The wastewater treatment plant in Madisonville, Kentucky (USA) processes waste activated sludge (WAS) with an initial dry solids content of 3–5%. Recently, the facility began facing increasing operational loads, which led to the search for a more effective sludge dewatering solution.
An operational challenge that triggered change
As the load increased, the plant encountered a serious challenge. To maintain process continuity, an additional dewatering unit was rented and a second operating shift was introduced to support the existing, worn equipment.
While this temporary solution allowed the process to continue, it involved high costs and did not deliver the expected performance. Over time, it became clear that a technology was needed that could ensure stable and efficient operation while optimising costs.
At that point, the plant team returned to pilot tests previously conducted together with ESMIL specialists. During those trials, an MDQ multi-disk screw press was tested under real operating conditions and achieved very good results—both in terms of dry solids content in the dewatered cake and polymer consumption.
During 16 test cycles, the unit reached an average dry solids content of 21.2%, with the best results exceeding 25%. These outcomes confirmed the effectiveness of the ESMIL solution in practice and became the basis for renewed contact with the ESMIL team to support the growing operational issue.
Fast response to an operational crisis – ESMIL Module D mobile dewatering station
At this stage, the ESMIL Module D containerised dewatering unit was introduced – a solution designed to provide flexibility, rapid deployment and real support in critical situations.
The entire system is installed inside a 40-foot container, adapted for HVAC installation, allowing operation in different locations and conditions. The station is fully equipped and includes:
- an MDQ-503CL multi-disc screw press with three dewatering drums,
- a polymer preparation and dosing unit with space for a tote container,
- sludge pump and flowmeter,
- macerator,
- ESMIL screw conveyor for transporting dewatered sludge.
Only a few days after the request, the Module D station was delivered and commissioned at the plant. Installation and start-up were carried out by ESMIL service engineers, who also provided on-site operator training to prepare the staff for independent system operation.
Implementation results
Immediately after installation, the Module D mobile dewatering station began operating at full capacity. The achieved results exceeded expectations – the ESMIL unit not only increased dewatering efficiency, but also outperformed the combined capacity of the existing equipment and the rented solution. An additional advantage was cost-related. Renting the ESMIL mobile system represented only a fraction of the weekly costs previously incurred for rented equipment. As a result, the plant restored stability to its dewatering process while significantly reducing operational costs.
The Madisonville case is another example of how ESMIL Module D supports facilities in crisis situations, providing efficiency, flexibility and continuity of operation when time is critical.
