News from Schwing Bioset

Big Changes at Pine Creek Wastewater Treatment Facility

 

Written by Larry Trojak, Trojak Communications

Version also published in TPO Magazine, February 2020

 

Alabama facility sets lofty goals for its upgrade; meets or exceeds them all.

When the City of Prattville, Alabama, recently chose to upgrade its Pine Creek wastewater treatment facility, it spared no effort in doing so. While they had made smaller, incremental modifications in the past, this time around they took the plant from simply adequate to boldly forward-thinking, designing it to be viable and effective for at least the next quarter century. Included in the wholesale changes was a rethinking of its solids handling capability which, up to that point, was both basic and costly. Today, the Pine Creek Clean Water Facility uses a new approach to aeration, dewaters through a pair of new screw presses, is generating a Class A biosolids for area land application, and is now accepting sludge from a nearby sister facility. In this case, being up a creek is definitely a good thing.

 

Dealing with Growth

Located 20 minutes northwest of Montgomery, Prattville is a city of 34,000 which has seen some impressive development of late. According to the local Chamber of Commerce, between 2014 and 2018 alone, more than 130 new businesses have opened in Prattville and immediate surrounding areas — a total of $760 million in capital investment. All that growth prompted city officials to look at existing infrastructure demands and determine that upgrades to their wastewater treatment effort were in order.

“This was a wholesale overhaul of the entire treatment process to help deal with the growth in the area,” said Greg
Thompson, project engineer with Engineers of the South. “We are a consulting engineering company and have been working with the City for more than 15 years now. So, we were actively involved in the research and planning leading to the upgrade. The original plant, built in 1979 as part of the Clean Water Act, had a 3 mgd capacity. In addition to options for dealing with the anticipated increases in volume, we talked with city officials about re-thinking the entire biosolids treatment and disposal process.”

 

Alabama Dream Sheet

Though a plant-wide change was in the cards, the evaluation criteria for that change were very ordered and specific. According to Dale Gandy, Prattville’s Director of Public Works, the desire to use state of the art technology headed up the list of desirables. 

“Obviously, we wanted to tap into the strengths of today’s newer technology,” he said. “However, we also wanted to try to utilize ‘green’ infrastructure within the plant; had our sights set on looking into a Class A biosolid; wanted to create an effluent that was cleaner than the environment into which it was headed; wanted the whole effort to be energy efficient; and needed the plant to gain an additional 25-30 years of viability. In addition, because we didn’t have unlimited funds to throw at the project, we had to be relatively cost conscious in our efforts. It was a long list to try to meet but we set out confident that it could get done.”

The new plant design that Thompson and his engineering team — working hand in hand with Gandy and Prattville’s
plant management — envisioned, would take the facility from 3.0 to 5.7 mgd — almost doubling in volume. That
increase in capacity, they felt, would give them the 25-30 year life expectancy they needed.

 

Schwing Bioset Screw Presses  Schwing Bioset - Bioset Process Reactor

 

Outdated Concepts

To get to that point, there was not one area of the Pine Creek facility that would be left untouched by the overhaul. Designed in the late 1970s as a conventional activated sludge facility, the plant utilized a coarse screen in a deep sump, prior to the raw sewage pump station, followed by aerated grit removal.

“Aeration in the original design consisted of three parallel basins with two fixed-mounted, low speed surface aerators per basin,” said Thompson. “Control of the aeration system consisted only of locally-mounted low/high-speed selector switches. Not only was the process energy-inefficient, the inability to aerate sufficiently or deal with varying flow rates and oxygen demands led to plant upsets and periodic effluent violations. The warm summer months, when effluent limits are lowest, made it particularly hard for operators to maintain compliance.”

At that time, once biosolids met Class B requirements, they were hauled off to a local field — with 100% of the liquid
— for land application. The facility averaged 10-15 tanker loads of the wet material per day. “But if it had rained and the field was wet, they couldn’t land-apply, so the plant had to be prepared to store material in the digesters,” added Thompson. “It’s not surprising they knew a change was needed.” Finally, the previous clarifiers utilized a mix of organ pipe and scraper blade solids-removal systems. Disinfection, which originally used gaseous chlorine, was updated to UV in a 1999 plant modification.

