Virtually maintenance free and for every application
You can rely on over 20 years of experience in the development of solvents, dosing, and control systems. Regardless of the size and application range – we support you during the configuration, optimization and implementation phase, as well as during commissioning. We guarantee a successful integration into your existing process control systems.
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In the past, the main focus was on optimising the use of liquid flocculants based on dispersions or emulsions. Currently, the use of powdered flocculants is in the foreground.
download >In the past, the main focus was on optimising the use of liquid flocculants based on dispersions or emulsions. Currently, the use of powdered flocculants is in the foreground.
As a reliable partner in the optimisation of operating equipment on the various sludge dewatering aggregates, ACAT was significantly involved in the development and the application of new powder polymers Intensive laboratory tests and subsequently supervised machine tests on the most diverse sludge dewatering aggregates with the most diverse sludge types and their compositions have led to the fact that the sewage treatment plant operators could be convinced to use increasingly powder polymers.
Furthermore, the development of dissolving and dosing technology made a substantial contribution to making the use of powder polymers easy to “handle” for the operator. In the past, the use of 25 kg bags was common, but currently 750 kg Big Bags are used as standard and, at the customer’s request, also 1000 kg Big Bags. The Big Bags only require a certain amount of “attention” when changing them, but subsequently the operator no longer comes into contact with the “dusty and slippery” material.
Due to the positive feedback of the plant operators and the constant efforts of the ACAT Company to stand out from the competition in accordance with the company’s motto “Technical Service is our Success”, the entire team of the Technique Centre Scheibbs developed polymer preparation plants for the operation with solid and liquid polymer.
The units from the PPU series allow the following modes of operation:
All the above-mentioned operating modes can be run both with and without the addition of a defoamer. This additionally increases the flexibility of the plant operator, if the filtrate/centrate tends to foam – which is particularly the case with high-performance centrifuges.
The advantage of the solid and liquid polymer mode of operation is obvious:
In the summer months, the sludge dewatering system can be operated with 100 % solid polymer; in the off-season or winter season, the optimum ratio is a mixed operation of 50 % liquid and 50 % solid polymer. The operating modes are very flexible and can be continuously adapted by the operator in terms of technical and economic aspects.
Due to the close cooperation of ACAT with the plant operators and their operating staff, the needs and procedural requirements as well as the wishes of the customer can be taken into account and individually implemented. These advantages and the flexibility of ACAT’s project design have already convinced a number of wastewater associations.
Project ARA Region Dornbirn-Schwarzach GmbH
Polymer dissolving station PPU 3 for sludge dewatering with 3 belt presses
Since the 1980s, the ARA Region Dornbirn-Schwarzach GmbH has been operating its digested sludge dewatering with three belt filter presses with downstream fluidised bed drying.
Constantly increasing energy costs and polymer prices and the fact that the aging plant did not have any measurement technology for balancing, prompted the management, represented by Mr. qualified industrial engineer MAS Alexander Zerlauth, to take a closer look at the conversion of the sludge dewatering system. For this purpose, a market survey was commissioned of the various suppliers of dissolving and dosing control systems.
The overall technical concept of a polymer processing station including dosing control and the use of synergies between the “old sludge dewatering system” and the “new system components” were the decisive reasons why ACAT was able to stand out from the competition.
After clarifying the technical details, the concept was also convincing from the commercial point of view. Thus, ARA Dornbirn-Schwarzach GmbH awarded ACAT the contract for the conversion of the sludge dewatering system.
Old Stock
Special features of the new plant
We would like to thank the management, Mr. qualified industrial engineer MAS Alexander Zerlauth and his team for the trust they have placed in us and for the quick and uncomplicated implementation of this very extensive project.
An “almost” trouble-free installation and commissioning would not have been possible in such a short time without the support of the entire team! Many thanks also for the hospitality during the “lock-down”.
Project Stadtwerke Schwaz – Department Waste Water
Polymer dissolving station PPU 3 for sludge dewatering with a high-performance decanter
The existing sludge dewatering system with a centrifuge was upgraded to the latest generation of high-performance decanters. The primary focus of the plant operator was on increasing the dry substance content of the discharge and on the high level of operational safety of the new plant components.
In a second optimisation step, the use of operating resources was examined more closely. The existing polymer dissolving station could only process liquid flocculants. In the course of the ongoing optimisation of the sludge dewatering, our sales representative Roland Auer installed a mobile FHM station for powder admixture, which was tested over several months. Different mixing ratios of solid and liquid polymer were tested and evaluated from a technical and economic point of view. The dry substance content of the sludge cake remained unchanged, but the centrate was more stable with this mixture than in the conventional liquid operation.
