Solid-liquid separation in the treatment of municipal and industrial wastewater and sludge
Our highly effective synthetic flocculants are water-soluble polymers with a high molecular weight. A wide range of molecular weights and charges ensures flocculation even with different media. Our products are available in solid, liquid and dispersion form.
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Complex sludges constitute a significant challenge for the operators of many fully biological wastewater treatment plants. With its proven polymers, ACAT offers optimal solutions to keep plants running as efficiently as possible. This brings benefits to municipalities and their citizens.
download >The central wastewater treatment plant of the Laßnitz-Wildbach-Gamsbach wastewater association in Styria treats the wastewater from the municipalities of Deutschlandsberg and Frauental. It operates on the principle of fully biological wastewater treatment. Microorganisms remove pollutants from the wastewater. This process is supported by extensive mechanical procedures to achieve a degree of purification of at least 95% for carbon compounds, at least 85% for phosphorus and at least 70% for nitrogen compounds. The wastewater treatment plant was built in 1973 for 16,000 PE (population equivalent). In 1995, the wastewater treatment plant was expanded to 22,000 PE. The maximum flow rate is 220 litres per second.
Special requirements
Excess sludge in the wastewater treatment plant is treated using a mechanical excess sludge dewatering system. This process pre-thickens excess sludge produced during wastewater treatment prior to further treatment. This sludge contains water and solid substances. Pre-thickening reduces the water content of the sludge, which facilitates subsequent dewatering. The sludge is then further dewatered in a centrifuge. The centrifugal force separates the water from the solids, making the sludge even drier.
Complex sludges
“The wastewater treatment plant in Frauental has very special requirements and cannot be compared with any other plant in Austria. The variable sludge conditions, which have led to a need for improvement in the solids content values, i.e. the proportion of solids in the sludge after the water has been removed, are a particular challenge,” says Reinhold Kreilmair, Sales & Technology ACAT watertech.
To improve performance (product range, solids content, polymer consumption), the wastewater association turned to ACAT. “First, we tested the ACAT polymer sampling on the mechanical excess sludge dewatering system. The favoured ACAT product worked immediately and achieved optimal results in terms of solids content and consumption. The sludge throughput was consistently high,” concludes Kreilmair. Plant manager Martin Wolfsberger also emphasises this: “Our experienced wastewater treatment team quickly observed visible improvements in the sludge even before the laboratory analyses were evaluated. The measured values from the laboratory then impressively confirmed this assessment.” The voluminous flocculation and perfect dewatering were crucial for an almost clear, transparent centrate water. Thanks to ACAT, the previously problematic and difficult-to-control foaming has also been reduced.
Optimal results
The central wastewater treatment plant of the Laßnitz-Wildbach-Gamsbach wastewater association in Styria treats the wastewater from the municipalities of Deutschlandsberg and Frauental. It operates on the principle of fully biological wastewater treatment. Microorganisms remove pollutants from the wastewater. This process is supported by extensive mechanical procedures to achieve a degree of purification of at least 95% for carbon compounds, at least 85% for phosphorus and at least 70% for nitrogen compounds. The wastewater treatment plant was built in 1973 for 16,000 PE (population equivalent). In 1995, the wastewater treatment plant was expanded to 22,000 PE. The maximum flow rate is 220 litres per second.
Special requirements
Excess sludge in the wastewater treatment plant is treated using a mechanical excess sludge dewatering system. This process pre-thickens excess sludge produced during wastewater treatment prior to further treatment. This sludge contains water and solid substances. Pre-thickening reduces the water content of the sludge, which facilitates subsequent dewatering. The sludge is then further dewatered in a centrifuge. The centrifugal force separates the water from the solids, making the sludge even drier.
Complex sludges
“The wastewater treatment plant in Frauental has very special requirements and cannot be compared with any other plant in Austria. The variable sludge conditions, which have led to a need for improvement in the solids content values, i.e. the proportion of solids in the sludge after the water has been removed, are a particular challenge,” says Reinhold Kreilmair, Sales & Technology ACAT watertech.