 

In With the New

Thompson and his group worked hard, not only to address all the issues with the existing design, but also to ensure
the plant’s viability for decades to come. In aeration, to deal with the high ammonia numbers caused by an inability to nitrify, they opted for a VertiCel solution (Evoqua Water Technologies, Pittsburgh, Pa.).

“VertiCel uses a combination of disk aeration followed by fine bubble diffused air,” said Thompson. “In that way, we
felt we could tap the efficiencies of both types of aeration to meet our need for an energy-efficient design and to get full biological nutrient removal.”

Conversely, changes to the plant’s digestion phase included taking them from using surface mechanical aeration to
diffused aeration. “Prattville always had issues getting enough oxygen transfer with the old system,” said Thompson. “This combination of disc aerators and fine bubble diffusers powered by Howden blowers (PD Blowers, Inc, Gainesville, Ga.) is both energy efficient and has great oxygen transfer.” Also covered in the expansion’s design were an all-new headworks, two new fine screens (Duperon, Saginaw, Mich.), and grit removal which incorporated Eutek HeadCell technology and WEMCO Hydrogritters.

 

Road Trip

With preliminary design considerations in place, representatives from both the City and Engineers of the
South, visited a number of wastewater treatment plants throughout the southeast U.S. to review various approaches
to dealing with biosolids. One of the things driving the city’s decision to create a Class A biosolid product was, again, growth in the area.

“We were seeing new industries coming in regularly and knew that we could soon be running out of industrial fields
like the one on which we’d been applying,” said Sam Russell, Pine Creek’s former plant manager who was brought on as a consultant during the upgrade. “So, we knew solids handling had to change and that dewatering would be a huge part of that discussion."

Evaluations of available dewatering options included visits to a half dozen facilities to view belt presses, screw presses and centrifuges, and conversations with operators about their experiences with each. With that growing volume of information at hand, the group started seeing the screw press as the best fit for Prattville, and a visit to a plant in Immokalee, Fla. confirmed that for them.

“Immokalee was an eye-opener for us,” said Thompson. “That installation utilizes a Schwing Bioset screw press
(Schwing Bioset, Somerset, Wisc.) for dewatering and creates a Class A product using the Bioset solution. We saw
so many similarities between what Immokalee had dealt with and our own situation at Prattville that we all felt we’d found our answer. ”

 

Pressing Issue

Coming online in August 2019, the biosolids treatment at Pine Creek now begins by taking material from WAS storage basins — where sludge is held, mixed and aerated — and fed to a pair of new Model FSP-1002 screw presses for dewatering. Each of Pine Creek’s screw presses is rated for 1,122 lbs. of dry solids per hour, with a minimum cake dryness of 17% and a 95% minimum system solids capture. With “tweaks” still being made to the process as operations stabilize, the facility is currently getting cake discharged up to 18%. While the performance stats proved key in making their decision, Prattville was also drawn by the self-cleaning function the Schwing Bioset screw press offered, where the units continue to dewater whenever a cleaning cycle is performed. This continuous operation ensures no equalization storage is necessary between dewatering and the Class A operations.

“We have each unit scheduled to clean itself every hour, but that function is flexible and easily changed,” said Napoleon Wilks, Pine Creek’s current plant manager. “We also like the fact that these presses are almost self-operating,” he said. “We have them programmed to run for only seven hours a day, five days a week, which allows us to keep staffing costs down.”

 

A Stabilizing Presence

In addition to being a sound decision for the City, the fact that both Sam Russell and Dale Gandy own and operate
farms helped solidify Prattville’s decision to go with a Class A product. Their understanding of the benefits a soil
amendment product can bring, the ways it can be used and how positive it could be to the community, led to that
decision.

“We like what can be done with a good Class A product — whether it’s a resident needing it for flower beds, for grass in front of City Hall, or a farmer using it on crops. And, after seeing the success Immokalee was having, it made sense to go with the Bioset solution,” said Russell. “We also felt that there was a real up-side in accountability
to sourcing both the dewatering and the Class A process from the same company.”

The Bioset process uses a screw conveyor to take Pine Creek’s untreated biosolids from the screw presses to
a twin-screw mixer where quicklime and sulfamic acid are added and mixed. From the mixer, a Schwing Bioset
KSP-25VKL pumps material through a 22 ft. long reactor. There, the chemical reactions raise the temperature and
the pH level, stabilizing the mixture and creating a product that meets EPA Class A requirements.

