News from Schwing Bioset

Two Solutions from Schwing Bioset in June International Mining Magazine


Schwing Bioset, Inc. is excited to be featured in the Paste Supplement section of International Mining's June 2016 issue.The article discusses Schwing Bioset's recently commissioned pump solutions for backfill and thickened tailings challenges.

View the Paste Supplement section where Schwing Bioset's projects are discussed.

View the entire International Mining June issue on their website.

You can read more about these and other projects on our blog.  To learn about Schwing Bioset's Mining Solutions, contact Miguel Jahncke or visit our Mining Pumps page.

 

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Tags: Mining, Mining Pumps, Paste Backfilling, Mining Paste, Tailings

Schwing Bioset Wraps Up 2016 Spring KSP Pump Service Seminar

 

May 17, 2016

Schwing Bioset KSP Pump Training Schwing Bioset KSP Pump Training

The first two days of training are held in the classroom and cover safety, operations, maintenance, and basic hydraulics.  The third day of training provides hands-on experience where attendees train with the SBI Parts and Service, Quality Control, and Customer Service departments working directly with equipment to learn about its use, maintenance, and using it safely.  Some of the topics discussed include hydraulics, poppet valves, power packs, schematic reading, troubleshooting, screw feeders, sludge pumps, preventative maintenance, and much more.

Schwing Bioset typically offers two KSP Pump Service Seminars per year.  The next training will take place in the fall of 2016.  Training fills up fast, so please consider registering ahead of time if you are interested in attending.

Our Service Department is also available to come to your location and train at your facilities. If that is something you’re interested in, we would be happy to provide you with a quote.  Please contact Paul Katka, the SBI Service Manager, at (715) 350-6913, if you would like more information for this option.

Some feedback we received from the seminar attendees include:

"Very accomidating to everyone's needs and opinions. All Schwing Bioset employees I met at both the seminar and plant were more than decent. Keep doing what you do, wouldn't change a thing."

"Everything was very professional and well rounded."

"I liked this program. I had a good chance to understand the hydraulic system and troubleshooting. The hands on portion in the shop was also impressive. It was a very good experience!"

"The seminar was very informational. The hands on portion was very good. I learned a lot and learned how to troubleshoot on the powerpack and pump. Very successful class."

"Very satisfied with the training, the people involved and the material. Thanks for all the care and the exceptional training."

For questions about this training or to inquire about a future training at Schwing Bioset, please contact Tanya at: tweinzierl@schwingbioset.com or marketing@schwingbioset.com

 

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Schwing Bioset, Inc. (SBI) held its Spring KSP Pump Service Seminar from May 10 to May 12.  The seminar was once again led by Schwing Bioset’s Quality Control Specialist, Jack Koehler.  The seminar and training is designed for Schwing Bioset customers to learn how to properly use and maintain their equipment, to help ensure they get the most out of it.  This spring, there were nine customer attendees and six of Schwing Bioset’s employees who attended.  The course builds 24 hours toward quality training and education for the attendee.

Tags: Events, KSP Service Seminar, Pumps, Equipment Maintenance

Orlando Selects Schwing Bioset over Anaerobic Digestion for Class AA Biosolids

 

Authored by Tom Welch, Southeast Sales Manager for Schwing Bioset, Inc., and Vic Godlewski Jr., PE, Wastewater Division Manager, City of Orlando

May10, 2016

The City of Orlando has been working for several years to move away from Class B land application of Biosolids.  The City explored use of an experimental technology that would almost fully oxidize Biosolids leaving very little residuals for disposal.  While investigating this experimental technology, the City delayed renovations to the anaerobic digestion systems at their Conserv II Water Reclamation Facility (WRF).  Ultimately it was determined that the oxidation technology was not yet commercially viable, at which point they could no longer postpone biosolids treatment improvements.  Orlando engaged the services of a Consulting Engineer to evaluate the digesters and prepare project cost estimates from simple renovation to Class A TPAD with sidestream treatment and combined heat and power.  The estimated project costs were over $40 million and climbing.  Since Orlando believes that the market is going to deliver better options than anaerobic digestion in the future, they began to look for interim options that could be implemented relatively quickly at low capital cost investment; improve their Biosolids treatment, potentially eliminate the need for land application, and not substantially increase O&M costs.  That was a tall order!