To improve performance (product range, solids content, polymer consumption), the wastewater association turned to ACAT. “First, we tested the ACAT polymer sampling on the mechanical excess sludge dewatering system. The favoured ACAT product worked immediately and achieved optimal results in terms of solids content and consumption. The sludge throughput was consistently high,” concludes Kreilmair. Plant manager Martin Wolfsberger also emphasises this: “Our experienced wastewater treatment team quickly observed visible improvements in the sludge even before the laboratory analyses were evaluated. The measured values from the laboratory then impressively confirmed this assessment.” The voluminous flocculation and perfect dewatering were crucial for an almost clear, transparent centrate water. Thanks to ACAT, the previously problematic and difficult-to-control foaming has also been reduced.
Optimal results
Remarkable progress has also been made in the second stage of sludge thickening, i.e. dewatering on the centrifuge. A contract dewatering company that used a product from ACAT achieved excellent results right from the start. These even exceeded those achieved with the in-house centrifuge.
The product’s effective performance led the customer to test it in the second stage of sludge thickening. Finally, tests on the newly overhauled in-house centrifuge confirmed the positive results of the dewatering contractor. The precisely calibrated system resulted in reduced consumption of defoamers and sedimentation accelerators. Maximum performance “With the right products and machine settings, ACAT has succeeded in covering the enormously wide range of sludge conditions, thus ensuring consistently high plant performance,” explains plant manager Martin Wolfsberger. Reinhold Kreilmair adds: “Efficient sludge dewatering is one of the biggest challenges for almost all wastewater treatment plant operators. Thanks to our many years of experience and our consistent focus on quality and innovation, we have the optimum solutions in our portfolio.” ●
Most industrial production facilities generate wastewater, which has to be treated and purified. For many years ACAT has been dealing with the various requirements of these cleaning processes.
download >Most industrial production facilities generate wastewater, which has to be treated and purified.
For many years ACAT has been dealing with the various requirements of these cleaning processes.
Usually, the first step of a purification process is the separation of the solids, which is achieved by adding various chemicals. Precipitation and flocculation cause an increase in the density difference between the particles and the liquid phase making separation possible.
Example of a Typical Flotation Plant
For many decades, precipitants such as iron or aluminium salts have been used very successfully for the pre-flocculation to achieve the desired clarity of the solution. But in some wastewater flows this process could cause undesirable side effects such as a reduction in pH, the introduction of metal ions, or an increase in salinity, etc.
Sometimes the separated solids can be reused, but the application possibilities are limited due to the use of conventional precipitants.
New Organic Polymers of Natural Origin
Currently ACAT is testing new organic polymers of natural origin.
Natural coagulants are present in two forms, first is plant based coagulants (PBC) and second is non-plant based coagulants. Natural coagulants are produced or extracted from different sources such as microorganisms, animals, or plants.
FlocStar® N is a range of coagulants composed of natural extracts from plants, algae or animals.
FlocStar® N is based on polymers of natural origin, mainly polysaccharides, substances soluble in water from materials of vegetable or animal origin that act as coagulation and / or flocculation agents. The plant-based coagulants are broadly utilized for the purification of contaminated water.
Advantages of Predominantly Plant-derived Products
The predominantly plant-derived products have many advantages compared to traditional inorganic coagulants:
A good example of application is the agri-food sector as it is an important consumer of water for different stages of the process.
One of the advantages of the FlocStar® N products for these sectors is that they are metal free and, therefore, do not provide metal to the sludge. Due to the organic nature of the products, a valuable sludge is obtained that can be used in agriculture.
Finally, the quality of the sludge produced is maximized, which optimizes also the amount of biogas produced. With that range of new products ACAT follows the strategy to enlarge the product range with green technology treatment processes for special applications in water and wastewater treatment.
Some producers of flocculants recommend certain quality requirements for the preparation water to produce an optimal polymer solution. These are only a recommendation for the operators, as these requirements cannot always be met. Therefore, they only serve as guide values for optimising sludge thickening or dewatering.
download >Some producers of flocculants recommend certain quality requirements for the preparation water to produce an optimal polymer solution. These are only a recommendation for the operators, as these requirements cannot always be met. Therefore, they only serve as guide values for optimising sludge thickening or dewatering. The quality requirements and their influence on the polymer solution can be summarised as follows:
Warm water accelerates the dissolving process of any polymer solution, the ideal water temperature is 10-30 °C
A high pH value leads to hydrolysis (degradation) of cationic polymers. The ideal pH value for the preparation water is pH 6-8. The ready to use polymer solution should have a pH value between 4-6.