According to Wilks, they are maintaining a minimum temperature of 131°F (55°C) in the reactor with a retention time of 40 minutes in accordance with the operating conditions approved by the Unites States Environmental Protection  Agency (USEPA) through the Process to Further Reduce Pathogens (PFRP) in the 503 regulations. “The way we process our biosolids today — pushing a lower quantity through there than our future design conditions — material is actually in the reactor far longer than that,” he said. “The results have been a consistently good Class A biosolid that we take to a field owned by the department, dump it, spread it a bit, and turn it for a few days until it dries to a point that we are able to pass it along to a local farmer — and right now he will take all that we can provide.”

 

Schwing Bioset Municipal Piston Pump  Schwing Bioset Truck Loading

 

No Mistake About It

In the past, a continual stream of trucks, each carrying roughly 6,800 gallons of liquid headed to the field to
land-apply as much as 81,600 gallons of liquid waste per day. Today’s disposal effort involves just two tri-axle
trucks loaded ¾ full per week. And that energy efficiency criteria? It’s been met to a degree they never imagined,
according to Gandy.

“This is amazing to even comprehend but, despite almost doubling the size of the plant in terms of capacity, when we ran the numbers we found that our energy consumption had only increased by 8%,” he said. “Thinking I must have missed something I checked the data several times and even had a representative from Alabama Power verify
it for me. There was no mistake — that’s how energy efficient this plant is.”

The new biosolids effort is working so well that Pine Creek CWF has already begun processing material from
its sister plant, the 4 mgd Autauga Creek CWF. To do that, the City hauls approximately 200,000 gallons of wet
sludge (at 1.75% concentration ) per month from Autauga Creek to Pine Creek for processing.

Said Gandy: “We set out with a pretty challenging to-do list. But tapping the innovative technology available to us,
we feel we accomplished it all — and then some.”

Click here to read more about our Products, then contact us to learn more about this project or find out how we can help your plant too.

 

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Tags: Class 'A' Biosolids, Bioset Process, Wastewater Treatment, Municipal Pumps, Screw Press

Schwing Bioset Trailer Mounted FSP 1103 Screw Presses Now Available for Contract Operations

 

Written by Kelly Kramer

 

Schwing Bioset is pleased to announce that we can now help solve your dewatering challenges with our fully automated trailer mounted FSP 1103 screw press dewatering systems. Available for onsite demonstrations and/or contract operations, the 1103 screw press is one of our largest models and is engineered for durability, reliability, ease of operation, and low power consumption, making the units an efficient method to dewater.

As with all of our screw presses, our mobile units are designed for quick set up, ease of use, and high-performance for dewatering all types of wastewater. 

One of the screw press features our customers are most excited about is the self-cleaning wash cycles. With low wash water requirements and automation, dewatering operations do not need to be suspended during cleaning and a cleaning cycle typically lasts less than five minutes.

Once dewatered, the solids can be treated, loaded, hauled away, and/or beneficially reused, depending upon the method of the end user.

For more information on our mobile screw press units, please contact our Regional Manager nearest to your plant. The screw press and Schwing Bioset’s full product offering can be viewed here.

 

Schwing Bioset Mobile Screw Press   Schwing Bioset Mobile Screw Press

 

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Tags: Wastewater Treatment, Screw Press, Dewatering, Mobile Screw Press

Screw Press Proves Efficient in Dewatering MBR Sludge

 

Written by Tom Welch

Version also Published in TPO Magazine, August 2019

 

The Decatur, AR, WWTP had existing dewatering technology that proved to be undersized and inefficient. With the additional demands of a new plant upgrade, Operations staff were struggling to meet current dewatering requirements.

The Design Build team and Owner selected an FSP 802 screw press from Schwing Bioset to replace the existing equipment. The new equipment was installed in the same building with primarily service connection modifications. The screw press started operating in November of 2018.

The improvements in the dewatering operations are remarkable, as it is saving Decatur operational expenses in every category. Dry solids content of the dewatered biosolids have improved from an average of 13% to 17%, resulting in less cake to haul. Solids capture rate has improved from less than 80% to 95%, resulting in a lower return load to the plant. Polymer usage is now at 18 pounds active per dry ton, which is well below the consumption rate of the previous technology reducing polymer expenditures.

In addition to these performance improvements, the dewatering capacity has more than doubled. Where it used to take at least two days to load a 25-ton trailer, the plant can now fill a trailer in 6.5 hours, reducing operator efforts in turn. 