Due to the good results, a new plant was planned and an overall concept was worked out. At the customer’s request, the preparation and storage tanks were integrated into a former storage room. The control system of the new polymer dissolving station was integrated into the existing sludge dewatering control system, which further increases the operator’s flexibility. Furthermore, ACAT installed two new polymer dosing pumps on a stainless steel frame and integrated them into the existing control system.
Special features of the system
The preparation and maturing tanks are located separately. The tanks are located on different floors.
We would like to thank the Stadtwerke Schwaz for the trust they have placed in us. Special thanks to Mr. Armin Schrottenbaum and Mr. Stefan Patka for their personal commitment and for co-ordinating the individual interfaces.
Project AWV (Waste Water Association) Grazerfeld
Polymer dissolving station PPU 3 for sludge dewatering with two high-performance decanters
The existing digested sludge dewatering with centrifuges was upgraded to the latest generation of high-performance decanters and the polymer processing station in the sludge line was redesigned. Years of co-operation and the AWV’s confidence in ACAT’s competence were decisive that the Managing Director Michael Lechner and the Managing Director Deputy DI Andreas Philadelphy accepted the application of a system change of the already tendered polymer processing station. Therefore, the contractor of the complete sludge dewatering system took over the components for the polymer dissolving station type PPU 3 according to the specifications of ACAT.
Special features of the system
The polymer plant is supplied with 750 kg Big Bag or IBC containers.
We would like to thank the AWV GrazerFeld Managing Director Mr. Michael Lechner, and Managing Director Deputy DI Andreas Philadelphy for the trust they have placed in us.
Our special thanks go to Mr. Wolfgang Mayer for his personal commitment and the coordination of the installation companies.
Project AWV (Waste Water Association) Hohe Tauern Süd
Polymer dissolving station FPU for sludge thickening with disc thickener; Polymer dissolving station FPU for sludge dewatering with screw press
The AWV Hohe Tauern Süd operates a mechanical excess sludge thickening system with a belt thickener. A liquid polymer is used for sludge conditioning. The aging “old plant” was prone to failures and met no longer the necessary technical requirements of the AWV Hohe Tauern Süd.
As a reliable supplier of sludge dewatering systems for many years ACAT was invited to a technical discussion and to submit an offer. Roland Auer, our long-standing sales representative with an extensive experience in the field of sludge dewatering, the ACAT Technique Centre Team Scheibbs and the waste water association worked out a customised offer together. It convinced the plant management and subsequently also the board of directors from both a technical and a business management point of view!
In December 2020, the new polymer dissolving station for the excess sludge thickening with a disk thickener was put into operation. Since then, the system has been running trouble-free.
Almost exactly one year later, in December 2021, the order for a second polymer dissolving station for a sludge dewatering system with a screw press was awarded to ACAT. We will exhibit this reference system at the IFAT 2022 in Munich.
Special features of the system
The entire installation, the mechanical piping and the integration into the existing control system was carried out as an in-house service.
We would like to thank the AWV Hohe Tauern Süd for the trust they have placed in us and to Deputy Operations Manager Gernot Ortner and his team!
Our operating site in Scheibbs is primarily an internal service centre. Its tasks are the production of Ecosorb and Skyvell, the construction and assembly of dissolving and dosing stations on behalf of the respective divisions, and the servicing of the equipment and machines we are supplying.
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In the years 1998 to 2000, ACAT was looking for a location to integrate the existing logistics, into the company, which were completely outsourced. From there service and installations on site should be supported by the technicians. In 2000, the time had come: a former printing plant was acquired in Scheibbs, Lower Austria, and adapted to our requirements. In the past 22 years, an extension followed to create office space and in 2021 the factory premises was extended by a further warehouse and production hall.
Polymer dissolving stations, bentonite make up units, pump stations and various dosing stations are manufactured in the technical and production centre in Scheibbs. Also the associated control systems and switch cabinets are planned, built and programmed in-house. The experience of our field staff in the application of our products flows into the continuous further development. Powder polymer systems are basically differentiated by the wetting technology used: the jet-wet and the disperser technology. Both types have been optimised to achieve perfect wetting and an optimal dissolving result. The control system currently used for the latest systems is a Siemens PLC (S7-1200). The units can also be supplied without a control system for the integration into a PCS system. The difference between the two systems of powder polymer units is the wetting technology of the powder polymer. In the disperser technology, the powder is conveyed directly into the disperser via a screw and wetted with water. The solution is then dissolved in the tank with a stirrer. This technology is often used in municipal wastewater treatment plants.