Too hard preparation water accelerates the hydrolysis (degradation) of a polymer solution. Medium-hard water 8-12 °, German hardness < 300 mg/l CaCo₃ is ideal.
Too high conductivity increases the maturing time and the dissolving process of the polymer solution, as well as its viscosity. Ideal conductivity < 10,000 µS/cm
A solid content in the process water reacts with the polymer solution and causes deposits in the dissolving station and in the pumps. Ideally no solids or < 5 mg/l
Free radicals can cleave the polymer chain and thus have an influence on the effectiveness. Ideal concentration < 1 mg/l
A too high chloride concentration can cleave the polymer chain and thus have an influence on the effectiveness. Ideal concentration < 0.5 mg/l
Bacterial growth accelerates the hydrolysis (degradation) of any polymer solution. Ideal: no biological activity
A high mixing energy and an appropriate maturation time increase the efficiency of a polymer solution. Ideal maturation: time more than 30 minutes
Analysis of the parameters of the preparation water
Using the example of AWV Völkermarkt Jaunfeld, the parameters of the preparation water for the production of a polymer solution were analysed. AWV Völkermarkt Jaunfeld operates a sludge dewatering system using IEA screw presses. The conditioning of the statically thickened excess sludge is carried out exclusively with liquid polymer. The polymer preparation station is a “tower plant“ with 750 litres batch volume per preparation. From the preparation tank equipped with an agitator, the polymer solution is transferred to the storage tank by using a transfer valve.
The maturing time is about 10 minutes! Drinking water from the local network was used for the preparation of the polymer solution. A water analysis was carried out, the exact results can be found in Table 1.
Furthermore, a polymer solution with a preparation concentration of 0.25 % commercial product = 0.125 % active polymer was prepared on a laboratory scale. The pH value and conductivity of this polymer solution were recorded over the entire period. Based on the conductivity and its course, a possible conclusion can be drawn about an ideal maturing time of the polymer solution. In a beaker, 800 ml of preparation water with about 6 °C was added and stirred with a magnetic stirrer.
Before adding the polymer, the pH value and the conductivity were noted. In addition, the pH value of the preparation water was adjusted to approximately pH 4 by adding acetic acid (0.6 ml acetic acid per 800 ml preparation water). Subsequently, 2 ml FlocStar® 200L (dispersion) were added under strong stirring and the conductivity and the pH value was recorded over the entire period.
The preparation concentration of the laboratory scale polymer solution was 0.25 % commercial or 0.125 % active polymer.
As can be seen from Table 2, the conductivity increases with increasing stirring time. The liquid polymer starts to dissolve in the water and causes an increase in conductivity.
From a stirring time/maturing time of 20 minutes, the maximum possible conductivity is reached, so that one can speak of an ideal dissolution of the liquid polymer. Therefore, we recommend a maturing time (net stirring time after reaching the maximum level of the preparation tank) of >/= 20 minutes.
The pH value of the polymer solution was about pH 4.
Summary:
An optimisation of sludge dewatering and, associated with this, a possibly higher dry residue in the discharge is particularly important in view of rising disposal costs. Depending on the sludge quality and dewatering unit, the selection of the conditioning agent is the most important factor from a technical and economic point of view.
When using solid polymer, optimum wetting of the solid polymer with the preparation water is crucial.
A sufficiently high mixing energy, a sufficient preparation volume, an optimal maturing time as well as the quality of the preparation water, are only a few parameters to dissolve the flocculant in the preparation water and thus positively influence the dewatering results. The quality characteristics of the preparation water listed above are recommendations of the polymer manufacturers. How these characteristics affect the respective sludge dewatering can only be determined empirically; it is not possible to make a general statement.
There is a whole range of factors that can positively influence sludge dewatering in terms of process technology and lead to improved dewatering values. However, the main component is always the existing sludge composition and the proportion of „free water“ (water that does not bind to the sludge particles) in the sludge suspension.
Since the beginning of this year ACAT has included in its product range a new line of highly efficient Demulsifiers.
download >Since the beginning of this year ACAT has included in its product range a new line of highly efficient Demulsifiers. But first of all what is an emulsion? An emulsion is a system of two immiscible liquids in which one of the liquids is dispersed as small droplets into the second liquid.
