Webster Texas is a suburb of Houston Texas which is the 4th largest metropolitan area in the USA. With close proximity to NASA and the Gulf of Mexico, Webster has a population of 10,680 and over 300 restaurants contributing to their wastewater treatment demands. This provides an ongoing challenge for both maintenance and performance reasons to the existing belt screen technology Webster City WWTP has been using to dewater sludge. Webster is a 3.3MGD Design and 1.4 MGD Actual treatment plant. Webster has also had some significate wear in their Headworks screen system further challenging reliability. EKOTON International Industrial Group is a leading producer of equipment for wastewater treatment and sludge dewatering and visited Webster to survey and engineer solutions to their challenges.
Prior the equipment installation Ekoton made full scale excess sludge dewatering pilot test using dehydrator MDQ-201. Achieved results were very successful so Ekoton offered MDQ 353 C with other auxiliary equipment including a Polymer Feeder unit, macerator and installation platform with safety walkway and fences. Also, important factors influencing the choice of EKOTON Industrial Group as a supplier of equipment were the optimal combination of operating costs (polymer consumption, spare parts, energy consumption, labor, etc.), capital costs as well as the guarantees provided.
During the third quarter of 2018, Ekoton shipped and installed an MDQ-354 C Multi-disc Screw Press and New Polymer Feeder unit to replace the aging belt press which was located 32’ above the plant facility in a press house. In addition to a challenging installation location, contractors had removed all of the existing belt press, piping and wiring requiring Ekoton to build a new custom floor base, safety walkway, new plumbing, conduit and wire. In addition, a Macerator to handle and consume errant plastic (think straws) and other foreign materials was installed in line to the existing sludge pump which was reused. We took responsibility for the provided technological solution and its implementation “turnkey”.
Dehydrator Installation Results
|Type Of Sludge||Excess activated sludge|
|Unit Sludge Supply||95 gpm
|Operation Time||8 h/d|
|Feed Sludge DS Concentration||1.5-2%|
|Cake DS Concentration||16%|
|Average Polymer Dose||22lb/ton DS|
Next, Ekoton shipped and installed a new RKE 0809 2.5MGD Rake Bar Screen (slot width – 5/16”) with accompanying Screw Compacting Press (5-7 times compacting volume) and removed the existing worn screen system. The new screen was engineered to fit the existing 24” channel and like the MDQ-354 installation, completely new wire, controls and actuators were supplied and installed.
Both systems are reportedly operating smoothly and efficiently and are tied into the 24 hour SCADA system in the Webster City control center. The installation of the new screen allowed more effective retention of mechanical inclusions, as well as reduced labor requirements.