News from Schwing Bioset

Schwing Bioset is Exhibiting at WEFTEC 2017

 

Schwing Bioset, Inc. (SBI) is looking forward to exhibiting at the 2017 WEFTEC Event in Chicago on October 2-4. 

Please be sure to stop by our booth (#2007) while you're on the exhibit floor. We will be displaying a dewatering screw press, as well as two new pieces of equipment.

Our new Membrane Bioreactor (MBR) filtration systems for water and wastewater utilize hollow fiber membranes. The unique end-free cartridge design provides an economical alternative to traditional longer fibers.

We are also debuting our new SBI Solutions system. This pre-packaged system is configurable to produce either Class A or B Biosolids in a convenient, pre-engineered skid mounted unit. The system is a compact, modular unit including a piston pump combined with the Bioset process, and optional screw press dewatering capabilities for an all-in-one package.    

MBR.png  SBI Solutions.png

 

 

 

 

 

 

 

The SBI team members attending the show include Executives, Regional Sales Managers, Aftermarket Support personnel, and more. If you'd like to meet with one of our team members, please email us and we'll put you in touch with the appropriate person.

Read about our Nutrient Removal and Struvite Harvesting, Dewatering Equipment, Piston Pumps, Bioset Process and Class A Biosolids, our new products, and other products hereand then stop by booth 2007 to learn more!

Visit the conference website to view the event details and exhibition map: http://www.weftec.org. Here is the Schwing Bioset listing for the show.

We hope to see you at WEFTEC 2017!


For more than 30 years, Schwing Bioset, Inc. has been helping wastewater treatment plants, mines, and industrial users by engineering solids handling solutions. Schwing Bioset’s custom-engineered solutions can be found in over a thousand facilities across North America and around the world.

Our products include, among others, sludge, industrial, and tunnel piston pumps, screw presses, nutrient removal and management, membrane bioreactors, sliding frame and push floor silos, fluid bed drying products, Bioset process for Class A Biosolids, container wagons, and screw conveyors. We also offer on-site demos, spare parts and equipment maintenance services, and training. 

 

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Tags: Bioset Process, Piston Pumps, Events, WEFTEC, Screw Press, Membrane Bioreactor

Heavy-Duty Pumps “Take the Cake” at Detroit’s Massive WWTP

 

Schwing Bioset Application Report 7, Detroit, MN

Written by Larry Trojak, Trojak Communications

Version also published in WaterWorld Magazine

 

Much like a chain, the wastewater treatment process is made up of individual segments, each linked to the next, each vital to its overall effectiveness. No single facet of the process, nor any single piece of major equipment, is more important than another; if one fails, it all suffers. Occasionally though, one piece of equipment has such challenging demands placed upon it that when it proves itself - and continues to do so for years - it bears mention.

At the Detroit Wastewater Treatment Plant (WWTP), a pair of heavy-duty pumps is used to take high solids-content cake from the dewatering operation to either incineration or a truck loading area.  That, in itself, is not noteworthy.  The fact that it accomplishes this both by pushing cake, dewatered to well over 20% dry solids content more than 500 linear feet, and taking it up five stories, is.  Today those pumps, a pair of Schwing Bioset KSP 110V(HD)L’s, move better than 100 wet tons of dewatered material per hour, have improved the efficiency of the incineration and haul-off operations, and have proven a key part of the system.

 Schwing Bioset Detroit WWTP Solids Pump

 

The Motor City Treatment

The first thing that strikes visitors upon arrival at Detroit’s WWTP is its sheer size. Covering several city blocks, the plant is the largest single-site wastewater treatment facility in the United States, with a capability for processing approximately 845 million gallons per day (MGD) through secondary treatment. The facility has undergone a number of major expansions since it was first built in 1940. At that time, it served Detroit and 11 neighboring communities; today it handles wastewater from 35 per cent of the state’s total population - a service area that covers 946 square miles.

The most recent of the major upgrades took place in 2004 when, according to Kenneth Paylor, Detroit WWTP’s Senior Maintenance Foreman (Solids), modifications to solids processing were included in the overall plan.

