The Clear Solution

Waste Water
Treatment
IPH GmbH
Pretschgasser 12
1110 Wien Austria
M fjarosch@chello.at
I www.environment-waste.com
Waste Water Treatment | 2
We offer worldwide services in regard to technologies,
design, engineering and construction of plants for the
treatment of municipal-, industrial- and agricultural
wastewaters, as well as the dewatering and thermal
recycling of sludge.
Providing State-of-theArt
Technologies to turn Waste
into Valuable Products ...
Whenever applicable, waste heat and/or gravitation are used as energy source, in order to avoid the usage of primary energy.
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Quick Sedimentation Unit
The Quick Sedimentation Unit is the central part of
an alternative sewage treatment plant, which can be
implemented in municipal-, industrial- and agricultural-
wastewater treatment plants. This unit replaces the
grid channel and pre-treatment (large primary treat-
ment clarifers) of conventional wastewater treatment
plants. From the entering wastewater solids are sepa-
rated up to 50 times faster compared to the conventi-
onal approach.
The water enters the Quick Sedimentation Unit with
high speed, attaining a nearly complete solid-liquid
separation by means of hydraulic processes and iner-
tia. The cleaned water leaves the tank via a ring flter.
This device was awarded with the R.I.O. innovation price.
Z Sedimentation in fow direction, not counter wise
Z 20-50 times higher sedimentation speed in com-
parison to conventional systems
Z The result: enormous energy and space savings
with tremendous results regarding immediate drop
of BOD5 and COD levels
Separation of
solids from
uids
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Pre-dewatering cylinder
Function
The sludge enters the cylinder from the
bottom. On its way organic polymer foccu-
lent is added and mixed into the sludge by a
slowly rotating paddle mixer which moves the
sludge upward. The upper part of the cylinder
is formed as a screen flter, from where the
main quantity of the fltrate water drops out of
the cylinder onto a slide.
Capacity and reachable level of sludge dehydration
The capacity of one cylinder is approx. 600
kg dry substance per hour, which corre-
sponds to 15 m sludge with 4% DS per
hour. For municipal digested sewage sludge
approx. 8-14% DS can be reached. The pre-
dewatering cylinder is very suitable for the
thickening of thin sludge with a DS
of > 0.5 %.
Sludge
dewatering
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Pre-thickening cylinder
Function
The pre-thickening cylinder serves for an additional
gravitational thickening of the pre-dewatered sludge.
The pre-dewatering cylinder and pre-thickening cylin-
der are connected by a slide. Inside of the cylinder the
sludge moves in a slowly downward motion where-
by it dewaters through an additional screen flter. To
increase dewatering effciency a slowly rotating coil
moves the sludge from the core to the peripheral
of the cylinder. The sludge leaves the cylinder via a
discharging device on the base of the cylinder. The
flter is periodically washed by a flter washing unit.
Capacity and reachable level of sludge dehydration
Approx. 600 kg dry substance per hour. Obtainable
degree of desiccation for municipal digested sewage
sludge is approx. 28% DS!
Advantages of the system
Due to the highly effcient pre-dewatering, the follow-
ing belt press can be operated with higher pressure.
Consequently sludge will be dewatered faster and
to a higher degree. Furthermore the effcient pre-
dewatering allows treatment of a quite high amount of
sludge (10-15 m/h) at a small belt press with a belt
size of just 1.0 meter. For municipal digested sludge
approx. 30% DS can be reached.
Belt press
The compact belt press serves for the dewatering of
large quantities of sludge ranging from 0.5 % DS - 30-
35% DS. It can be prearranged either as stationary or
as mobile unit (container). It is equipped with a sludge
pump, focculent preparation unit, dosage unit and all
necessary controls.
It equally processes municipal and industrial sludge.
The very effcient pre-dewatering does not only sur-
pass a wider belt, but also allows a pressing under
higher pressure with less downtime.
Additional advantages:
Z completely made of stainless steel
Z space requirement only 3.6 x 1.8 x 2.7 m
Z light weight of only 1.900 kg
Z self-adjusting flter cloth
Z easy servicing and cleaning due to simple design
Z cleaning water and fltrate drainage are separate
units
Z low maintenance cost
Z pre-dewatering, thickening and belt press can be
operated separately
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The alternative process makes every effort to produce
an almost absolutely dry product (95-98% DS). The
procedure is based on the fnding, that an economical
dewatering of sludge needs different technologies to
be utilized for each phase of the dewatering process.
This understanding led to the development of a simple inte-
grated system with an economic viability, which until now
has not been achieved by any other method.