The City became aware of the Schwing Bioset process and immediately saw the potential it had to meet all of their requirements for both short and long-term implementation.  In addition, Schwing Bioset could offer conversion of the stabilized Biosolids to a licensed commercial fertilizer product.  The City staff visited current Bioset operations in St. Petersburg as well as other locations in Florida and were impressed with what they saw and with the simplicity of the process.  The City conducted an in-house feasibility study that considered Bioset and other technologies and concluded that Bioset was the preferred treatment process.

Schwing Bioset offered a Design Build approach that was very appealing.  However, due to the City’s procurement constraints this path was not available. To speed up project delivery the Bioset process equipment was purchased directly by the City and installation was competitively bid.

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As shown in the photos above, the Bioset equipment is currently being installed at the Conserv II facility and is scheduled for startup in the summer of 2016.  Schwing Bioset has a sister company, Biosolids Distribution Services (BDS), that manages Class AA Fertilizer Grade Biosolids in the state of Florida.  They have marketed in excess of one-million wet tons of Class AA fertilizer in the state of Florida over the last 10 years.  BDS will be managing the Biosolids produced at the Orlando Conserv II facility when the Bioset process becomes operational.

To learn more about our Bioset process or this project specifically, contact this blog’s author, Tom Welch, and/or visit our website here: SBI Bioset Process. For other inquiries, call 715.247.3433, visit our website, or find us on social media.

 

Download Our  Bioset Process Brochure

 

Tags: Bioset Process, Class 'AA' Biosolids, Wastewater Treatment, Biosolids Distribution Services, Commercial Fertilizer

Meeting the Growing Demands of a Successful Mining Operation – The Schwing Bioset Solution

 

Written by Miguel Jahncke, May 2, 2016

The San Jose mine, one of the flagship operations of Fortuna Silver Mines, Inc., located in the state of Oaxaca in Mexico, was commissioned in July 2011 and began commercial production in September 2011 at a rate of 1,000 tpd. In September of 2013, the mill was expanded from 1,150 tpd to 1,800 tpd and in April 2014, the mill was further expanded to 2,000 tpd. Expansion of the mill from 2,000 tpd to 3,000 tpd was initiated in the first quarter of 2015 with commissioning planned for July 2016.

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(Shown Above: Old Plant Installation)

During the initial installation, the operation received two Schwing Bioset KSP80 pumps, one for operation and one for stand-by. As the reserves increased and the mine production and processing plant expanded, San Jose evaluated different options for handling the additional mine backfill requirement, finally deciding upon the reconfiguration of the KSP80 pumps and their installation at the new and improved Paste Plant, in a parallel arrangement. This new arrangement allows San Jose to handle double their initial paste flow capacity with no additional investment in larger pumps.

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(Shown Above: New Plant Installation)

In addition to the parallel arrangement, Schwing Bioset also upgraded the Control Panel with its patented multi-pump synchronization system. This system allows both pumps to continuously “talk” and make adjustments to their stroke timing while pumping, ensuring that, regardless of the pump speed, continuous flow through the pipeline is achieved, mitigating the potentially negative effects of water hammer. 

The new system was recently commissioned and now operates as a single 4-cylinder pump with no need for additional pipeline pressure dampening to maintain smooth pumping operations, as would be expected from multiple independent pumps feeding a common pipeline. The configuration also allows for the units to be decoupled for maintenance or when plant tailings delivery is reduced, continuing operation with two cylinders to maintain the single pump flow capacity.

Further proving their versatility and toughness, the Schwing Bioset pumps were the only component that was saved from the old Paste Plant to be reutilized in the new Paste Plant. Upon completion of the 3,000 tpd expansion, the mine will produce 9-10 million ounces of silver and 52,000-53,000 ounces of gold per year, ranking the San Jose Mine among the world's top-13 primary silver producing mines.