“One of the biggest changes that impacted this area of the plant was the addition of a Central Offload Facility (COF).  Up to that time, dewatered cake was taken by conveyor to a lime pad that was used to support land application for the biosolids.  When that land use was discontinued, however, an alternative was needed.  The COF, essentially a truck loading area to transfer biosolids to area landfills for disposal, is now that  alternative

 

Dewater is Different

To process its huge volumes of sludge, Detroit’s WWTP relies upon 14 incinerators located in two separate solids buildings, identified as Complex 1 and Complex 2 (C1 and C2). Solids content before dewatering ranges from 1.2 to 7% - generally in the 4.5% range. Paylor says the plant’s dewatering effort also underwent major changes in the ‘04 upgrade.

“To upgrade the dewatering operation, a number of belt presses were totally replaced and centrifuges were added in ’04,” he says. “We now dewater sludge with ten centrifuges and 22 belt presses: ten in C1, twelve in C2. Material exiting the presses has a solids content of about 23-27%; out of the centrifuges it can be in the 27-32% range.”

 

The Need to COF

In an ideal world, all of Detroit’s dewatered sludge would be sent directly to incineration, making the need for alternative disposal efforts a moot point. But this is not a perfect world and, to best deal with situations that are occasionally out of the ordinary, the COF was included in the design.

“There are times when we might have an incinerator or two that are down for maintenance and material needs to be re-routed,” says Paylor. “Another example is if our incoming volumes rise quickly - as they can after a heavy rain - and we are exceeding what we can normally handle. There was no way to avoid it; we needed a way to get material from C1 to a point where it could be hauled off site for disposal.”

Such occurrences are more commonplace than one would suspect. Even given the large number of incinerators in use and the obvious preference to keep those units fed with material to minimize fuel costs, Paylor says roughly 40% of their cake still heads to the COF. “That is when the Schwing Bioset pumps come into play: getting the cake from the belt presses in C1 to the COF where it can be treated with lime for odor control and loaded into trucks.”

 Schwing Bioset Detroit WWTP Truck Loading

 

The Long Haul

Using pumps to move cake in wastewater treatment plants is hardly a new concept. Scores of plants throughout the country—and internationally as well—have seen the benefits pumping can provide over moving material by conveyor. Improved production, better efficiency, improvements in site cleanliness and reductions in odor are just some of the gains that can be made by pumping.

“To get material to the Schwing Bioset pumps, which are located in the lowest level of the facility, a belt conveyor first collects the cake from all ten belt presses in C1,” says Paylor. “That belt feeds a Schwing push floor, which, in turn, feeds the two KSP 110V(HD)L pumps.”

With a maximum operating pressure of 1,500 psi, cake is pumped in high-pressure piping out to the COF. Mind you, it’s a fairly decent distance out to there.”

That assessment would appear to be something of an understatement. According to Keith McWilliams, Detroit’s Plant Supervisor, the distance from the C1 pumps to the COF is in excess of 500 feet. “Material first has to go up five stories—that’s 60-70 feet alone,” he says. “Then it has to make its way over to the facility, so 500 linear feet is probably a conservative guess.”

 

The Best Approach

McWilliams says there are alternatives to pumping the cake such a long distance. One of those, he says, is pumping it over to C2 where it could be dropped onto belts and taken to the COF.

“While that’s feasible, it is much better to do it this way,” he says. “Once we’ve put the cake into the pump, we may as well take it as far as we can. There is no advantage to dropping it on a belt—in fact, it’s a whole lot messier—and the pumps have shown that they can more than stand up to the challenge.”

Both Paylor and McWilliams say that since installation, the Schwing Bioset pumps, some of the largest the company makes, have been solid performers. XL model pumps were selected for Detroit WWTP based on the anticipated challenges to be placed on the units. Those particular models feature heavy duty poppets which reduce material velocity through the poppet housing. Doing so can result in a variety of benefits including: a reduction in pressure drop through the valve housing, an increased filling efficiency of the pumping cylinders, and a reduction in wear on the poppet discs, seats and pumping rams.