The liquid that is dispersed is called the internal phase. The liquid into which it is dispersed is called the external phase. There are two types of emulsions that are common in industry: Water-in-oil emulsions (lean emulsion) and oil-in-water emulsions (fat emulsion). The most common emulsion is the oil-in-water emulsion: it is formed during treatments such as metal processing of iron and steel and therefore mainly in wire drawing mills, or it is generally formed when tools are used to process metals with cutting oils.
It is almost impossible to realize oil separation without an effective system for breaking the emulsion. Demulsifiers are specific products for the separation (breakage) of the oily emulsions and there are two types of these products, demulsifiers for the treatment of „lean“ emulsions (oil in water) and demulsifiers for the treatment of „fat“ emulsions (water in oil). The most common types are the lean emulsions. For this emulsions the ACAT product line “green” is used. “Green“, because it consists of cationic and non-cationic polymers and no environmentally harmful products are released during treatment. Their use is very simple: they are used with „batch“ treatments under agitation (no turbo) or with air insufflation. Simple laboratory tests (Jar-Test) determine the optimal dosage.
Fat emulsions (water in oil) are treated with completely different demulsifiers than those mentioned above, both as formulation and as application. These products are mainly used in the refineries (for the treatment of tank sloops) and they are classified as ADR products. These demulsifiers are used independently of the type of treatment – static (batch) or dynamic (continuous) – with centrifuges at a temperature between 75 and 80°C.
The liquid to be treated is in fact very thick and viscous and it needs high temperatures to reduce its viscosity and this facilitates mixing with our demulsifier. Also in this field of application, the product suitable for the treatment is identified by previous laboratory tests.
Our new DispStars® are highly efficient organic demulsifiers and they offer unique properties in all areas of emulsion splitting, from the petrochemical industry to wastewater treatment.
download >Who does not know the famous milk lemon experiment? A few drops of lemon juice are enough to make a nice tasty fresh milk a flaky unappetizing liquid. An unpleasant, unwanted effect “happening” in many areas, needed to be prevented. I would like to deal with this topic today.
Milk is a classic example of an emulsion. An emulsion is a highly dispersed mixture of two normally immiscible liquids (such as oil and water). One liquid (phase) forming small droplets is dispersed in the other one. The phase forming droplets is called the internal or dispersed phase, the phase in which the droplets “swim” is called the outer phase or continuous phase. Emulsions belong to the disperse systems and they differ from completely miscible liquids, like for example ethanol and water. Usually, emulsions are cloudy, milky liquids. In the case of milk, we are happy about the stable emulsion. But in many chemical processes, the emulsified liquids have to be separated. For this purpose, demulsifiers, also called emulsion breakers, are used. Demulsifiers are typically based on acids (example: lemon / milk) or on organic compounds.
ACAT has developed a new product line of highly efficient organic demulsifiers. Our new DispStar® products are used in all areas of emulsion splitting, from the petrochemical industry to wastewater treatment.
If you are looking for a solution to such problems, please contact our field service!
ACAT always strives to identify customer needs and to evaluate opportunities to align its own product development. Our latest development: FlocStar® Giga 1970 L!
download >FlocStar® Giga 1970 L is the result of specific customer needs. We combined a product suitable for a variety of applications with very easy handling. For many years, we have been dealing with the various problems and we have been carrying out several trials to find out the desired characteristics of the new product.
MUNICIPAL & INDUSTRIAL
WASTE WATER TREATMENT
Our product was developed for the use in Municipal and Industrial waste water treatment processes to successfully cope with the increasing hydraulic loads in the primary and secondary clarifier. In addition, it reduces the undissolved substances after the preliminary sedimentation and in the final clarification. It can be used when needed or prophylactically. The sludge properties are improved sustainably, the finest flakes are bounded very quickly and already after a few hours a better visibility depth is measurable. The GUS-values (total undissolved substances) in the effluent are improved very quickly. The sludge index returns very quickly to its normal state, thus preventing sludge flotation in the case of hydraulic overload. Our product also contains aluminum for the proactively fighting against filamentous bacteria.
