References

Size of WWTP –  700 gallons per day
End User / Customer – Dairy Processing Plant
Start of Operation – March 2023

At Esmil, we excel at providing tailored solutions that address even the most unique industrial challenges. Our recent success story in Pennsylvania demonstrates our commitment to efficiency, cost savings, and environmental responsibility.

Challenge

A processing/industrial facility in Pennsylvania faced a daunting task – dewatering up to 7000 gallons per day of dairy sludge, starting with an initial dry solids content ranging between 3 and 3.5%. Their primary goal was to elevate the dry cake solids to above 15%, significantly reducing the expenses associated with haul out.

Solution

Esmil stepped in with an approach that perfectly matches the plant’s requirements:
– 2-Drum Multi-Disk Screw Press MDQ-302CD: With relatively light processing needs, we specified the MDQ-302CD, a compact yet high-performance dewatering solution.
– Enclosed Shaftless Screw Conveyor: As part of our comprehensive solution, we included our enclosed shaftless screw conveyor, ensuring smooth and efficient transport of dewatered sludge.

Minimizing polymer consumption

Our solution not only achieved the desired dry cake solids content but also kept polymer consumption to a minimum. Esmil’s MDQ dewatering technology empowers operators to optimize polymer dosing during setup. Operators can control the polymer dosing process. They can visually monitor the flocculation tank and adjust polymer dosing in real-time. The operator interface terminal (OIT) allows for precise adjustments to achieve optimal flocculation. Operators can fine-tune the polymer dose until the perfect flocculation point is reached, ensuring maximum efficiency.

The outstanding results

Esmil’s solution not only met but exceeded the customer’s expectations:
–Achieving High Cake Solids: The MDQ-302CD system successfully increased the dry cake solids to above 20%, dramatically reducing haul-out
– Cost Efficiency: Minimizing polymer consumption was achieved without compromising performance, ensuring cost savings and environmental responsibility.
– Customer Satisfaction: The customer was completely satisfied with our solution, which was installed in March 2023.

Conclusion

Esmil’s commitment to innovation, efficiency, and sustainability shines through in every project. Our dairy sludge dewatering success story in Pennsylvania exemplifies our dedication to meeting unique challenges and surpassing expectations.

Are you ready to transform your dewatering processes, reduce costs, and achieve remarkable results? Contact Esmil today to explore how our cutting-edge solutions can make a difference in your operations. Efficiency, sustainability, and cost savings are not aspirations; they’re a guarantee with Esmil.

Model of Multi-Disk Screw Press –MDQ-354(2)CL
Start of operation – 2020 June

ISSUE

In the plant sludge drying beds for sludge dewatering were used. This method required lots of labor and constant maintenance. Due to this reason, the customer was looking for an efficient and minimal maintenance solution.

SOLUTION

On-site pilot tests were carried out, using mobile dewatering unit MDQ-201, to find the best dewatering technology. According to the test results Esmil offered sludge dewatering complex based on Multi-Disk Screw Press MDQ-354(2)CL. The complex includes – influent sludge feed pump, polymer feeder, three screw conveyors and service platform.

Results

Model of Multi-Disk Screw Press – MDQ-353 C
Start of operation –2020 February

ISSUE

Soapberry WWTP located near Kingston Harbour has been operated since 2004. Biological wastewater treatment process is based on wetland lagoons. The WWTP has not previously had any sludge processing equipment, therefore since the start-up of the plant lagoons have been gradually filled with dry solid particles. As a result, sludge accumulation had impact on biological process efficiency, because of the reduced effective volume of the lagoons. For this reason, customer was looking for the solution to clean the bottom of the lagoons and process the sludge.

SOLUTION

The lagoons cover an area of nearly 1480 acre. Bottom sludge from the lagoons is removed by remote controlled dredger supplied by Dragflow. For this reason, ESMIL offered Mobile dewatering complex based on Multi-Disk Screw Press MDQ-353 C. The complex includes a mechanical screen, sludge tank, influent sludge feed pump, polymer solution preparation unit, polymer dosing pump, water tank, water pump and screw conveyors. All the equipment is mounted on the common platform. The complex can be fitted in a standard 40’ container or on a trailer, which allows easy relocation.

Results

Type of industry – Renewable energy
Model of Multi-Disk Screw Press – MDQ-354CL
Start of operation – 2020 January

Issue

The customer was looking for a solution to replace one of the three existing centrifuges as well as to increase dry solid content, reduce energy consumption and improve operation.

Solution

On-site pilot tests were carried out, using mobile dewatering unit MDQ-201, to find the best dewatering technology. According to the test results Esmil offered sludge dewatering technology based on Multi-Disk Screw Press MDQ-354CL together with service platform.

Results

Type of Industry – Food and Beverage Industry
Start of Operation – 2019 November

ISSUE

In this plant sludge from DAF-unit and MBBR reactor was stored on-site in tanks and its utilization was outsourced to an external company. Due to expansiveness of such service, it was decided to build a local dewatering facility to reduce sludge volume and its disposal cost.

SOLUTION

Esmil offered a sludge dewatering solution based on Multi-Disk Screw Press MDQ- 353C. Other auxiliary equipment including a polymer solution preparation unit and pumps as well as piping was supplied by our local partners, assembled by the customer and commissioned by Esmil representatives to meet the highest dewatering process efficiency.

END USER’S COMMENT

Since the commissioning, the performance of the dewatering equipment has been stable, highly efficient and with no issues. High dewatering efficiency resulted in significant sludge volume reduction, so the construction of the local dewatering facility has paid off very quickly.

Results

Model of Multi-Disk Screw Press – MDQ-102C
Start of Operation – 2019 November

ISSUE

The customer was looking for a low-cost, yet reliable and easy-to-operate solution for sewage from a construction site of an offshore platform treatment.

SOLUTION

Project was carried together with our partner MABAREX. Esmil offered Multi-Disk Screw Press MDQ-102 C, which is part of the containerized wastewater treatment plant.

Results (Canada, Argentia)

Type of Industry – Dairy Processing
Model of Multi-Disk Screw Press – MDQ-353C
Start of Operation – 2018 December

ISSUE

The customer had an interest in reducing sludge disposal costs in their industrial wastewater treatment plant by obtaining lower maintenance costs and lower energy consumption. The plant treats industrial wastewater from a nearby cheese factory and generates about 15,000 gallons of activated sludge from its MBR system per day.

SOLUTION

On-site pilot tests were carried out, using mobile dewatering unit MDQ-201, to find the best dewatering technology. According to the test results Esmil offered sludge dewatering technology based on Multi-Disk Screw Press MDQ-353C.

Results

Model of Multi-Disk Screw Press – MDQ-354C

Start of operation – 2018 August

ISSUE

The customer had an interest in reducing sludge disposal costs in their municipal wastewater treatment plant by obtaining lower maintenance costs and lower energy consumption. The plant treats wastewater from nearby residential areas and numerous local restaurants and generates about 120 gallons of aerobically digested sludge from their digesters per minute.

SOLUTION

On-site pilot tests were carried out, using mobile dewatering unit MDQ-201, to find the best dewatering technology. According to the test results Esmil offered sludge dewatering complex based on Multi-Disk Screw Press MDQ-354 C. The complex includes macerator, polymer feeder and service platform.

Results