“In the five years the pumps have been in place, we’ve had very few issues with them, and those we’ve had, have all been minor” says Paylor. “That’s outstanding, given what they’re asked to do for roughly 30 hours every week, year round. Providing a continuous flow rate in the 150 to 200gpm range and taking it that distance is really impressive.”

 

Ongoing Changes

As mentioned, Detroit WWTP has seen its share of changes over the years, and new approaches to dealing with the biosolids are always under consideration. 

“We even have contingency plans already in place to handle things before any of those major changes occur,“ says McWilliams. “We put in different access points, for example, where the Schwing Bioset pumps could feed the conveyors in C2. 

Regardless of the direction Detroit’s WWTP takes, both McWilliams and Paylor say they are confident the pair of Schwing Bioset pumps will figure into those plans.  “Whatever happens will most likely involve further movement of the cake, says Paylor.  “And, given what we’ve seen from the pumps so far, I’m sure they can meet that challenge. They’ve been real workhorses for us.”

 

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Tags: Piston Pumps, Dewatered Sludge Cake, Wastewater Treatment Plant

Push Floor Bin and Biosolids Pumps Help Plant Stabilize Operations

 

Written by Chuck Wanstrom

The City of High Point, NC, was previously pumping biosolids to an incinerator using hydraulically actuated piston pumps supplied by another manufacturer. These pumps were aging and the city couldn’t reliably obtain spare parts to support their operation. Additionally, the wastewater treatment plant occasionally struggled with operations as it didn’t have any buffering capacity for the dewatered biosolids ahead of the piston pumps. In an effort to solve the support issues with the existing equipment and stabilize operations, the city solicited bids from consulting engineering firms to update and improve their process.

The selected engineer began surveying biosolids handling systems available in the market and with input from their Client, settled on a push floor storage bin and piston pump arrangement as offered by Schwing Bioset. With over 30-years of experience in biosolids storage and conveyance, and numerous successful installations to its credit, Schwing Bioset was the logical choice to provide the design and equipment for this retrofit application.

A new push floor bunker with 60 yards of storage capacity was supplied to handle the centrifuge dewatered biosolids. Directly coupled to the bottom of the new push floor bunker are two Schwing Bioset model SD 350 screw feeders and KSP 17 piston pumps. The piston pumps have a dual-discharges that allows the biosolids flow to be split and fed into the incinerator at a total of four injection points for more efficient incinerator operations as well. If the incinerator goes down, biosolids can also discharge to a new truck loading facility.

To learn more about our pumps and push floor bins, visit our Products page, Contact Us, visit our Website, or find us on social media.

 

High Point Piston Pumps  High Point Truck Loading

 

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Tags: Piston Pumps, Biosolids, Wastewater Treatment, hydraulic push floor bin

City of Orlando WWTP Utilizes Schwing Bioset Piston Pumps in Class AA Process

 

City of Orlando, FL, Conserv II WWTP Utilizes Schwing Bioset KSP 25 Piston Pumps in Class AA Biosolids Process

Written by Tom Welch, December 14, 2016

The City of Orlando, FL, Conserv II WWTP 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 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.

The current dewatering facility has four belt filter presses that discharge onto two belt conveyors that converge onto one common belt conveyor that takes the dewatered Biosolids to truck loading.  The decision was made to move away from the common belt conveyor to make the process more robust.  A KSP 25 piston pump was added at the end of each belt conveyor.  The two pumps are utilized to transfer the dewatered cake to the Bioset (Class A alkaline process).  The Bioset process also utilizes a third KSP 25 pump as the heart and soul of the system to blend the chemicals needed for the Class A process and pumps the end product into a plug flow reactor and ultimately out to two truck loading areas.  These pumps are programmed to work together to make sure that a consistent flow of Biosolids can be treated to Class A status through the reactor.

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

Schwing Bioset Piston Pump

 

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Tags: Bioset Process, Piston Pumps, Class 'AA' Biosolids, Wastewater Treatment

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.

