Green Technology Industrial Waste Water Treatment
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Colorado Produced Water

Oily Wastewater Treatment Jar Test Colorado Oil Patch

This sample is representative of the produced water from the Colorado oil patch region. The sample contains free and emulsified oil, dirt, and water.

The water is very saline (high in dissolved solids especially chlorides and sodium) which is common in this industry. The sample pH was measured to be 6.8. Floccin™ 1105 was used at a dosage of 0.8 grams/1,000 ml which is a dosage of 6.7 lbs per 1,000 gallons. The jar testing results are in the photo below:

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Another treatability test of our flocculating agents.

Potato Flume Water Treatabiliy with Floccin™ is VERY HIGH!

This is the wastewater sample that was received from a potato processing facility.

The facility utilizes water in a flume to transport potatoes. The resulting flume water has high levels of suspended solids. The flume water from the facility was tested with the Floccin™ K and it treated well at a dosage of 0.75g/1000 ml which equates to a dosage of 6.26 lbs/1,000 gallon.

A 1,000ml beaker filled with the water sample was used to conduct the treatability; the starting pH was recorded at 6.3. Floccin™ K was used for testing. 0.75 grams of Floccin™ K was added to the 1,000 ml beaker containing the wastewater.

Flocculation occurred around 30 seconds of mixing and after 3 minutes of mixing, the beaker was removed from the mixer and the solids were allowed to settle. The treated water had very low turbidity.

The results are shown in the photos below:

Left: Untreated Wastewater Sample Right: Treated

The water was tested with different dosages of Floccin™ in order to observe the clarity of the water at different dosages. The water was treated with 0.5 grams and flocculated well but the treated water was slightly cloudy. Treating with 1 gram of Floccin™ K produced results that were indistinguishable from the water treated with 0.75 grams.

The results are pictured below.

Left: .5 Grams/1000ml Wastewater Right: .75 Grams/1000ml

Good flocculation was achieved with 0.5 grams Floccin™ K in a 1000ml beaker however the resulting treated water had higher turbidity than the water treated with higher dosages.

There was no perceivable improvement in water clarity for water treated at higher dosages than 0.75 gm/1000ml.

Left: .75 Grams/1000ml Wastewater Right: 1 Gram/1000ml Wastewater

Wastewater Lagoon

The water from Lagoon 1 was treated with Floccin™ K and it treated well with 0.5 grams of Floccin™ K in a 1,000 ml beaker. This equates to 4.17 lbs/1000 gallons. Flocculation began after about 30 second and after 3 minutes of mixing the solids were allowed to settle and the settling occurred quickly.

Left: Untreated Lagoon 1 Sample Right: Treated

The water from Lagoon 2 was treated with Floccin™ K and it treated well with 0.5 grams of Floccin™ K in a 1000 ml beaker which equates to 4.17 lbs/1000 gallons. Flocculation began after about 30 second and after 3 minutes of mixing the solids were allowed to settle and the settling occurred quickly. The results are shown in the picture below.

Left: Untreated Lagoon 2 Sample Right: Treated

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“Treatability” is actually a noun that describes the ability of something “to treat” something. Makes sense when you look at the word broken down “treat+ability”.

Still in all, we mostly use it as an adjective, like “treatable”, to mean “able to be treated”. The killer Floccin™ line of flocculating agents has fantastic treat ability. Water samples may be very treatable or may be not so treatable, usually with our flocculating agents problem water is rendered highly treatable.

This particular fish processor sample proved to be easily treated.

Fish Processor Case Study

Fish Processor Wastewater Treatability? VERY TREATABLE

The wastewater was received from a fish processing plant that utilizes water to float fish.

Jar testing revealed that Floccin™ 1106 as the most effective product for treating the wastewater. A 1,000 ml beaker filled with the water sample was used to conduct the treatability. 2 grams of Floccin™ 1106 were mixed in 1,000 ml of wastewater which equates to 16.7 lbs/1000 gallons.

The results are pictured below.

Left: Untreated Wastewater Sample Right: Treated

The facility would like to reuse the water which will require post hydrocarbon removal and ozonation subsequent to Floccin treatment.

