operation, performance, optimization, advantages
TRANSCRIPT
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Operation, Performance, Optimization, Advantages & Disadvantages
BDP Industries
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� Recessed Chamber Press – Plate & Frame� Centrifuge� Screw Press / Rotary Press� Belt Press� Recent Trends� Material Properties� Dewatering Septage & Grease
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Filter Cloth
Recessed PlateCloth Shaker
Assembly
Cloth Wash Header
Plate Support
Feed Port
Filtrate Ports
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� Recent Improvements in Technology:� Increased Automation.� Control Interfaces.� Materials of Construction.
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Advantages:� Highest filtration pressure:
100 to 225psi.� Excellent solids capture
when conditioned properly.� Conditioning chemical costs
can be lower for some materials.
� Amenable to daily operation. Must insure 2-5 hr cycle can be completed.
� Can process incompressible material.
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Disadvantages� Batch process.� Complicated Systems for: Feed pump, pre-coating, conditioning and
metering of lime, ferric and fly ash. Variable Flow Rate effects dosage.� Blow outs / Plate Breakage.� Labor intensive for performing cake discharge and plate washing etc. or
spend more $ for an automated system.� Highest Operation & Maintenance Costs� Large footprint for press and accessory systems: Feed pumps,
conditioning tank, pre-coat make up, lime metering, pressure washer etc.
� Significant building structure to deal with size and weight of press and accessories.
� Frequent maintenance and cleaning.� Can’t observe process. At end of cycle, cake discharge can be wet due
to improper conditioning or blinded cloth.� Expensive Discharge System: cake breakage and storage required due
to batch operation.� Odor containment difficult.
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3 4 1
1) Feed2) Feed Acceleration in Feed Zone3) Solid Blanket4) Clarified Liquid 5) Solids discharge6) Liquid Discharge7) Main Drive8) Scroll Drive
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Feed Ports Cake Scroll
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H2O
Conveying Solids - Centrifuge
Sludge feed
Cake Centrate
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30” Diameter Bowl
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� Recent Improvements in Technology:� Increased Motor Efficiencies.� Materials of Construction – decreased wear.� High Speed solid bowl, backdrive scroll on VFD.� Operational feedback loops – scroll amp draw.� Refined bowl shapes for particular materials.� Directional centrate ports � Automation and remote monitoring
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� Advantages:� Highest unit capacity per footprint, reduces
number of units for large plants.� Containment of odor and process fluids.� Easier to keep operator area clean.� Less frequent preventative maintenance.� Maintains cake solids at higher than design
loading, although solids capture suffers.� Smaller building.� Can process any material with S.G.
differences.� Three Phase Separation is possible
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� Disadvantages:� Highest energy consumption.� High usage of polymer.� Down time for repairs usually takes weeks/months.� Start-up and Shutdown take time and must be done
carefully to avoid damage to unit. � Operation needs to be continuous.� Instable sludge feed can make performance
difficult to monitor and make proper adjustments.� Special structural requirements for equipment
foundation.� Hearing protection for larger units.� Centrate often carries entrained air and polymer.� Becomes more economically viable with multiple
units.
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0 0.5 1 1.5 2 2.5 3 3.5 4 4.5
Solid
s C
aptu
re,
% o
r C
ake
So
lids,
wtT
Pool Depth, inches
Solids Capture / Cake Solids vs Pool Depth
Cake Solids, wt%
Solids Capture, %
Source: WEF MOP 20
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H2O
Conveying Solids - Centrifuge
Sludge feed
Cake Centrate
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� Recent Improvements in Technology:� Brush / Flight Tip Design.� Pneumatic discharge cone.� Polymer mixing.� Independent pre-thickening.� Filtrate Recycle� Screen design.� Dual Mode operation.� Automation!
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Image Source: FKC Web Site
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Perforated ScreenBasket
Tapered Shaft
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Image Source: Fournier Co. Product Brochure
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Front Royal, VA WWTP
Source: Treatment Plant Operators Magazine.
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� Advantages:� Containment of process fluids and some odor.� Low energy consumption, similar to belt press.� Slow speed.� Low noise level.� Most maintenance can be handled by staff.� Facility easy to keep clean.� High torque possible with compressible material.� Easy start up and shutdown amenable to intermittent operation, a few
hours daily.� Remote operation possible with correct ancillary equipment.
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� Disadvantages� Low capacity.� Low solids capture.� Difficult to maintain solids loading/performance if influent
concentration is variable.� Difficult to clean blinded filtration surface without shutting down and
emptying.� Some designs need to remove screw for major maintenance.� Not meant to dewater incompressible solids.
