chemical manufacturing facility turn a logistical challenge into a long-term operational advantage.
To learn more about Esmil dewatering systems, visit www.esmil.us or contact 646-286-5512.
