References

Equipment: MDQ-502 CS Multi-Disc Screw Press

Industry: Production of raw materials for feed, fertilizers, biofuels, food and renewable energy from organic by-products

ISSUE

An industrial facility in Knoxville, Tennessee (USA), processing organic by-products faced insufficient sludge dewatering performance with its existing screw press system.

The previous installation operated at:

• capacity: 55 GPM at 1.2% DS inlet
• outlet dry solids content: approx. 13%

Low dewatering efficiency resulted in increased sludge transport and disposal costs.

SOLUTION

To improve dewatering performance, the client implemented an MDQ-502 CS multi-disc screw press equipped with two dewatering drums. Delivered under a rental program, the unit enabled rapid deployment and on-site evaluation under real operating conditions without the need for full capital investment.

The MDQ screw press dewatered sludge directly from the clarifier, eliminating the need for a separate thickening stage. This simplified the overall process layout while reducing operating costs.

RESULTS

After implementation, the facility achieved:

• increased capacity from 55 GPM to 120 GPM
• dry solids content improved to 17-18%
• reduced sludge volume for transport and disposal
• simplified process layout without sludge thickening
• improved sludge handling efficiency and lower OPEX

The project demonstrated how the MDQ multi-disc screw press can increase dewatering performance and process stability while simplifying sludge management in industrial applications.

Equipment: xJD-1500 Roller Press

Type of sludge: Mixed Waste Digestate (source: various industrial feedstocks and municipal wastewater treatment sludge)

ISSUE

A biogas plant in Cleveland, Ohio (USA), required an effective dewatering solution for mixed waste digestate generated from industrial feedstocks and municipal wastewater treatment sludge.

The digestate contained high amounts of abrasive materials, sand, stones and fibrous debris, with dry solids content ranging from 6% to 9%. The process required stable dewatering performance, clean filtrate and reliable operation without the use of wash water.

SOLUTION

To address these requirements, ESMIL supplied the xJD-1500 Roller Press designed for demanding sludge dewatering applications involving abrasive and difficult-to-process sludge.

The patented roller press technology enables efficient dewatering while handling large debris and preventing clogging through mechanically self-cleaning filtration slots.

RESULTS

The installation provided stable and reliable operation despite the highly abrasive sludge characteristics, while delivering clean filtrate suitable for further treatment.

Equipment: Mobile sludge dewatering system based on the MDQ-503CS Multi-Disc Screw Press

Type of sludge: Mixture of chemical sludge and biologically activated sludge

ISSUE

A chemical production plant in Charleston, North Carolina (USA), faced rapidly increasing sludge disposal and transportation costs related to the handling of chemical and biologically activated sludge with an average dry solids content of approx. 8%.

The facility required a sludge dewatering solution capable of processing approx. 30 GPM continuously, while increasing dry solids content, reducing disposal costs and minimising operator involvement.

SOLUTION

To address these requirements, ESMIL supplied a mobile sludge dewatering system based on the MDQ-503CS multi-disc screw press.

The trailer-mounted unit included:

• sludge feed pump with integrated flow meter
• polymer preparation and dosing system
• macerator
• MDQ-503CS multi-disc screw press
• screw conveyor for dewatered sludge transport
• centralised control panel for automated operation

The mobile system required only connections to sludge feed, water and power supply, enabling fast deployment and commissioning directly at the facility.

RESULTS

The implementation allowed the plant to:

• achieve dry solids content above 25%
• reduce sludge transportation and disposal costs
• process sludge at a capacity of 30 GPM
• minimise operator involvement through automated operation

The project demonstrates how mobile sludge dewatering systems can help industrial facilities quickly stabilise sludge handling processes while improving operational efficiency and reducing costs.

Equipment: MDQ-404(3) CLD Multi-Disc Screw Press

Type of sludge: Waste activated sludge (WAS) generated in its SBR reactors

ISSUE

The wastewater treatment plant in Wilmington, Ohio (USA), faced increasing sludge volumes, making it difficult to maintain efficient and stable sludge dewatering with the existing system.

SOLUTION

To modernise the dewatering process, ESMIL supplied a Multi-Disc Screw Press MDQ-404(3) CLD equipped with:

• three active dewatering drums
• integrated polymer preparation and dosing system
• control panel with touch-screen interface

The MDQ-404(3) CLD was factory-prepared for future installation of a fourth dewatering drum, allowing the plant to increase dewatering capacity whenever needed – without replacing the entire unit or carrying out major reconstruction works.

RESULTS

The new dewatering system provided:

• improved dewatering efficiency and reduced sludge hauling costs
• stable 24/7 operation
• fully automated process with reduced operator involvement
• scalable capacity ready for future increase of sludge volumes

CONCLUSION

The Wilmington project reflects the ESMIL approach to sludge dewatering: delivering solutions that solve current operational challenges while giving facilities the flexibility to adapt to future process demands.

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