 

Rumichaca_mining pumps.jpg 

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

How Transitioning to Class A Biosolids Saves Money

 

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

 

A southwest Florida treatment plant turns to lime stabilization to create Class A biosolids for land application and cuts handling costs significantly.

Cost-effective handling of biosolids is essential to clean-water plants’ economic and environmental performance.

The Immokalee Water and Sewer District in Florida faced a biosolids challenge in 2006. The district had been using drying beds to create Class B biosolids and spending about $500,000 a year to dewater and haul excess material from that process to a landfill.

Facing a change in regulations on land application of Class B material, and wanting to reach the biosolids’ full economic potential, the district looked at alternatives. The ultimate solution was a facility redesign centered on using the Bioset process (Schwing Bioset) to create Class A biosolids. As a result, the district has reduced handling costs by more than two-thirds and produces a Class A product for beneficial use.

Anticipating change

Located about 30 miles southeast of Fort Myers, the heavily agricultural Immokalee district is home to about 24,000 residents. Its wastewater treatment plant was expanded in 2013 from 2.5 mgd to 4.0 mgd design capacity. Until fairly recently, it generated 23,500 gallons of Class B biosolids per day at 1 to 1.5 percent solids.

Gary Ferrante, P.E., an engineer with the Greeley and Hansen engineering firm, says a number of factors in 2006 led the district to review its biosolids operation. “Immokalee’s plant was originally designed with a half-dozen drying beds in which a Class B biosolids was created and used on permitted area farms,” he says.

“While that was effective, the facility is next to a school, which repeatedly complained about students’ health risks and odor. The district later learned that the U.S. Department of Agriculture and the Florida Department of Environmental Protection were considering changes to biosolids land application regulations (passed in 2010 as Florida Biosolids Regulation Chapter 62-640 F.A.C.). All that prompted the district to hire a consultant to look at alternatives.”

Lots of options

Based on recommendations from the consultant’s report, in 2007 the district contracted with Synagro Technologies to dewater the Class B biosolids and haul it to a landfill more than 100 miles away. In time, rising prices and an increase in biosolids volume raised annual costs from $309,000 to more than $470,000, providing incentive for the district to pursue other options.

“Working with the district, we put together a couple of proposals and a couple of scenarios within each proposal,” says Ferrante. “The first one covered the design/build/finance of a biosolids facility at the existing location. Options under this plan included handling material from Immokalee only, as well as accepting material from Collier County and making Immokalee a regional processing facility. The second proposal had an outside entity leasing land from the district and constructing a Class A regional processing facility on it.”

An option under that proposal included a continuation of the contract dewatering program while the regional facility was taking shape. In the end, the district chose to establish a turnkey processing facility for its own biosolids sludge only and selected the Bioset process to deliver Class A material.

Schwing Bioset - Bioset Process  Schwing Bioset - Bioset Process

Class A operation

At the new facility, material exits the primary treatment facility’s sludge holding tanks at 1.5 percent solids and is fed directly to a high-performance screw press, selected for a number of reasons, including its relatively compact design.

“Because of the limited availability of usable land, a small footprint for the entire biosolids system was a major consideration, and the Bioset screw press fit in nicely,” Ferrante says. “We’ve found it to be an outstanding dewatering tool, yet extremely efficient in power usage.

“The belt press we looked at would have taken the material from 1.5 or 2 percent solids up to 8 to 10 percent. A centrifuge might get that up to 20 percent, but the electricity costs would be much higher. The screw press takes the material up to 16 percent solids. It uses twin augers and a changing pitch on the screws to advance the material and remove the water. Because it takes far less energy to turn those two screws than to power a centrifuge, the savings in power consumption can be significant.”

Another feature is that district personnel can wash the screw press down while it remains operational, says Michael Castilla, service technician 1: “The Bioset screw press has an automated self-cleaning function which in itself is nice. However, when we have a situation that calls for additional cleaning, we can simply push a button and a cleaning cycle will start. That’s a bonus. To shut a press down for maintenance or repair could cost us a half-day’s performance.”