In recent years, however, Jet-Wet technology has taken the lead also in the field of wastewater treatment. In the Jet-Wet technology, the powder polymer is fed into a venturi with a screw (volumetric quantity measurement) and the powder is blown into the Jet-Wet head with a fan. The fine distribution of the powder and the special arrangement of the nozzles ensure even a better and more effective wetting of the powder with water. The necessary maturation takes place in a storage tank. Then the polyelectrolyte solution is pumped from the solution tank into the storage tank with a transfer pump. We also offer a system for liquid polymers. It is based on a high-energy mixing unit in which the liquid polymer is activated with water.
After overflowing into the storage tank, the solution can be added in the final process by the means of dosing pumps. On request, this system can also be integrated into powder polymer systems and operated as a combination system. A maximum concentration of the polymer solution of approx. 1.0% must be observed for all systems. The polymer feed can be selected in different variants, with big bags or sacks. Special dosing systems can also be added to the preparation units to enable the dilution to the desired polymer concentration and a good dosing.
Depending on the application, pump stations of all types and designs are available. Our competent team consists of very experienced technicians, some of whom have been working with these systems for 25 years, and young engineers who bring in new ideas for further innovations. The strength of this team lies in the individual development and adaptation of the units to customer requirements. Our sales and plant engineers are always at your disposal for more detailed information.
In 1994 polymers were the first major pillar of environmental engineering of the newly established company ACAT. But soon, the question arose whether it would not be strategically advantageous to link the years of knowledge of the employees in the environmental technology with the associated engineering technology to be able to offer total solutions in application technology.
download >In 1994 polymers were the first major pillar of environmental engineering of the newly established company ACAT. But soon, the question arose whether it would not be strategically advantageous to link the years of knowledge of the employees in the environmental technology with the associated engineering technology to be able to offer total solutions in application technology.
The combination of equipment, chemical products, and the expertise and experience of the staff has been very successful.
First steps in construction of smaller units were made in the backyards and garages of our employees. The pioneering work in this field is contributed to our “veteran” in plant engineering, Bernhard Anzenberger, actively supported by the Heads of Department of paper and of environment, Theo Weinbrenner and Erich Sailer.
In 2000 the technology center in Scheibbs, LowerAustria, was bought and converted. A major activity is the design and construction of polymer dissolving units for environmental engineering. The strength of our small manufacturer plant is, above all, to meet special customer requests and to be able to fulfill almost every request with the existing base technology. This flexibility allows us to meet the needs of each municipal sewage treatment plant and to support the environmental technology in the preparation and dosing of its wide range of polymers.
In general polymer systems are distinguished depending on the dissolving technique used.
There are two techniques: the Jet Wet and the dispersion technique.
The procedure and construction of the systems are kept as simple as possible to avoid unnecessary sources of error. The control units used have changed over the years. Today also very simple systems are controlled exclusively by PLC systems.
Of course, for the integration into a process control PCS system our systems are also available without control units. All systems are designed for continuous 24 hour operation.
Dispersing technology
In the case of dispersing technology the powder is con-veyed via a screw, directly into the disperser and wetted with water. Then the powder is dissolved by stirring in the container. This method is often used in municipal wastewater treatment plants.
Jet Wet technology
Alternative solutions are required by our customers and one of these is the Jet Wet technology. In this case the polymer powder is conveyed with a screw into a venture tube and blown with a fan into the Jet Wet head. The fine distribution of the powder ensures a better and more effective wetting.
In both systems the necessary maturing time is achieved in a storage tank. The polyelectrolyte solution is pumped with a transfer pump from the dissolution tank into the storage tank.
We also offer systems for liquid polymers. They are based on a pot fitted with a high-speed agitator mixing the liquid polymer with water. If the pot is full, the mixture overflows into a storage tank. This system is also available in different sizes. It has to be noted that in all systems a maximum concentration of the polymer solution of approximately 1.0% must not be exceeded. The polymer feed can be chosen in different variants, such as big bag or sack.
The following systems are ACAT basic versions
This treatment systems can be equipped with special dosing systems, enabling the dilution to the desired polymer / bentonite concentration and a continuous dosage. All types and designs of pumping stations are available.