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DAF Pilot Dissolved Air Flotation Wastewater Liquids Solids Separation

Industrial Wastewater DAF Treatibility Testing Portable Unit

The DAF Pilot (Dissolved Air Flotation) is used to demonstrate the onsite treatibility of customer’s wastewater.

The unit requires 30 amps at 480volts to operate (8GA 4-wire extension cord). The unit operates automatically, treating, filling and skimming, then repeating as long as there is water in the sump to be treated. The DAF pilot has two separate Mixing Tanks a built in Floccin™ Feeder and variable speed controls for the skimmer, the feeder and the mixers. This unit is capable of 10-25 GPM, depending on the % solids is your wastewater.

Overall Dimensions (includes trailer, wheels and mixer motors)
20’L x 8’ W x 10’H

Left: Untreated Water Right: Floccin/ DAF Treated Water

DAF skimming sludge off of the Treated Water.

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Corrugating Facility Wastewater Optimization

This corrugating company did not have an existing pretreatment system. Wastewater from their converting and corrugating operations was sent directly to the city’s three stage clarifier for discharge. Sludge generated from this process within the city’s three stage clarifier, along with the water discharge without any pretreatment, resulted in high contaminants; such as various metals, BOD, TSS, resulting in discharge violations, multiple surcharge fees, and an additional annual cost of $50,000.00 for sludge haul off and excessive surcharge fees to the city.

This company contacted Integrated Engineers, Inc. for a wastewater treatment system that would accommodate their facility and solve their current issues. Our engineering department completed an onsite visit to detail the process that was to be recommended to the customer. A treatability study was also conducted with wastewater that was generated daily from their treatment process for the company’s review.

Box Company Wastewater Jar Test Click For Larger Image

Integrated Engineers, Inc. proposed a manual batch system sized for a facility that generates 5,000 gallons of wastewater per day. Our Floccin 1119 product was also included as this produced the most favorable results during testing. (Pictured above.) Floccin 1119 is a non-hazardous granular product that has replaced traditional chemistry (coagulants, caustic, polymer), over the years.

The layout of the facility required two Equalization tanks to hold the influent wastewater, one reaction tank for the pretreatment process, access platform was measured to make access to the treatment tank, a Filter Press was sized for sludge dewatering, and a Floccin Feeder was included for dispensing our granular product. Mixers were also integrated with the system based on tank design and capacity.

Drawing of Box Company Wastewater Treatment System

The Filter Press generated drier filter cakes with a 45-50% solids consistency making it possible to dispose the dewatered sludge to a local landfill without paying hazardous disposal fees. (Drier filter cakes also make cleaning the filter press less time consuming which can result in reduced labor costs.)

Filter Press Cake

After Integrated Engineers, Inc. completed the installation/start-up and training, a sample of the treated water was sent to a lab for analysis to determine if this facility is now in compliance with city discharge requirements.

Foundation for Wastewater Treatment Tanks Click Image for Larger View, Use Your Back Button to Return

Competed Install Click Image for Larger View, Use Your Back Button to Return

Lab Analysis confirmed they were in compliance and this facility continues to operate their system properly without experiencing any mechanical issues, they have been maintaining compliance, and are relieved to not have to deal with their previous issues.

The Total Threshold Limit Concentration (TTLC) and the California Soluble Threshold Limit Concentration (STLC) is used when determining the hazardous waste characterized under California State regulations as outlined in Title 26 of the California Code of Regulations (CCR). The intent of the leachate procedures are to simulate the conditions that may be present in a landfill where water may pass through the landfilled waste and travel on into the groundwater carrying the soluble materials with it. The first test conducted is the TTLC analysis, if a contaminant does not pass then an STLC test is performed to see if the contaminants are within the state’s discharge requirements.

Copper was a contaminant that consistently created issues between this facility and the city where at this time the effluent water has successfully passed the CAM 17 Metals test.

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Corrugating Facility Wastewater Optimization

Integrated Engineers, Inc. modified a corrugating facility in Southern California that required a design build solution to improve their existing wastewater treatment process.