Positive reaction

After dewatering, untreated biosolids are taken via screw conveyor to a twin-screw mixer in which quicklime and sulfamic acid are added. The mixing resolves issues such as unreacted lime in the final product and yields a highly homogeneous material. From the mixer, a Schwing Bioset KSP-10HKR pump feeds material into a 56 1/2-cubic-foot reactor in which heat from the acid and quicklime reaction raises the pH, stabilizing the mixture and creating a product that meets both Florida Chapter 503.33 and U.S. EPA Class A requirements.

“Retention time in the reactor is about 30 to 45 minutes at temperatures in the range of 122 degrees Fahrenheit,” says Ferrante. “The plant wastes sludge for 16 hours a day, consistently generating about­­­­­ 11 dry tons of the Class A material weekly and doing so at a markedly lower cost than for outright hauling and landfilling.”
Castilla adds that the system’s ease of operation was also key to getting up to speed quickly.

“It is very intuitive and simple to operate,” he says. “However, Schwing Bioset still went to great lengths to ensure that people involved in day-to-day operation are comfortable with it, have a handle on the maintenance routines, and so on. Ian Keyes from their Wisconsin office spent time here mentoring me to such a degree that there’s very little about the system I don’t understand.”

The Class A material exits the system, is loaded onto a manure spreader and taken to an area field where it is applied in place of fertilizer. Eliminating those fertilizer costs alone has saved about $50,000 per year.

In addition to lower costs, the district benefits from a much cleaner, less maintenance-intensive, more environmentally friendly operation. Dust from the lime-based process is controlled using hard-piped or totally enclosed components. Odorous air is contained by the pressurized reactor and then captured and scrubbed under a collection hood before release.

Schwing Bioset - Biosolids Hauling    Schwing Bioset - Biosolids Hauling

Room to grow

The district’s biosolids plant was designed with ample space to install a second identical processing line in case the regional concept becomes a reality. “One of the most important aspects of this system is its ability to accommodate the changes a regional operation would entail,” says Ferrante. “Things like fluctuations in the percentage of solids, increases and decreases in throughput, and compatibility with biosolids from aerobic or anaerobic digestion processes without modification, are all within its design capability.

“Simply put, the district is well positioned to have its wastewater treatment needs met for the foreseeable future. After the $2 million design/build/finance contract was awarded, the district, seeing itself in a good financial position, opted to pay that cost out of pocket, rather than financing it over 20 years.”

The annual operating cost for the new system is about $130,000 a year, including chemicals and electricity. With estimated savings of $370,000 per year over landfilling, the system will pay for itself by about mid-2019.

“This was a case in which Immokalee, a small independent special district with a serious financial headache, took real initiative in getting things done,” says Ferrante. “They will be the beneficiaries of those sound decisions for decades to come.”

 

To view this story on TPO Magazine's website, click here.

To learn more about Schwing Bioset and the Bioset Process, click here.

 

 

Tags: Class 'A' Biosolids, Bioset Process, Piston Pumps, Bioset System, Wastewater Treatment, Fertilizer, Screw Press

Diversity, Equipment Longevity are Key for New York Wastewater Plant

 

Schwing Bioset Application Report 15, Glens Falls, NY

Written by Larry Trojak, Trojak Communications

Version also published in TPO Magazine, August 2013

Dewatering at WWTP

While most wastewater treatment plants focus their efforts solely on the material collected from within their own municipality, some choose-often for economic reasons-to supplement that volume with outside waste. After a major expansion in the late 1980s, and an upgrade in the mid-1990s, the city of Glens Falls (NY) Wastewater Treatment Plant found itself in just such a situation and opened up its facility to non-system waste. Today, drawing from a wide range of sources, the plant accepts an equally broad range of materials including: grease trap waste, sanitary holding tank waste, septage, sewer cleaning debris and wastewater sludge-both liquid and cake-from off-site facilities. That product diversity, coupled with impressive long-term equipment performance, has helped the plant remain viable in serving the upstate New York city and surrounding areas.

