The Barberton Wastewater Treatment Plant (WWTP) in Barberton, OH, recently enhanced its sludge management process by installing an Esmil MDQ-404CL Multi-Disk Screw Press, which significantly improved dewatering efficiency. However, when the plant began renovations on their dewatering building, they faced the challenge of being unable to operate the newly installed equipment. To ensure continuous operation, Esmil provided a cutting-edge, containerized dewatering unit, known as the “Module D.” This modular system served as a temporary yet fully functional replacement for the entire dewatering facility, allowing Barberton WWTP to maintain seamless sludge dewatering operations throughout the renovation period.
Client Overview:
Barberton WWTP is responsible for treating and managing wastewater for the City of Barberton, OH. In their ongoing efforts to improve sludge management, the plant had recently installed an Esmil MDQ-404CL Multi-Disk Screw Press. This upgrade significantly enhanced their dewatering performance, reducing sludge volumes and operational costs.
Challenges:
Shortly after the installation of the new Esmil screw press, Barberton WWTP initiated renovations on their dewatering building, making it impossible to use the new equipment on-site. Without a temporary solution, the plant risked halting sludge processing, leading to operational inefficiencies and increased sludge hauling costs.
Solution:
To address this operational gap, Esmil proposed the use of a brand-new containerized dewatering unit, the “Module D.” This portable, modular system is designed to replace an entire dewatering facility, offering a fully functional solution that includes all necessary components for efficient sludge handling. The Module D unit was equipped with an MDQ-503CS Multi-Disk Screw Press, polymer dosing systems, control panels, and conveyors, all housed in an insulated 40-foot container with HVAC.
The containerized Module D was rapidly delivered and connected to Barberton WWTP’s existing systems, ensuring minimal downtime. Its plug-and-play design allowed for an easy and quick setup, with Esmil providing technical support to guarantee smooth operation. This solution offered the plant the flexibility to continue its dewatering processes without the need for permanent infrastructure during the renovation period.
Performance:
The MDQ-503CS Multi-Disk Screw Press delivered outstanding dewatering performance. Operating at a capacity of 60-70 gallons per minute, the system efficiently processed sludge with an initial dry solids content of 3.5%. The screw press produced a final sludge cake with a dry solids content of 26%, substantially reducing sludge volume and further enhancing dewatering efficiency compared to the plant’s older belt filter presses.
Main Advantages of the Esmil Containerized Dewatering System Module D:
- Portability and Flexibility: The Module D is a fully portable solution that can be quickly deployed and set up, making it ideal for temporary use during renovations, emergencies, or as a stop-gap during equipment upgrades.
- Plug-and-Play Design: The system is designed for easy integration with existing infrastructure, allowing for quick and seamless setup with minimal disruption to ongoing operations.
- Superior Dewatering Efficiency: Equipped with the MDQ-503CS Multi-Disk Screw Press, the system delivers high dry solids content, effectively reducing sludge volumes and disposal costs.
- Low Maintenance and Operational Costs: Designed with fewer moving parts and robust construction, the Module D system requires minimal maintenance, lowering operational expenses.
- Energy Efficiency: The containerized unit is energy-efficient, consuming less power than traditional dewatering systems, which contributes to cost savings and sustainability.
- Compact and Self-Contained: Housed in a 40-foot insulated container with HVAC, the Module D includes all necessary components—sludge pumps, macerator, polymer feeder, conveyors, and control systems—within a compact, self-contained unit.
- User-Friendly Operation: The advanced control system allows for easy operation and real-time monitoring, ensuring smooth and efficient dewatering processes.
Made in the USA with Compliance to US Standards:
The MDQ-503CS Multi-Disk Screw Press, along with the entire Module D unit, is proudly manufactured in the USA, adhering to strict US standards such as ASME and BABA. This compliance ensures safety, reliability, and quality, making Esmil’s solutions a trusted choice for wastewater treatment facilities across the country.
Equipment:
Esmil Module D, including:
- Insulated 40′ container with HVAC
- MDQ-503CS Screw Press
- Sludge feed pumps
- Sludge macerator
- Polymer Feeder Velodyne
- Screw conveyor
- Booster pumps
- Control system
Conclusion:
Esmil’s innovative Module D containerized dewatering solution enabled Barberton WWTP to continue its sludge processing operations uninterrupted during their dewatering building renovations. The successful implementation of this temporary solution highlights Esmil’s ability to deliver flexible, high-performance technologies that meet the evolving needs of wastewater treatment plants, ensuring both operational continuity and efficiency.