To learn more about this project specifically or learn more about our mining backfill pumps, please contact this blog’s author, Miguel Jahncke, call 715.247.3433, and/or visit our website here: SBI Mining Pumps.

 

 Download Our Brochures    or Application Reports

 

Tags: Mining, Mining Pumps, Paste Backfilling

Bioset Demo Confirms Direction for New Class A Biosolids Equipment at Russellville WWTP

 

Written by Lance Bartlett, Utility Engineering Manager for City Corporation and Tom Welch, Southeast Regional Sales Manager for Schwing Bioset, Inc.

April 25, 2016

 

In early 2015, City Corporation, the commission established by the City of Russellville to operate the municipal water system, completed a construction project to abandon existing fixed film treatment facilities and convert the wastewater treatment plant to a denitrifying activated sludge facility.  Activated sludge technologies produce more sludge than fixed film and initial calculations predicted an increase of 6 to 7 times the current production rate when operated at the design capacity of the facility.

City Corporation had processed sludge through aging aerobic digesters and produced a Class B biosolid under 40 CFR 503 that was then dewatered and land applied to three nearby fields.  Two of the three permitted fields were no longer available, leaving only 49 acres for use.  The increase of sludge production was predicted to require around 160 acres.

The expected increase in sludge production and lack of land available for land application prompted staff to explore options.  The alternatives explored included composting, additional aerobic digesters, dryers, and the Bioset process from Schwing Bioset, Inc. (SBI). The Bioset process was selected for piloting in February and March of 2015 due to its low cost, simple operation, and the high quality Class A product that it produces.  The lone concern was with respect to the increase in volume due to the addition of chemicals, and staff wanted to get the new process up and running to obtain empirical data on sludge volume.  The engineering firm performing the preliminary study had built in a large contingency due to not being familiar with the Bioset technology and the uncertainty in sludge volume, thus raising concerns that the Bioset technology would be the proper process for the future of the Russellville WWTP.  Ultimately the volumetric increase was less than 10%, and with the Class A designation the number of outlets and demand for the material exceeds production rates.

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Following that successful pilot test, in April of 2015, Schwing Bioset agreed to continue to lease the pilot machine under a monthly contract basis for the sludge handling process.  By the fall, City Corporation had a good feel for their solids production and had a great experience with the Bioset full scale pilot equipment.  Given the years of struggling with the Class B sludge process, management and staff were very pleased with the Class A process and end product and the thought of returning to a Class B process was taken off the table. With all the uncertainty taken out of the equation, staff was ready to make a decision and chose to move forward with a permanent Bioset installation.  City Corporation and Schwing Bioset continue to operate under a contract that allows City Corporation to operate the pilot unit until the permanent unit is installed and operational.  This arrangement allows City Corporation to manage their sludge and operate the plant in accordance with the design parameters, keeping the facility in compliance with the ADEQ, which otherwise would not be possible.  The new facility is anticipated to be operational in mid-October 2016.  The current digester will only be used as a sludge holding tank, thus reducing the power consumption needed for complete aerobic digestion to meet Class B standards, and allowing just WAS sludge to be converted to Class A EQ fertilizer through the Bioset process.

To learn more about our Bioset process or this project specifically, contact this blog’s author, Tom Welch, and/or visit the SBI Bioset Process page. For other inquiries, call 715.247.3433, visit our website, or find us on social media.

Download Our  Bioset Process Brochure

 

Tags: Bioset Process, Class AA/EQ Biosolids, Wastewater Treatment, Lime Stabilization, Bioset Demo

Larry Larson Retires from Schwing Bioset

 

April 7, 2016

The Schwing Bioset team would like to congratulate Larry Larson on his retirement and thank him for his years of service.

Larry has been an invaluable asset to our team for 27 years (to the day!). He has helped the parts department to be one of the best in the business and helped to prepare the department to continue to strive for excellence into the future. His dedication to push us to the next level will be greatly missed.

Larry has been a friend and a mentor to many throughout his years with our company.