Legacy Lives On

Located on the Hudson River about 45 minutes north of Albany, Glens Falls is a picturesque small city, home to just under 15,000 residents, and a thriving base for the medical device and medical services industries. The city was also the site of a huge pigment manufacturing facility that was shut down in the 1980s, but left a legacy of contaminated soil in its wake. Today, nearly three decades after its closing, wastewater from the site’s groundwater treatment and collection system is still being processed at the Glens Falls WWTP, according to Jason Vilander, the plant’s maintenance manager.

“That pigment plant was actually a driving force in an expansion that took place here in the mid-‘80s,” he said. “A lot of water is used in chemical and dye work—water that couldn’t simply be discharged to the river—so the plant was designed to accommodate that additional wastewater volume. That expansion allowed us to move to activated sludge treatment and prompted installation of a fluid bed incinerator. Unfortunately for us, the pigment plant shut down during the latter part of our expansion, leaving us with a good deal of extra capacity.”

Since that time, Glens Falls WWTP has had an ongoing contract to accept and treat water from the groundwater collection system from the pigment plant site.

Filling the Void

Needing to fill the excess capacity left by the pigment plant’s untimely closing, Glens Falls WWTP began to actively seek companies or organizations looking to outsource their wastewater and waste product treatment needs. To say those efforts were a success would be an understatement. Today, the plant serves a fairly localized geographic area, taking in material from the town of Queensbury (six of its seven districts), as well as the Village of South Glens Falls, including the business centerpiece, Moreau Industrial Park.

But, because they were aggressive in reaching out to businesses throughout the region, they now also count many of them as customers. 

“We’ve had success in some unlikely places,” says, Vilander. “Most of our liquid sludge, for example, comes out of Vermont. That includes some of the larger ski resorts as well as many of the treatment plants from other towns and villages—plants that don’t have drying beds or digesters or any other means to take product through the final steps needed for it to be safe for disposal. So we provide that last step for them.”

Volumes are also supplemented by outside cake haulers, including regional correctional facilities such as Comstock Prison and the Washington County (VT) jail.

“These facilities all have their own wastewater treatment systems, complete with belt presses, which allows them to generate a cake. But that’s as far as they can go with it. So, twice or three times a week, they send us five tons of cake in a single-axle dump truck, and dump it onto a pad. We then use a pay loader to load that cake into a receiving station where it is stored until we have the time and manpower to incinerate it,” he adds.

Three Decades of Sludge

The benefits gained by reaching out for additional material would be a moot point were Glens Falls unable to effectively incinerate what it collects. Vilander says the equipment in place in many parts of the facility has amazed him in both its capability and its longevity.

“A good case in point would be our sludge pumps,” he says. “We had a pair of Schwing KSP-5 sludge pumps that were installed during that first plant upgrade in the 1980s. Those pumps—which were among the first made by Schwing for this market—have been outstanding for us, given what they’re asked to do. They were replaced just a couple years ago after nearly three decades of pumping. And mind you, they were replaced not because of wear issues, but because our volumes had grown so much over the years that we needed to upsize.”

He adds that the pumps’ impressive performance is made even more so given the fact that one of the critical steps in their routine maintenance was often overlooked for being “too inconvenient.”

“I’ve always felt that keeping the water in a pump’s water box clean is second only to keeping the hydraulic fluid clean,” he says. “Unfortunately for us, in the prior expansion, a grate, which allowed personnel to walk around the belt presses, was installed right over the top of the pumps’ water boxes, making access difficult. As a result, the water was changed far too infrequently. I’m still amazed at how well those pumps worked—and how long they performed for us—even with that lapse in an important operating procedure.”

With This Ring

Schwing Bioset Sludge Piston Pump at WWTP

With the upsizing to a larger pair of sludge pumps (Schwing KSP-10s), Glens Falls has increased their pumping capability to deal with the growth in biosolids handling at the plant. The new pumps take cake that has been dewatered to about 24%-26% solids and route it for incineration where a 32-ton load of cake (an 18-wheeler full) can be reduced to 100 pounds of ash. Moving that high solids content says Vilander, is helped by the addition of a “slip ring,” or pipeline lubrication system, a feature that injects a thin film of water to reduce friction loss in the pipeline and lower pipeline operating pressures—in some cases by more than 50%.

