Green Technology Industrial Waste Water Treatment
Profit Boosting Industrial Waste Water Treatment Made Easy

100% Wastewater Recycling

55 Gallon Drum & 275 Gallon Tote Washing Operation’s Wastewater Floccin™ 909 Treatability Wastewater Treatment

Floccin™ 909 Wastewater Treatment Creates 100% Wastewater Reuse

This facility receives 55-gallon drums (plastic) and 275 gallon totes (plastic and SS) from several different industries and manufacturer’s including paint, oil field chemicals, acids, caustics, and others.

The RCRA regulated facility cleans the containers and returns them to the customer or grinds them up and recycles the plastic. The facility was using ferric and polymer with some success but recently received their 3rd metals violation for zinc. One more violation and the POTW was going to pull their discharge permit resulting in their shut down.

The sample from this washing operation was at a pH of 6.8 and using Floccin™ 909 quickly separated the solids from the water. The facility is purchasing (3) CFU-50’s for their three facilities and will reuse 100% of their water thereby not discharge water to the local POTW.

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Aggregrate Industry Wastewater Success

Floccin™ 1105 Facilitates Wastewater Reuse

This facility manufactures crushed rock and DOT approved road base for several state highway and airport expansions.

The facility neglected to install a soils entrainment and control plan or system and is in violation of their discharge permit. Integrated Engineers was requested to evaluate the site and make recommendations and a proposed system to mitigate this surface water runoff problem.

The sample from this aggregate operation was jar tested onsite with Floccin™ 1105. With minimal mixing (less than 30 seconds), the solids were agglomerated into a quick settling Floc as shown below.

Part of the proposed 500 gpm system was to utilize this water and reuse 100% of it in their rock washing operations. The dosage was 0.25 grams/1,000 ml.

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Sand & Gravel Industry Wastewater Test

Floccin™ 909 Wastewater Proves Highly Effective

The wastewater sample that was received from the facility was at a pH of 6. The sample was jar tested with the Floccin™ 909, mixed for 3 minutes and it treated easily with a dosage of 0.3 grams/1,000 ml which equates to a dosage of 2.5 lbs/1,000 gallons.

The solids in the treated water beaker settled in 30 seconds. The facility uses 1,000 gpm in a closed loop to wash the crushed rock to wash off the sand and dust and would like to obtain cleaner wash water to eliminate the dusting when the finished rock is loaded, transported and dumped at the customer’s site.

For this flow, the usage rate is 2.5 lb/minute or 150 lbs/hour. The treated water had very low turbidity with a suspended solids less than 10 ppm. The results are shown in the photos 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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