For more than 35 years we have been gaining experience in the construction of dissolving systems for a difficult to dissolve chemical: the polymer polyacrylamide. The process engineering knowledge of our field staff combined with the knowledge of our experienced employees of the Technical Centre Scheibbs made it possible to further develop the design and the control technology of our dissolving and dosing systems according to the latest requirements.
download >For more than 35 years we have been gaining experience in the construction of dissolving systems for a difficult to dissolve chemical: the polymer polyacrylamide. The process engineering knowledge of our field staff combined with the knowledge of our experienced employees of the Technical Centre Scheibbs made it possible to further develop the design and the control technology of our dissolving and dosing systems according to the latest requirements. Due to a close cooperation with the plant operators and their operating staff, the demand, the process engineering requirements and the wishes of the costumers were taken into account and individually implemented. The close cooperation with our customers and ACAT‘s flexibility in project implementation convinced three major Tyrolean wastewater associations.
PROJECT WWA HALL, TYROL – FRITZENS
Link: https://www.abwasserverband.com/
Polymer dissolving unit FPU for sludge thickening with belt thickener
16 municipalities have one mission: “We pull together when it comes to cleaning the wastewater from the region and finally discharging it cleanly into the Inn”. Large investments have been made in the past. Today the focus is on keeping the existing infrastructure at a high technical level, expanding and optimizing it. ” This concern was an occasion for the management, represented by Ing. Christian Callegari and for the operating staff, to take a closer look at the thickening of the surplus sludge.
The AWV (wastewater association) operates a mechanical surplus sludge thickening system with a belt thickener. A liquid polymer is used for conditioning. The existing system was outdated, it was prone to failures and met no longer the technical requirements of the AWV Hall Fritzens. In October 2017, the technical options for an investment in the surplus sludge thickening system were examined and offers were invited. As ACAT is a long-standing supplier with a lot of experience in the field of sludge dewatering, our technical experts were also invited to an interview and to submit an offer.
Together with the association our sales representative Roland Auer and the team of the ACAT Technical Centre Scheibbs worked out a tailor-made offer. This offer convinced the board of directors both from a technical and a business point of view! The contract was awarded to ACAT in December 2017. The project was implemented within the desired assembly and commissioning deadlines in the first quarter of 2018 and since then the plant has been running smoothly.
Special features of the system
We would like to thank the management of the AWV Hall in Tyrol-Fritzens for the trust you have placed in us. Thanks also to the two plant managers Manfred Anfang, Hubert Klingenschmied and their teams for their active support and patience when the work sometimes lasted until late at night!
PROJECT ARAB GMBH – AWV WÖRGL, KIRCHBICHL AND SURROUNDINGS
Link: http://www.arab-kirchbichl.at/
Polymer dissolving unit PPU 3 for sludge de-watering with high-performance decanter
In Kirchbichl, about 55,000 m³ of digested sludge with a dry substance content of approx. 3.0 % is dewatered annually. The processing of food waste and the co-processing of a wastewater/sludge mixture from a nearby food processing plant have a significant influence on the quality and composition of the sewage sludge to be treated. In 2017, our sales representative Roland Auer installed a mobile FHM station for powder admixture on a decanter to optimize sludge dewatering. The system was then tested over several winter months. 40 % powder polymer was added to the liquid FHM. The dry substance of the sludge cake remained the same, but the centrate was more stable with this mixture than in conventional liquid operation.
Due to the very good results, a new plant was planned being 100% compatible for the powder processing of both decanters. Together with the association and the Scheibbs Technical Centre, we prepared a tailor-made offer and an economic efficiency calculation was carried out. Our motto “a long-term partnership and the best solution for the customer” was able to convince the association’s decision-makers. The financial means for the conversion were released. The investment for the “New Polymer Plant” should have paid for itself within a few years. In autumn 2018 the plant was installed and since then the plant has been operating with a mixture of 60 % liquid polymer and 40 % powder polymer.
Special features of the system
Results
In a year-on-year comparison of 2018 and 2019, the dry substance content of the discharge was kept stable. Operating the same mode and adding a mixture of 60 % liquid polymer and 40 % powder polymer results in a cost advantage of over 15 % of the operating resources used. Another positive feature is the quality of the centrate. It is much more stable than when operating the plant with liquid polymer only.
We would like to thank the AWV Wörgl, Kirchbichl and the surrounding area for the confidence placed in us. Our special thanks go to the technical manager, Mr. Ing. Johann Kitzbichler, B.Eng. for his commitment and the coordination between the individual areas.
In one of the next issues of inside acat you can read about the Projekct Stadtwerke Schwaz – Waste water department Link: https://www.stadtwerkeschwaz.at/
Polymer dissolving unit PPU 3 for sludge dewatering with high-performance decanter Project award: December 2019 – commissioning March 2020
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