Congrats Larry and enjoy your retirement!

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Tom Anderson (Schwing Bioset President) and Larry Larson

 

For your parts needs going forward, please contact Jeff Joy (jjoy@schwingbioset.com) or Brad Dopp (bdopp@schwingbioset.com) at 715-247-3433. 

 

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Tags: Announcements, Events

Phosphorus Removal and Nutrient Harvesting Continuing Education

 

Written by Eric Wanstrom, March 22, 2016

Schwing Bioset is pleased to announce the Schwing Bioset Phosphorus Removal and Nutrient Harvesting paper has received accreditation and official approval for continuing education credits in New York State.  

Schwing Bioset’s Nutrient recovery system recovers Ortho Phosphate and Ammonia Nitrogen from wastewater while offering great benefits to the treatment plant, not only by significantly reducing phosphorus in the waste stream, but also preventing unwanted scaling and accumulations, and creating a valuable end product.  The phosphorus forms a stable Struvite crystal that can be marketed and sold for beneficial reuse, thus keeping excess phosphorus out of the local waterways and helping close the phosphorus recycling loop.   

Engineers and operators can receive one (1) hour of CEU credits for attending a presentation on these topics.  Please contact us to schedule the presentation for your office or plant.

You can learn more about the NuReSys Nutrient Harvesting Process at the links below.

http://www.schwingbioset.com/struvite-recovery

http://www.schwingbioset.com/news/topic/nutrient-recovery

 

For questions or comments, please email this blogs author, Eric Wanstrom, call 715.247.3433, and/or visit our website.

 

Schwing Bioset Nutrient Harvesting

 

Tags: Wastewater Treatment, Continuing Education, Struvite Recovery, Phosphorus Removal, Nutrient Harvesting

Solving Several Challenges with One Schwing Bioset Solution

 

Written by Miguel Jahncke, March 10, 2016

In late 2012, Volcan Compania Minera S.A.A.’s Victoria mineral processing plant, located in the Yauli district, department of Junin in Peru, was facing a number of challenges including the approval of their Environmental Impact Statement for the capacity expansion from 2,400 to 4,000 tpd of ore.

The project also required the expansion of the Rumichaca Tailings site to accommodate the increased production levels. Pumping thickened tailings, rather than conventional tailings, was determined to be the best long-term and financial solution to handle the mining rejects. The project continued to evolve in that direction. 

In mid-2014, when the final solution for the thickened tailings transport was being evaluated, it was determined that the solution offered by Schwing Bioset, its model KSP440 piston pump, was ideal for the project for the following reasons:

  • The KSP 440 unit is capable of the required maximum flow of 185 m3/hr as well as reduced flow of 92 m3/hr when at low plant production rates, which is expected at certain times by idling a module within the pump.
  • Half of the pump can be idled while half continues to operate allowing for preventive maintenance to be performed while operations continue at a slower pace or to accommodate unscheduled downtime.
  • Elimination of additional and costly stand-by equipment, with the modular pump arrangement.
  • Drastic reduction of water hammer in the discharge line without the use of Pulsation Dampeners through PLC synchronization that monitors and adjusts the timing of the pumping strokes.
  • Electric motor and hydraulic redundancy in the power pack allowing partial capacity in the event of unscheduled maintenance.

To learn more about this project specifically or our mining pumps, please contact this blog’s author, Miguel Jahncke, call 715.247.3433, and/or visit our website here: SBI Mining Pumps.

 

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Tags: Piston Pumps, Mining, Mining Pumps, Mining Paste

Pressing Issues (for Water Treatment Plant)

 

Published in WaterWorld Magazine, February 2016. Written by Larry Trojak.

When a new plant that Davidson Water Inc. (Lexington, N.C.) had recently inaugurated started producing levels of solids almost double what it had anticipated, the company worried that all its advance planning was for naught and the dewatering facet of the process was doomed. However, one of the key components in that effort, a new screw press, met the challenge, giving plant operators the results - and the peace of mind - they needed.

To view this story in its entirety on WaterWorld Magazine's website, click here.

