Tag Archives: Floccin

Allways Something New

  By Integrated Engineers | March 5, 2009 - 2:04 pm | New at I.E.
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Powder Feeder Weight

Floccin comes in both a granular and powder form.   The powder Floccin tends to “bridge” which causes the powder to not freely flow.  This inhibits the use of our commercial auger feeder without proper modifications.  We are modifying our commercial feeder to handle the powder Floccin.  The addition of an electric vibrator with a powder bridge breaker solved this problem.  The vibrator and bridge breaker combination liquefies the powder and allows it to flow freely through tank outlet.  Shown in the pic below is the bridge breaker that we are testing.  That’s what we do engineer new ways to clean water.

Chad showing vibration weight.

Chad showing vibration adapter.

Vibration weight inside tank

Vibration adapter inside tank

Here is a pic with the unit inside the feeder.

Commerical Auger Feeder

Commercial Auger Feeder

Commercial Auger Feeder with vibration adapter

Commercial Auger Feeder with vibration adapter

We Installed the Vibration Adapter, filled the feeder with the powder floccin, and let it sit for 2 days. Now is the true test! after letting the unit sit all of the powder is compacted to the bottom of the tank.

We started the vibrating adapter and nothing happened….. I guess it is back to the drawing board. This is not the end we will succeed.

So after finding out this unit did not work, we decided to upgrade the vibratation unit. We tried a circuclar styal vibration unit it would give about 10 lbs of force. Our engineers found a pneumatic linear vibration unit. This unit would give 500 lbs of force! Thats a big upgrade! After bolting it on and giving it a little air, the feeder was jumping across the floor. we also found out that the frame was not sturdy enough to handle the weight plus the constant vibration.  so we added some support rods to the feeder stand and it works perfect.

Commercial Feeder W/ Vibration Unit

Commercial Feeder W/ Vibration Unit

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B.O.D C.O.D. T.D.S. T.S.S. Removal Teflon

  By Integrated Engineers | March 5, 2009 - 1:35 pm | BOD / COD, EC / TDS, Removal, TSS
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Teflon (PTFE) Coating Operation

A manufacturer of Teflon coated products contacted Integrated Engineers seeking a solution to their wastewater problems. They were generating 3,500 gallons of wastewater each week that had to be hauled off site. They were looking for a method to treat this water and reuse the treated water within their facility. Integrated Engineers performed treat ability studies of the wastewater and identified the FloccinAgentTM that would meet their goal.

Watsewater System

Watsewater System

Integrated Engineers designed, built, and installed a system to treat their wastewater. The system integrated existing holding tanks with a new equalizing tank where the water is mixed and aerated prior to treatment. The water from the equalizing tank is treated in a Continuous Flow Unit (CFU), where it is mixed with the FloccinAgentTM and then separated from the resulting sludge. The sludge is collected in a sludge cart for disposal, while the clean water from the CFU is directed to an ozone contact tank.  In this tank the water is treated with ozone, generated by the ozone skid, to remove any remaining organics. The clean, treated water is then ready to enter the water reuse system.

CFU in Action

CFU in Action

The analytical results presented on the next page come from samples collected approximately one month after startup

Ozone Skid

Ozone Skid

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B.O.D. C.O.D. T.S.S. T.D.S. Removal

  By Integrated Engineers | March 5, 2009 - 12:54 pm | BOD / COD, EC / TDS, Removal, TSS
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Chicken Processor

This chicken slaughter and processing facility has a wastewater system that treats 1.2 MGD.  Their process uses ferric chloride as the coagulant, caustic to stabilize the pH and an anionic polymer prior to separation in the DAF units.  The facility also does some further processing with addition of seasoning and brines which add TDS/EC to the water.  The ferric/anionic polymer combination is hindered in its ability to handle the brine water causing spikes in effluent BOD/TSS and increased surcharges.  Their treatment costs are at $2.50/1,000 gallons.

Befor and After Floccin

Before and After Floccin

Integrated Engineers, Inc. was asked to evaluate the Floccin 1105 with their wastewater.  The performance of the Floccin 1105 is not effected by the brine water.  Jar tests indicate an improvement in effluent water quality, larger floc size and an improvement in the DAF performances at the same cost of $2.50/1,000 gallons.

Constituent

Untreated

Ferric/anionic

Floccin 1105

BOD

1,100

230

190

COD

2,000

290

270

TSS

2,600

38

31

TDS

960

1190

970

The Ferric/anionic water has a higher level of TDS.  The local POTW is going to start surcharging for levels of TDS for industries in excess of 500 ppm over the potable water going to the facility.  The simplification of using 1 chemical, it’s wider operating pH range and performance over the ferric makes a savings in reduced surcharges, labor, and consistent treatment.