CHARACTERISTICS OF FLOCSTAR® GIGA 1970 L
Due to the amphoteric nature our product can be used in media with high inorganic and high organic content. It adapts itself to the existing
reaction partners and thus guarantees optimal results, because stable sludge flakes are formed extremely fast. The sludge properties are improved quickly and sustainably.
On picture 1 you can see the sewage flowing towards the secondary clarifier – the picture was taken three minutes after sampling. On the left side in the picture you can see the waste water treated with FlocStar® Giga 1970 L. The improvement of settling behavior is clearly seen. The supernatant is already very clear, the organic content is > 80%.
ROAD & TUNNEL CONSTRUCTION
Further applications of FlocStar® Giga 1970 L are in road and tunnel construction where it is used for sewage and wash water treatment.
ROAD CLEANING
Today flocculants are also used with modern suction vehicles for street cleaning. This application has not been existence for a long time and there is still room for improvement. Because of the compact design of the suction vehicle, usually there is only one single metering device. Therefore, either the precipitant or
the flocculent can be used leading to unsatisfactory results: the supernatant is cloudy, or the flakes are greasy. In these cases our product works optimally as it is highly soluble in water and it forms a stable and well sediment able flake within a few seconds and the recirculated water can be optimally used. The dosage continues to be via the existing system.
The waste water on picture 2 was taken from a suction vehicle and it contains sludge from street collectors. The picture was taken after three minutes. Left in the picture, the waste water was treated with FlocStar® Giga 1970 L. The supernatant is very clear and the sludge flake is very stable. The content of inorganic substances in this waste water is > 80%.
You are only one step away from trouble-free plant operation! We are looking forward to your contact. Our team will be happy to advise you.
The word „Plastic“ – is colloquially synonymous for all kinds of plastics. It describes a substance that does not occur in nature, but must be produced. The starting point of the plastics production is crude oil – a resource not available indefinitely. And the final product poses more and difficulties with disposal problems. Two reasons why one should handle it with care and caution.
download >Plastics are produced by polymerization. Polymers: (poly = many, meros = part). Nomen est omen. In fact, carbon compounds are extracted from the raw material crude oil. In addition to these carbons, the plastic also contains the elements hydrogen, oxygen, nitrogen and sulphur. By adding plasticizers, stabilizers, reinforcing agents, fire retardants and dyes, the properties of the respective plastic can be individually influenced. Thus, many different plastics can be produced with a wide variety of properties. Plastics are mainly distinguished according to the following properties:
THERMOPLASTICS:
Thermoplastics consist of long macromolecules making it possible to form these plastics under the influenceof heat. Thermoplastics can be processed in different ways; for example they can be melted, injection moulded, foamed or glued. Primarily we know the injection moulding, in which plastic is heated and pressed into a mould under great pressure. The starting material is granulated thermoplastics. In this way, for example, the PET bottles are produced, we use almost daily.
THERMOSETS:
Unlike thermoplastics thermosets are produced by the hardening of powdery basic substances. Under high pressure and high temperature the basic substance is pressed into a mold to link the macromolecules together. Thermosets are used, for example, in mattresses, shoe soles or protective helmets.
ELASTOMERS:
Elastomers are wide-meshed cross-linked polymers. The main characteristic of these plastics is their enormous extensibility. Elastomers are able to return to their original shape even after extreme elongation. We know elastomers as rubber bands or sterile disposable gloves. One problem of all types of plastic is their disposal. We all know the frightening images of animals trapped in plastic waste and the reports of huge floating „plastic islands“ in the oceans. According to current studies, around 50 billion plastic parts are floating in the oceans of our planet.
These parts collect in the so-called current vortices of the oceans when they are carried along by the flow. Today there are five of these garbage collections in the oceans, two in the Pacific, two in the Atlantic and one in the Indian Ocean. The area of one of these „plastic islands“ is estimated to be 16 times the size of Austria. The surprising thing is that these huge „islands“ represent only one percent of the total plastic waste. The remaining 99 percent of the plastic in the sea is not visible on the surface.
WHERE IS THE REST TO FIND?
The answer is micro plastics! The majority of the packaging materials and other plastic products are not found in their original form in the oceans, but they appear much more
inconspicuous: as micro plastics. This term is used to describe plastic pieces with a size of up to five millimetres, with the smallest particles being only a few micrometres in size and thus they are invisible to the naked eye. In this form, plastic can only be detected under the microscope.