 

To learn more about Schwing Bioset and our screw presses, click here. 

 

Tags: Water Treatment, Screw Press, Dewatering, Ferric Sludge

Heat Integration – Opportunities and Concerns

 

Written by Joe Scholl, February 11, 2016

The word “heat” may be defined as the amount of energy that is transferred from one system to another, typically via a temperature differential or “gradient,” and the amount of heat something possesses may be stated in terms of British Thermal Units (BTU), Joules (J), calories (cal), etc. (as compared to reference temperature or datum state).  Measured over time, heat becomes energy that is used to accomplish tasks, and that energy may be measured in BTU/hr, J/sec, etc.  There is a definite cost to energy usage, as evidenced by any plant’s energy utility bill.  As such, there is a high emphasis nowadays in energy re-use (“heat integration”) via applying “waste” heat from one process to another process needing energy.  While many such heat/energy integration techniques may be easily accomplished, there may, under certain circumstances, be limitations to the extent such energy re-utilization efforts may be accomplished.

Many municipal wastewater treatment plants (WWTP’s) are utilizing anaerobic digestion systems and these processes may produce digester gas or “biogas” (chiefly methane and carbon dioxide with other trace chemical constituents and/or contaminants).  The biogas produced may be used by a variety of means, such as for maintaining heated conditions in the digester units and/or in gas engines that drive generators to produce electricity in a combined heat and power cycle (CHP).  These CHP processes generally produce two “waste” heat streams by which heat may be extracted and re-utilized (i.e. “integrated”) in another process.  These two streams are the exhaust (or “stack”) gas from the biogas combustion process itself and a hot water stream (typically a water/glycol mixture) or steam produced from using cooling water to maintain reasonable CHP engine temperatures. 

The extent to which these particular waste heat sources can be utilized depends on many factors, including the costs associated with purchasing, installing, and operating the heat recovery equipment.  With respect to utilizing a waste heat source in a sludge thermal drying operation, some of these factors may include:

  • How close to the drying system is the heat source? Specifically, what are the fluid movement costs from point A to point B, in terms of liquid pumping or gas handling requirements and how does this impact the overall heat integration strategy?  
  • What is the additional capital expenditure (“Capex”) requirement to install insulated piping or ducting from the source to the drying system and are these Capex requirements so high that the payback to incorporate the waste heat into the drying system result in an unreasonably long payback period? 
  • Are long-term corrosion issues a concern, such as materials of selection for digester gas piping, stack gas ducting, etc. (especially if “acid gases” condense-out of the gas stream upon cooling, leading to corrosive conditions within the piping, ducting, or heat transfer equipment) and, if so, what is their Capex impact, as well operating expense (“Opex”) impact (e.g. will long-term corrosion issues require long-term maintenance expenses)? 
  • How much heat will the waste heat stream lose from point A to B and will this heat loss drive the heat recovery economics toward an unfavorable overall result? This point is particularly important if the waste heat stream is steam, where the latent (or condensing/phase change) heat of the steam is the primary (or desirable) heat transfer mechanism.  For example, if the waste steam loses sufficient energy in transit from its source to the drying system, will the steam lose so much heat that it condenses to liquid form, thereby “robbing” the heat integration scheme of the steam’s latent/condensing heat prior to the drying system (noting that the latent/condensing heat of steam is significantly higher than the specific heat capacity of either the steam or liquid forms)?

In general, there are many possibilities for incorporating waste heat into a thermal drying process.  However, the costs (in terms of Capex and Opex considerations) to incorporate the heat integration step must also be considered to determine whether doing so is practical. 

To learn more about waste heat integration strategies and our Fluid Bed Drying Technology, please contact a Schwing Bioset Regional Sales Manager by calling 715-247-3433, email us, and/or visit our website here.

 

Below is just one example of numerous heat recovery possibilities.

Schwing Bioset Stack Gas Heat Integration Schematic

  

Tags: Fluid Bed Drying, Wastewater Treatment, Heat Integration, Energy Re-Use, Heat Recovery