“We work so hard to get all the water out, so it seems a bit contradictory to be putting some back in," he says. "But, because we’re running these slip rings at about 20-30% of their capacity and they come on for only a matter of seconds, we are adding no more than three gallons per hour. So the amount of water added is minimal and pales by comparison to the improvement in throughput and the fuel savings we achieve with the drier sludge cake,” stated Vilander.

Additional benefits provided by the newer pumps include a much greater degree of versatility. Because the pumps are PLC-controlled, Vilander and his crew are able to have them run in several different modes including: “pressure,” tracking” or “manual.” That means they now have the capability to automatically control the speed of the hopper screws and the pump itself.

“With the old pumps, we could adjust our pressures a bit to get the speed we needed, but we couldn’t get independent control of both components—the screws and the pump, says Vilander. "Now we can and it’s made a huge difference. Because the pumps run nice and slow—and quiet— I’m not even seeing the level of maintenance that I had with the old ones. I can see these outlasting even those previous workhorses,” said Vilander.

Grease is the Word

The ultimate destination for all the cake processed through Glens Falls is a fluid bed incinerator which 18’ 3” in diameter with a height of 44’ 9”. The unit is designed to maintain an effective operating temperature of 1500°F and uses the cake itself as the primary fuel source. According to Vilander, if the cake is dry enough, it will reach an autogenous state and burn without an additional fuel source.

“However, if it’s too wet, or does not have enough VOC in it, we have to add BTUs through an alternative heat source which, in the past, was fuel oil. While the new belt presses gave us a much drier cake, we still found ourselves having to rely upon the fuel oil and the costs associated with it. As part of an overall cost savings move, we installed a two part grease system consisting of a concentrator and a storage tank,” said Vilander.

Doing so not only dramatically reduced the operational costs at Glens Falls; it also gave area businesses a way to efficiently dispose of grease from their operations. Now, the septage haulers simply bring the grease to the plant, pay a disposal fee and it gets concentrated, thickened and burned.

“Occasionally we will get a load of grease with wastewater added to it which has to be treated differently. So it goes into our storage tank where it is mixed and pumped up to our belt presses, combined with the cake and moved—once again using the Schwing pumps—out to incineration. The grease, which was once a waste product, is now both a fuel source and a small revenue stream,” said Vilander.

Better in the Long Run

If it sounds as though Vilander is a proponent of piston-style pumps versus their progressive cavity (PC) counterparts, it’s because he is, and that feeling is based on experience he’s gained at Glens Falls.

“We had an emergency situation arise a while back in which the incinerator was down and we had to take some steps to effectively store the cake until it was back online. We stockpiled it onsite but then had to find a way to re-introduce it into the system when we were up and running. So we teamed up a conveyor and a PC pump as sort of a makeshift solution. That experience taught me that, while PC pumps are certainly a lot less expensive; they do not handle grit at all and, given what we went through then, won’t last nearly as long,” said Vilander. He adds that they’ve never done a study to determine the total life cycle ownership/operation cost of their piston pumps versus that PC unit, but says he wouldn’t be surprised at all to find it costs more to run the PC pump.

“Our piston-style pumps were more expensive up front but we know they will provide decades of good service. I think we’ve already proven that,” said Vilander.

 

To download the entire #15 application report for Glens Falls, NY, click here.

To learn more about Schwing Bioset, our products and engineering, or this project specifically, please call 715-247-3433, email marketing@schwingbioset.com, view our website, or find us on social media.

To view a version of this story published in TPO Magazine, click here.

 

Tags: Sludge Pumps, Piston Pumps, Wastewater Treatment, Pumps, Dewatered Sludge Cake

Update: Start Up of Piston Pumps at Big Island Mine

 

Written by Dale Bone, December 9, 2015

Here’s an update to the OCI Big Island Mine story that was posted in August of 2015.

In late October, the first Schwing Bioset KSP 220 piston pump was successfully commissioned at the OCI Big Island Mine.  The Schwing Bioset, Inc. (SBI) team was able to give OCI all of the information and control to their DCS system allowing them to monitor pressures, volumes, and all systems deemed critical by OCI. 