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B.O.D. and T.S.S. Removal

  By Integrated Engineers | March 5, 2009 - 10:41 am | BOD / COD, Removal, TSS
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Fruit Cannery

This facility cans peaches and pears and wanted to investigate the reduction in BOD and TSS using the Floccin Agents.  Samples were made in the off season using 2/3 by weight of peach to 1/3 pear with a total amount of 100 grams in 2,000 ml (5% by weight to simulate the wastewater generated from the facility).

The samples were flocculated with Floccin J at a dosage of 0.25 gram/1,000 ml (250 ppm), screened with coarse filter paper, and analyzed for BOD and TSS.  The results show that the Floccin J can reduce some of the BOD and a majority of the TSS.  Traditional chemistry only reduces the BOD by 8-9%.

Before and After Floccin / Filter

Before and After Floccin / Filter

The results are shown below:

Analyte Untreated Floccin J %Reduction
Biological Oxygen Demand 4,200 ppm 2,600 ppm 14.3%
Total Suspended Solids 3,600 ppm 130 ppm 95%

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Copper and Nickel Removal

  By Integrated Engineers | March 5, 2009 - 10:21 am | Metals
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Circuit Board Manufacturer

A Circuit Board Manufacturer in southern California was not able to achieve the discharge levels of copper and nickel with their existing system of coagulant, anionic and cationic flocculants and metal precipitant treatment process followed by lamella plate clarification. The previous treatment process developed a settled sludge that had poor shear characteristics and required further coagulant addition to be able to dewater in the filter press. The facility processes 50,000 gal/day and recycles all but 2,500 gal/day, which is discharged to the Los Angeles County Sanitary Sewer system. Their target was 1.0 ppm and they were achieving 0.5 to 1.5 ppmin a sporadic manner.

Before and After Floccin

Before and After Floccin

Integrated Engineers treated the water with IE-061 (a metal precipitant) to a set point pH of 10.2 and flocked with Floccin D. Samples were analyzed using current EPA methods on an ICP.

Component

Untreated

Previous Treatment

Floccin
Treatment

Copper

156 ppm

0.5-1.5 ppm

0.3 ppm

Nickel

210 ppm

0.6-1.5 ppm

0.4 ppm

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Copper and Zinc Removal

  By Integrated Engineers | March 5, 2009 - 9:37 am | Metals
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Ammunitions Manufacturing

An ammunition manufacturing facility was having problems removing copper and zinc from their 900 gpm wastewater system. The process used lime to raise the pH from 1.5 to 10, sodium carbamate for a metal precipitant, and an anionic flocculant to increase the flock size and get the solids to settle in the clarifier. Current chemical costs are estimated at $225,000/year with a significant amount of sludge addition from the lime, thereby adding to the operational costs due to the sludge being a hazardous waste. Integrated Engineers, Inc. tested the wastewater and found that adding caustic to a pH of 10.0 and Floccin D worked as well as the current chemistry. The Floccin D dosage was 0.35 grams in 800 ml (280 ppm). The third sample shown below is with 160 ppm of IE-061. The test results are shown below:

Before and After Floccin

Before and After Floccin

In addition, by switching from lime to caustic the reduction in solids generation would be a significant cost reduction. At peak flow the amount of lime required (17.3 lbs./1,000 gallons) generates 7,450 pounds of 100% dry solids. In a normally dry cake the solids are 30%, therefore they were generating nearly 25,000 lbs. of sludge per day that was hazardous and expensive to dispose of in a landfill. Based on a disposal cost of $35/ton, the cost reduction due to the lime addition to the sludge would be $450 per day ($160,000/year).

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Continuous Flow Unit (CFU)

  By Integrated Engineers | February 25, 2009 - 4:38 pm | Continuous Flow Unit
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This unit is designed to easily treat a continuous stream of wastewater for utilizing the highest performance FloccinAgents™ available. The unit is completely automated, requiring operator attention only to restock the FloccinAgent™ and disposable filtering media, and employing alarms to alert the operator when restocking is required or when the process is interrupted.

CFU-50 with 60 GAL Floccin Feeder

CFU-50 with 60 GAL Floccin Feeder

Features and Benefits
-  Wettable components constructed of 304 stainless steel to resist corrosion
-  Filter Table with variable speed control
-  Mixing motor with variable speed control
-  Effluent pump with independent float control
-  Use a single wastewater treatment product
-  Fully automated operation with alarms for FloccinAgent™ and filter paper
-  Controls allow full customization of process for optimal water clarity
-  Variable speed FloccinFeeder™ allows dose to be customized to
wastewater and contamination load

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