With the widest range of machine sizes for several applications, and mobile pilot units available for testing your materials, Schwing Bioset is your comprehensive solutions provider for dewatering.

Click here to learn more about our products or contact our regional manager closest to you.

 

Decatur Dewatering Screw Press

 

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Tags: Biosolids, Screw Press, Dewatering, Membrane Bioreactor

West Rankin Utility Authority to Install Three Schwing Bioset Screw Presses

 

Written by Kelly Kramer, October 2019

 

The West Rankin Utility Authority (WRUA) provides services to several communities in Western Rankin County in Mississippi. WRUA generates approximately 10 to 12 million gallons of wastewater each day, which is currently transmitted to the Savanna Street Wastewater Treatment Plant in Jackson. To take advantage of this service, the authority has to pay Jackson, which costs it a few million dollars each year.

In an effort to save costs in the long run, and operate independently, WRUA has decided to build a brand-new wastewater treatment plant of its own. Schwing Bioset is pleased to announce that our team will be part of this project, with WRUA ordering three of our largest dewatering screw presses, the model FSP1203’s.

The FSP 1203’s are designed to handle a capacity of up to 7,468 dry pounds per hour. For West Rankin, the expectation is to process 24 dry tons per day operating at 60 hours per week, dewatering of 0.75% solids WAS with a 17% solids sludge cake output, and a ≥ 90% solids capture rate.

Schwing Bioset Screw Press     Schwing Bioset Screw Press

The West Rankin screw press system is designed for continuous dewatering of flocculated slurry and consists of a screw press dewatering unit, a flocculation tank, a rotary lobe sludge feed pump, and a liquid polymer blending system. Slow movement and the high-quality design of the structural components guarantee a high service life, and the back-washing cycle cleans the screens automatically so dewatering operations will not be interrupted during washing cycle.

With the new equipment in the new wastewater treatment plant, Schwing Bioset will be able to help West Rankin to bring its system into compliance with federal water quality laws, increase plant capacity, and save on costs in the long run.

To learn more about Schwing Bioset’s dewatering screw presses, contact Chuck at cwanstrom@schwingbioset.com or visit our website.

 

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Tags: Screw Press, Dewatering, Wastewater Treatment Plant

Screw Presses Help Plant Reduce Maintenance Costs

 

Written by Chuck Wanstrom

Version also Published in TPO Magazine, August 2018

 

The city of Bradenton, Florida, operates a wastewater treatment plant that processes roughly 8 million gallon per day. The plant had historically aerobically digested their biosolids and dewatered them to 15% dry solids content using two, 2.0-meter belt filter presses. Due to the age of the belt filter presses, the maintenance expenditures were continually increasing and were creating a burden not only with expenses, but also with personnel time to keep the equipment functioning.

Bradenton began a search to identify new dewatering techniques that could replace the aging belt filter presses.  Several pilot studies were completed, and Schwing Bioset was invited to run our screw press pilot. The pilot proved successful with results of up to 21% dry solids. The Schwing Bioset screw presses were also able to fit within the confines of the available space on the second floor of the existing dewatering building. 

The Schwing Bioset equipment was chosen as the best value and was procured under a sole source contract. The two new FSP902 screw presses were designed into the existing dewatering building and were commissioned early in 2018. The dewatered biosolids exceed the old belt presses cake performance and reduces the city’s hauling and disposal costs while at the same time reducing the amount of wash water required and significantly reducing the maintenance load to city staff. 

Learn more about our screw presses or contact our regional manager closest to you.

 

Bradenton Screw Presses

 

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Tags: Biosolids, Wastewater Treatment, Screw Press, Dewatering, screw presses

City Converts Biosolids Processing Equipment After Fire Disaster

 

Written by Chuck Wanstrom

Version also published in TPO Magazine, February 2019

 

Home to both St. Olaf and Carleton colleges, the City of Northfield, MN, is located approximately an hour south of Minneapolis and has a population of 20,000. The wastewater plant is approximately 3 MGD and has historically produced Class A biosolids via an open alkaline and thermal stabilization process. Disaster struck in May 2018 when a fire destroyed all of the Class A biosolids processing equipment, as well as the surrounding dewatering and odor control equipment in the building. 