Since they are pumping material nearly three miles through an eight inch pipe, SBI was able to set the soft shift at the optimal position for the required pressure and volume range.  According to the OCI Project Manager, OCI is now able to pump higher solids content, which allows the material to stack better in the mine stopes and reduce water usage.  The underground crew also commented that the pipe is very still and the dynamics are nearly nonexistent. 

Once power was installed on the second pump, SBI returned to Big Island Mine and commissioned the second unit.  Minor enhancements were made on the programming of both PLC’s after pump one had been running continuously for three weeks.  SBI installed test equipment to monitor housing pressure and determined there was virtually no pressure spike during shifting, which ensures maximum component life and no pipeline dynamics. 

SBI also trained OCI employees on service and maintenance using one machine during down time.  The SBI equipment is working perfectly and a follow up visit in January will be conducted for onsite customer-specific Pump Service School.

To learn more about this project or product, contact this blog’s author, Dale Bone or visit our mining pumps page. For other information call 715.247.3433, visit our website, or follow us on social media.

Schwing Bioset Mining Piston Pump   Schwing Bioset Big Island Mine Piston Pump

 

  

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Tags: Piston Pumps, Mining, Mining Pumps

Schwing Bioset Featured in International Mining

 

Schwing Bioset, Inc. is excited to be featured in the Slurry Pumping section of International Mining's December issue.

The article discusses Schwing Bioset's recently commissioned pumps for a backfill application at Volcan Compañía Minera's Andaychagua mine, as well as the new piston pump installation at OCI Chemical Corp's Big Island Mine.

View the Slurry Pumping section where Schwing Bioset's projects are discussed (starting on page 36).

View the entire International Mining December issue.

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

 

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

Upgrading a Reliable Necessity - Piston Pumps at the Greeley WWTP

 

Written by Joshua DiValentino, December 2, 2015

The City of Greeley, Colorado, wastewater treatment facility recently implemented a series of strategic upgrades and major improvements were made to the Biosolids Facility. The Greeley facility repurposes its dewatered biosolids cake by trucking it for land application into remote Northern Colorado. The existing Schwing Bioset piston pump located in the sludge dewatering building had been in operation for 20 years and was a key component of this process.

The Greeley facility had relied on its sole Schwing Bioset KSP 25 cake pump for two decades prior to the upgrades. During that time, the existing pump was the only means of transportation for dewatered biosolids between the centrifuge dewatering equipment and the truck loading bin. The piston pump could have been a “bottle-neck” for a facility with limited storage capacity. However, the existing pump provided an exceptionally high level of uptime over its operational life at Greeley, with minimal wear part consumption.   

By 2014-15 the sole KSP 25 had been in operation since the mid 90’s. The City of Greeley facility, working on a larger plant upgrade, decided to implement a new pumping system for the coming decades. Greeley once again chose to invest in a Schwing Bioset KSP Piston pump.

In order to be as cost effective as possible, but also provide maximum redundancy for the foreseeable future, Greeley chose to purchase a new KSP 25, as well as upgrade the existing KSP unit to modern standards. The existing pump was upgraded to match the new KSP unit with control modifications, and upgraded safety features offer easier remote operation and even longer wear part life. The existing unit was also outfitted with a new Hydraulic Power Unit, offering modern hydraulic feed pumps and unlimited control variability.  The two pumps provide redundancy and additional capacity for growth, as well as a modern control network with the current plant SCADA.

Schwing Bioset KSP Municipal Piston Pump  Schwing Bioset Hydraulic Power Pack

The new pump system included a Hydraulic Power Pack, a Twin Screw Feeder, the Control Panel, and of course the Piston Pump. The Schwing Bioset services team worked with the installing contractor and Greeley personnel to integrate the updated control system features on both pumps with the plant MCC.  The new Schwing Bioset KSP cake pumping system (complete with two fully-operational pumps) was turned over to the City of Greeley in the fall of 2015.       

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

 

Tags: Piston Pumps, Biosolids, Wastewater Treatment, Pumps, Municipal Pumps