Their previous treatment process involved using Sodium Hydroxide to raise the pH, coagulant in the form of aluminum chloride, and an anionic polyacrylamide polymer. This company would blend polymer daily with water to create a 1% solution. Coagulant is combined with the wastewater, where sodium hydroxide is added to increase the pH to a level of 6.5. The anionic flocculant is mixed in the reaction tank just prior to being pumped to the DAF (Dissolved Air Flotation) unit, where sludge is skimmed off and dewatered through a Filter Press. The faculty had to retreat their filtrate water of 1,000 gallons per day due to solids in the filtrate.

Previous Corrugating Facility Wastewater Treatment System

Integrated Engineers, Inc. proposed the Floccin Process to generate their wastewater through a pretreatment system with optimal efficiency.

The Floccin replaced their conventional chemistry, all three chemicals (one of which is hazardous), to treat the wastewater; minimizing costs for labor, maintenance, permit and hazardous waste fees, and produces filter cakes with a 40-50% solids consistency, and sludge reclassified as non-hazardous waste, for local landfill disposal.

New Corrugating Facility Wastewater Treatment System

The new process is simplified and required 50% less horsepower to run. The Floccin Process uses a mixer and a reaction tank to treat the influent water. The solids are allowed to settle and the clear water is decanted through the Filter Press. The settled solids are dewatered and the filtrate is clean enough to discharge without being retreated.

Mix Tank

Wastewater Mixer

Changes to the system include installation of the Floccin Feeder, a mixing bridge and mixer for the mix tank. The faculty was able to remove the Chemical Reaction Tank, the DAF, the sodium hydroxide, coagulant, and polymer containers as these were no longer needed. The result increased the system capacity by 40% by not having to retreat the filtrate water, 40% savings on chemicals and six man hours a day in labor savings.

Lab Analysis confirmed the sludge passed the TCLP/STLC (reclassification of the sludge from hazardous to non-hazardous, but regulated), thereby reducing the sludge haul off costs and any environmental liability for the facility in regards to landfill disposal. Operator time and monitoring is greatly reduced saving hours of labor.

This is a great example of how and why the wastewater water optimization process is so desirable.

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Aluminum Anodizer Case Study 2

The facility treats their wastewater using an EQ Tank followed by a Mix tank and clarifier. The solids that settle are dewatered with a plate and frame press. The treatment process uses caustic to raise the pH from 4 to 9 and then a coagulant along with a metal precipitant as well as a flocculent to treat their wastewater. The clarified water is discharged to the local POTW and the sludge is hauled offsite for landfill disposal. The filtrate from the plate and frame press estimated at 600 gallons/day is returned for retreatment to the EQ Tank.

Wastewater Sample

The sample of the wastewater was bench tested and according to the client, was the worst case scenario and at a pH of 1.3. The 1,000 ml sample was pH adjusted with 5.4 grams of caustic to a pH of 9.0. The Floccin 1105 was added at a dosage of 0.75 grams in the 1,000 ml (750 ppm or 6.3 lbs/1,000 gallons) and a good settled floc formed after mixing for 2 minutes. The solids settled in as shown in the photo (below) in 45 seconds.

Sludge Cake

The settled sludge volume was 25% by volume (refer to the photo). It dewatered well in our simulation and generated a sludge weight of 7.2 grams from 1,000 ml of wastewater with a % solids of 30%. So this represents a sludge generation rate of 60lbs/1,000 gallons.

The treatment cost for the caustic is estimated at $15/1,000 gal (45 lbs./1,000 gallons) and the Floccin 1105 at $9.45/1,000 gallons.

Units in ppm or mg/L

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pH Adjust co2 Control Unit

These pH control systems use a programmable pH controller and pH probe to proportionally control the flow of carbon dioxide direct injection into any flowing liquid. This decreases the pH from a basic level to a programmable set point on an ongoing automated basis.

This carbon dioxide injection in water using gas diffuser(s) converts the carbon dioxide to carbonic acid in the water, consuming alkalinity, thereby decreasing the pH.

The system is easy to calibrate and uses 120-volts AC, 3 amps, for power. The system includes the sc100 pH controller, pH probe, gas regulator, NEMA 4X control panel with swing out sub panel, clear window and optional stainless steel stand.