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� Replaceable Wiper� Wear Part� Increased
Performance
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� High Feed Solids
� Low GPM� Example:
� 6 - 8% feed� 600 – 1,000
lb/hr� 27 – 35%
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Image Source: FKC Web Site
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� Feed to Unit: 50 gpm at 1% or 25 gpm at 2%Average discharge from drum is 5 – 8%
Result: 6 – 8 gpm to the Screw
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� Reduced Footprint
� Low RPM� Better
Performance� Solids Capture� Hydraulic
Throughput� Changing
conditions
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Gravity Zone
Wedge Zone
Pressure Zone
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� Advantages:� Low energy requirement.� Lowest polymer dosage.� Easy start up and shutdown amenable to
intermittent operation, a few hours daily.� Maintenance can be done by plant personnel.� Process is observable allowing quick operator
response to unstable conditions to avoid upsets.� Most repairs can be made in a couple of hours.� Ideal for processing incompressible material� Least expensive total Life Cycle Cost.� Higher Cake Solids possible: linear relationship to
polymer dosage.
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� Disadvantages:� Containment of odor and process fluids requires additional attention at
design phase.� Frequent maintenance and cleaning.� Height requirements. � Footprint requirements for large plants with multiple units.� Sump design is critical: Process upsets can require significant
cleaning in certain layouts.
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� Recent Improvements in Technology:� Improved Feed Distribution.� Independent Gravity Zone.� Dual Mode operation.� Curved Wedge Zone.� Improved Plow, more compression, exposing more filter cloth.� Vertical Compression Zone.� Floor Level Installation – no platforms.� Automation.� Odor control enclosures & piping.
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Dewa
tering
Box
Cham
ber P
ress
Centr
ifuge
Belt P
ress
Scre
w Pre
ss
Dewa
tering
Box
Cham
ber P
ress
Centr
ifuge
Belt P
ress
Scre
w Pre
ss
Dewa
tering
Box
Cham
ber P
ress
Centr
ifuge
Belt P
ress
Scre
w Pre
ss
Dewa
tering
Box
Cham
ber P
ress
Centr
ifuge
Belt P
ress
Scre
w Pre
ss
Aerobic Digested Anaerobic Digested Septage Lime Stabilized Septage
Cake
Sol
ids,
wt%
Equipment / Sludge Type
Average Cake Solids (%)
EPA 832-F-00-053, September 2000
37%
Lim
e, 7
.7%
Fer
ric C
hlor
ide
35%
Lim
e, 7
.1%
Fer
ric C
hlor
ide
13.4
% L
ime,
4.5
% F
erric
Chl
orid
e
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� Hydraulic Loading – gpm
� Solids Loading or Throughput – lb/hr
� Chemical Dosage – lb / dry ton
� Discharge Cake Solids – %wt
� Solids Capture – %
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What Makes Septage & Hauled Waste Different?
▪ Incompressible vs. Compressible ▪ Specific Gravity▪ Abrasiveness▪ Grease▪ Chemical Treatment▪ Odor Control and Containment• Example: Cake solids 18% – 45%
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Model 3DP Belt Press
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Belt Press Design Considerations for Septage
▪ Distribution – Feedbox ▪ Curved Wedge – Pressure Profile▪ Dual Drive – Performance, looping▪ Roll Construction – Coatings ▪ Operation & Maintenance
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Wedge Section DesignTraditional Straight Wedge – less effective with incompressible materials
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Curved Wedge
• Self Compensating for Material Pressure Profile• Edges Encapsulate Material• Prior to First Compression Roller
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Pressure Section Design
Time under pressure
Cak
e P
ress
ure
Extrusion area
Material Dewatering Curve
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FEED DISTRIBUTION
• Uneven distribution causes:– Premature clipper wire failure– Accelerated wear on roll
coating– Cake solids concentration is
lowered– Belt misalignment
Direction of filter belt travel
Belt Seam
Filter Cloth
Cake Thickness
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Poor Distribution: Clipper Seam
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Roll Wear
◼ Even cake = Even roll coating wear
◼ Uneven cake = Uneven roll coating wear:– Tracking misalignment– Lowers cloth life– Lowers cake solids
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Up-Flow Feedbox with Paddlewheel Distributor
▪ Eliminates dead zones and plugging.▪ Full width belt distribution.▪ Uniform cake thickness.▪ Slower even roll coating and filter cloth wear.▪ Maximizes effective filtration area.▪ Improved thickening performance.▪ Reliable operation.
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Initially observed in mining, sand & gravel operations
Distribution
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Dewatering Abrasive Material
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3 Meter 3DP - Distribution
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Thickening vs. Dewatering
▪ Mechanical Thickening▪ Square feet of open belt media
▪ Dewatering▪ Amount of Pressure▪ Time under pressure
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Gravity Section Cake Formation
• “Experimental Techniques in Solid Liquid Separation”, DA Dahlstrom and C.E. Silverblatt
• As cake thickness increases, the filtration rate (lb/hr per ft2) decreases
Faster Belt Speed = Higher Solids
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Belt Press SchematicConventional 2-Belt Design
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questions?
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In The Round DewateringJames Penner
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Always screen wastewater as it is dumped
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Submersible trash pump
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Hydraulic power unit
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Polymer can be purchased in different size
containers
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Inside of Dewatering Drum
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Water passes through slots
in PVC tile
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or the bottom
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Filling drum with flocking material
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Drum half full
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Dried material after rotation
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