In the form of micro plastics the plastic waste is less visible in the sea, however it is no less problematic. On the contrary! This makes it even easier for the small plastic particles to find their way into the ecosystem. For example, fish and other marine animals also absorb micro plastics in their natural environment in addition to their food. This can become particularly problematic because the micro plastics in water attract chemicals, bind them chemically and this way it can get toxic characteristics. Primary micro plastics are plastics that are already small in their original form. This includes, for example, tiny plastic beads added to cosmetics to enhance the cleaning effect. These products and the containing micro plastics find their way with the waste water into the sewage system. However, these particles are so small that to the present day it has not been possible to develop suitable filters for sewage treatment plants to remove them from wastewater. Another type of primary micro plastics are small plastic pellets used to make other plastic products. They too can get into the rivers and finally the oceans via the drains of factories. The effects are devastating: On some beaches of the Canary Islands in one kilogram of sand up to 100 grams of micro plastics can be detected and plastic pellets account for a large proportion of the total quantity.
The secondary micro plastics are plastic particles having detached themselves from larger plastic parts, such as electronic waste or the like. Therefore, it is particularly important to be careful when using plastics.
It is recommended to use recirculating plastic such as PET if possible. PET – RECYCLE PLASTICS! For the production of PET polyethylene terephthalate (PET) no plasticizers and NO bisphenol A is used, as it is often wrongly claimed. In the recycling process PET must first be separated from other plastics such as PVC, HDPE bottles and impurities such as aluminum etc. Then the PET bottles and the containers are shredded. In several further steps the labels and other impurities are separated. The PET flakes enter the mixing screw, where they are mixed with 50% caustic soda (sodium hydroxide). In the kiln the flake-lye mixture is heated to temperatures from 197 to 207 degrees Celsius. The hot caustic solves
a thin PET layer from the surface of the flakes. In this way, the impurities are removed. The PET flakes are washed with water and then dried. Finally, a laser sorter measures the structure of the flakes and ejects any foreign material particles (such as silicon). At the end of the recycling process, the flakes are of such a high quality that they are suitable for food packaging.
ENVIRONMENTALLY FRIENDLY CLEANING OF WASTE WATER
To clean the waste water the caustic solution is neutralized with AluStar® products. The dirt particles are separated with FlocStar® products and various other products are used in the cooling and in the boiler area.
Thus, ACAT can make a significant contribution to the sustainable use of resources as well as to the protection of our environment, both in the reuse of PET products and in the water cycle.
In addition to polymers and equipment for industrial and municipal sewage treatment plants, ACAT is now also your contact for splitting agents used in the garage and recycling sector. ACAT strives to be together with you at the forefront wherever environmental protection is required.
download >In addition to polymers and equipment for industrial and municipal sewage treatment plants, ACAT is now also your contact for splitting agents used in the garage and recycling sector. ACAT strives to be together with you at the forefront wherever environmental protection is required.
Our new product FlocStar® Wash consists of various partially water-soluble components with a very high proportion of absorbent sub-
stances and coagulating polymers. It is used in the treatment of industrial waste water to eliminate high amounts of organic and inorganic contaminants.
As required, we offer you a wide range of services together with our products. Our service technician will be happy to assist you with any questions you may have. Filter bags and filter rolls can be ordered together with the product.
The exact description of the properties of our products will help you to find the right product, but of course we will also be pleased to advise you on site. Please do not hesitate to contact us.
Applied Chemicals International Group AG
Neubadstrasse 7
CH-4054 Basle
Switzerland
T +41 61 282 82 82
Applied Chemicals International AG
Neubadstrasse 7
CH-4054 Basle
Switzerland
T +41 61 282 82 82
Applied Chemicals Handels-GmbH
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A-1147 Vienna
Austria
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Technic & Production Center
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Austria
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Germany
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Hungary
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Viale A. Doria 42
I-20124 Milan
Italy
T +39 02 870430 12
Applied Chemicals Application Technology ZA (PTY) Ltd
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ZA-3610 Hillcrest
South Africa
T +27 31 765 5096
Applied Chemicals Schweiz GmbH
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CH-4054 Basle
Switzerland
T +41 61 282 82 80