CO2 is commonly available in 50 lb, 600 lb and bulk containers. All components are neatly housed in the compact enclosure that can either be wall mounted or free standing with the optional stainless steel stand. The system supports gas flows up to 500 CFM.

Benefits of CO2 VS. Mineral Acids

• Non hazardous (documented inventory or manifests)
• No drum disposal costs
• No secondary containment needed
• Minimal EC/TDS addition
• CO2 operating costs are less than using mineral acids
• No liability for operators

Cooling Tower Applications

Cooling Tower Sketch co2 pH Adjustment Application

Well Potable Water Applications

Well Potable Water co2 pH Adjust Application Drawing

Standard Features:

• In Tank Diffuser (If needed)
• pH probe
• Hach SC100 pH Controller

Standard Features co2 pH Automated Control Systems

Optional Features:

• Inline Pipe Diffuser
• Additional Diffusers
• Additional pH Probe
• Inline Probe Adaptor
• Chart Recorder
• Stainless Steel Stand

Inline Pipe Installation

Inline Pipe Installation with Diffuser & co2 pH Control Adjustment Controller

Gas Diffuser Plate:

• Nearly 100% CO2 saturation
• State of the art engineering
• Spectacular results

Gas Diffuser Plate for co2 Injection pH Control System

Chart Recorder:

• Track your pH
• Ensure pH compliance
• Charts available with a variety of increments

Chart Recorder for co2 Injection pH Control Adjustment System

Inline pH Probe:

Inline pH Probe & Mounting Hardware

pH Probe Mounting Hardware Options:

1. PVC fitting; Mount to NPT threads (enclosed probe)
2. PVC fitting; Mount to NPT threads (exposed probe)
3. PVC fitting; Mount inline with adaptor (enclosed probe)
4. Stainless Steel fitting: Mount inline with adaptor (enclosed probe)

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Why control pH with co2?

In wastewater treatment, a pH control system that uses a programmable pH controller and pH probe to proportionally control the flow of carbon dioxide injection decreasing the pH from a basic level to a programmable set point, can substantially streamline any pH adjustment process.

The process of adding carbon dioxide to water using a gas diffuser(s) converts the carbon dioxide to carbonic acid in the water, consuming alkalinity, thereby decreasing the pH. This type of system is very easy to calibrate and can use as little as 120-volts AC, 3 amps, for power. When automated, these systems will also include a pH controller, pH probe, gas regulator, a control panel and can be mounted in a number of ways. CO2 is commonly available in 50 lb, 600 lb and bulk containers.

In a well designed automatic pH control system, all components are neatly housed in a compact enclosure that can either be wall mounted or free standing on a stand. These systems can be scaled to support virtually any gas flow with most not exceeding 500 CFM.

Benefits of CO2 VS. Mineral Acids

• Non hazardous (documented inventory or manifests)
• No drum disposal costs
• No secondary containment needed
• Minimal EC/TDS addition
• CO2 operating costs are less than using mineral acids
• No liability for operators

Features of this type of system:

• In Tank Diffuser (If needed)
• pH probe
• Hach SC100 pH Controller
• Gas Diffuser Plate
  • Nearly 100% CO2 saturation
  • State of the art engineering
  • Spectacular results
• Chart Recorder
  • Track your pH
  • Ensure pH compliance
  • Charts available with a variety of increment

Optional Features:

• Inline pH Probe
• Inline Pipe Diffuser
• Additional Diffusers
• Additional pH Probe
• Inline Probe Adaptor
• Chart Recorder
• Stainless Steel Stand

Typical Applications

• Wastewater pH Adjustment
• Well Potable Water Applications
• Cooling Tower Applications

pH Probe Mounting Hardware Options:

1. PVC fitting; Mount to NPT threads (enclosed probe)
2. PVC fitting; Mount to NPT threads (exposed probe)
3. PVC fitting; Mount inline with adaptor (enclosed probe)
4. Stainless Steel fitting: Mount inline with adaptor (enclosed probe)

Using co2 injection can be a very cost effective and efficient way of easily and automatically adjusting the pH of water in a number of different applications. More pH Adjustment.