When rising sludge disposal costs began to spiral out of control and place a serious strain on the operating budget of a chemical production plant in Charleston, North Carolina (USA), a fast and effective solution was urgently needed. The company began an intensive search for a modern sludge dewatering technology that would not only reduce expenses but also improve overall process efficiency. The plant turned to ESMIL, which quickly delivered the perfect answer – a mobile sludge dewatering system.
About the Facility
The facility is one of the leading producers of specialty chemicals for applications such as asphalt, adhesives, industrial coatings, and printing resins. Its production processes generate significant volumes of wastewater, which in turn produce sludge requiring further treatment and disposal.
Until recently, this sludge was transported off-site. However, due to the large volumes involved, rising transportation costs increasingly strained the plant’s operating budget. This challenge prompted the search for a more efficient sludge dewatering solution.
Sludge Characteristics
The plant’s processes generate a mixture of chemical sludge and biologically activated sludge, with an average dry solids content of around 8%.
Process Requirements
Based on operational needs, the new dewatering system had to be capable of processing approximately 30 GPM of sludge continuously.
Implementation Goals
The project set out to address current operational challenges with three main objectives:
Increase dewatered sludge content to 20–25% dry solids,
Reduce sludge disposal frequency and overall operating costs,
Minimise operator involvement, limiting manual handling to essential tasks only.
A Practical Approach to Operational Challenges – ESMIL Mobile Sludge Dewatering System
To address the project requirements, ESMIL specialists recommended the use of a mobile sludge dewatering system built around the MDQ-503CS multi-disk screw press. The entire installation is mounted on a trailer, ensuring full mobility, straightforward transport, and rapid deployment – without the need for complex on-site construction or installation work.
The mobile dewatering unit is a fully self-contained solution, equipped with:
Sludge feed pump with integrated flow meter,
Polymer preparation and dosing system with tote-type storage tank,
Macerator for sludge homogenisation prior to dewatering,
ESMIL MDQ-503CS multi-disk screw press – the core dewatering component,
Screw conveyor for the collection and transfer of dewatered sludge,
Centralised control panel enabling automated, stable operation with minimal operator input.
This flexible and efficient configuration allows the facility to manage sludge volumes effectively, reduce disposal costs, and improve process stability – all without disrupting ongoing production.
As per the standard for all ESMIL mobile solutions, the installation required only three connections: to the sludge source, electrical power supply and water supply.
Once the system was up and running, ESMIL service technicians carried out a full setup, adjusting the operating parameters to match the actual on-site conditions. This was followed by operator training, covering both equipment handling and basic maintenance procedures.
Another Successful ESMIL Implementation
The deployment of a mobile sludge dewatering system based on the MDQ series multi-disk screw press enabled the chemical manufacturing facility to successfully address its most critical operational challenges. The installation streamlined sludge management logistics and significantly reduced costs related to sludge transport and disposal.
Thanks to its compact, plug-and-play design, the system was up and running almost immediately after delivery, with no need for lengthy installation work.
Implementation results:
Achieved a dry solids content above 25%, reducing sludge volume and lowering disposal costs,
Reached a throughput of 30 GPM, fully aligned with the facility’s process requirements,
Delivered a high level of automation, limiting operator involvement to basic supervision and improving process efficiency.