Rather than simply replace the old equipment, the city of Northfield evaluated current available technologies and elected to convert from belt presses to screw presses for its dewatering needs and has purchased two machines from Schwing Bioset to accomplish this. Additionally, the city will continue with Class A biosolids production, but they are converting to Schwing Bioset's Bioset process. The Bioset process is a closed process that contains odors and dust that does not require supplemental heat and has also been approved by the USEPA through the PFRP process to operate at temperatures below those specified in the 503 regulations. 

Final detail design of this pre-purchased equipment is underway and the plant is scheduled to be operational later in 2019. To help the plant bridge the gap in biosolids processing while the new facility is in being constructed, the city is also renting a mobile screw press and Bioset trailer to process their current biosolids production. 

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Bioset Process and Screw Press Dewatering

 

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Tags: Class 'A' Biosolids, Bioset Process, Screw Press, Dewatering

Sugar Creek WWTP Screw Press Records Impressive Data

 

Written by Tom Welch, November 2018

The Sugar Creek WWTP, owned by the Sangamon County Water Reclamation District located in Springfield, IL, has two Schwing Bioset model FSP 1102 screw presses and our Class B alkaline stabilization process. The screw presses dewater the plant’s aerobically treated biosolids and the downstream equipment produces the alkaline stabilized Class B biosolids. These biosolids are then windrowed in the District’s storage shed and eventually land applied for beneficial use. Data recorded from a recent site visit on a single screw press in operation was impressive and can be seen below.

Incoming Flow: 280 gpm
Incoming % DS: 1.5%
Throughput: 2,100 lbsdry/hr
Polymer Dose: 12 lbs/ton
Output % DS: 22%
Capture: >95%

 

Check out the included photos and operational videos, which show an overview of the installation and the equipment in action. 

Contact your Schwing Bioset Regional Sales Manager to learn more about how our biosolids management systems may be able to improve your current processes.

 

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Tags: Alkaline Stabilization, Biosolids, Screw Press, Dewatering

Dewatering with a Screw Press at Bradenton WWTP

 

Written by Chuck Wanstrom, May 2018

The city of Bradenton, Florida, operates a wastewater treatment plant that processes roughly eight million gallons per day. The plant had historically aerobically digested their biosolids and dewatered them to 15% dry solids content using two, 2.0-meter belt filter presses. Due to the age of the belt filter presses, the maintenance expenditures were continually increasing and creating a burden not only in expenses, but also on personnel time to keep the equipment functioning.

Bradenton began a search to identify new dewatering techniques that could replace the aging belt filter presses. Several pilot studies were completed and Schwing Bioset was invited to run their screw press pilot. The pilot proved successful with results of up to 21% dry solids. The Schwing Bioset screw presses were also able to fit within the confines of the available space on the second floor of the existing dewatering building. 

The Schwing Bioset equipment was chosen as the best value and was procured under a sole source contract. The two new FSP902 screw presses were designed into the existing dewatering building and were commissioned early in 2018. The dewatered biosolids exceed the old belt presses cake performance and reduces the city’s hauling and disposal costs while at the same time reducing the amount of wash water required and significantly reducing the maintenance load to city staff. 

To learn more about this project or our screw presses, contact a regional manager or email us.

 

1  DSCN8025

 

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Tags: Biosolids, Screw Press, Dewatering, Wastewater Treatment Plant

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

Schwing Bioset Onsite Demonstrations Help Find Solutions

 

Written by Dan Anderson

The past year has been full of onsite demonstrations and we are looking forward to another busy year for our demo fleet.

In 2016, we completed several successful onsite demos for solids pumping, the Bioset process for Class A Biosolids, nutrient removal/struvite recovery, and screw press dewatering.

Our demo program is a great way to see first-hand how our equipment can help your plant. Demos can run anywhere from a few days to a few months, depending on the needs of the plant.

Whether it is pumping material with ease, producing a beneficial re-use product, dewatering sludge efficiently, or removing unwanted nutrients to help your plant and the environment, Schwing Bioset has a vast array of knowledge, tools, and equipment to help your plant find the right solution.

For more information on our demos, please contact Chuck Wanstrom at cwanstrom@schwingbioset.com or 715.247.3433.

Schwing Bioset Class A Biosolids Demo Unit  Schwing Bioset Screw Press Demo Unit

 

 

Tags: Bioset Process, Biosolids Handling, Screw Press, Bioset Demo, Screw Press Demo