The system consists of 3 stages:
Z gravity dewatering and thickening
Z pressing and
Z air drying after pelletizing the sludge.
It was essential to develop new equipment for this
technique. The unique stages can be used separately
or combined with existing conventional dewatering
processes.
For an economical drying two factors play an es-
sential role: The water content and the form of the
material. To dry sludge from 30 % to 95 % requires
evaporating 133% more water than drying from 50
% to 95 %. As a result energy demands and costs
increase.
Likewise important is the shape of the material. Water
is evaporated from the surface which causes water to
disperse from the core toward the outside. Therefo-
re a pellet with a cylindrical shape and a diameter of
6-8 mm is desirable. It has been found out, that the
fabrication of short pellets comply best with the drying
necessities: Moisture evaporates quickly from the
surface.
The smaller diameter facilitates rapid passage of the
water from the core to the surface and that the span
of the diffusion path from the core is the same in all
directions. The pellets have point contact only and
therefore allow a simultaneous drying of the entire
surface.
To ensure that all pel-
lets are dried equally
in a given time period
a near uniform size
of the pellets is also
important.
Sludge drying
with off-heat
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The drying occurs through contact with heated sec-
tions of the dryer and by contact with hot dry air. The
construction of the dryer is made of galvanized sheet
metal elements. The individual modules are fastened
either next to or on the top of another module.
The sludge pellets are continuously fed into the top of
the dryer. The pellets slowly trickle from the top to the
bottom of the dryer. By the downward movement and
the shape of the heating trays the pellets are continu-
ously shifting from one side to the other, thus drying
fast and uniform in the warm airstream.
In order to prevent odor emissions the fan of the
dryer is placed on the suction side creating a low
pressure environment inside of the dryer. Apart from
exhaust air ducts, the entire dryer is heat-insulated.
The moisture loaded drying air is sucked off and
passed through an exhaust air scrubber before the
cleaned air leaves the system through a duct. At the
exhaust air scrubber cool water washes out dust and
condenses vapors. In a fnal stage the air passes a
biofltration unit where microorganisms eliminate even-
tually existing malodorous organic loads.
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Municipal sewage sludge contains nutrients in high
concentration, whereupon in the past it was mainly
used as fertilizer. Beside nutrients sewage sludge
also contains harmful substance in very wide-ranging
composition and concentration, depending on the
character of the incoming water. The use of sludge as
a fertilizer caused severe problems. With contact to
soil even less harmful substances may change their
structure which makes a risk assessment very diffcult
or even impossible.
The most environmentally benign disposal
of sludge is its incineration and mandatory
in Germany. However, the biggest drawback
is the use of expensive primary energy,
which is required to incinerate wet sludge.
At conventional sewage treatment
plants a large part of the energy
contained in the sludge is just eliminated instead of
using it effciently. It starts with feeding the sludge to
microorganisms, which thrive on the energy contained
in the sludge.
Without getting the sludge exposed to microorganisms its
energy value is higher than brown coal!
Therefore microorganisms destroy a valuable, high
energy containing product. Later on, a digester con-
verts just 1/3 of the organic matter into methane gas.
Indeed some of the produced metha-
ne gas will be incinerated and conver-
ted into electrical energy; nevertheless
large amounts of the heat energy are
used for the heating of the digester to
keep the process of methane active.
Z With the above mentioned technology
sludge is dried with off-heat up to 95-
98% DS before it is incinerated.
Z There is practically no heat loss caused by water
evaporation.
Z Dry sludge pellets burn so well, that they can be
inamed by a candle and continuing burning without
any co-ring.
Z The caloric value is so high that an electrical power
generation is recommendable. Yet after electrical po-
wer generation there remains enough heat (energy)
for the drying process of the sludge!
Z The ash of the incineration can be used for both
material- and thermal-recycling.
One application for ash from sewage
sludge incineration is to facilitate bricks.
The picture above shows a brick which
contains 50% of ash from sewage sludge
incineration.
In same way the system can be applied
for any kind of industrial sludge. Dried pa-
per sludge for example can be used as oil
binder or as raw material for the produc-
tions of paperboard products.
Sludge
recycling
Municipal sewage sludge
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Pulp and paper industry
The paper and pulp industry is characterized by its
enormous water consumption. As one knows the
water does not remain in the product. It is accumu-
lating to vast volumes of wastewater to be cleaned
before discharge into streams or sewer lines.
Required fresh water is taken from surface waters,
springs or from the public water lines as tab water. As
far as the water is not tab water, the water has as well
to be processed (purifed) before it can be utilized in
the production.
In the process of cleaning up the wastewater a paper
mill produces a large volume of sludge. In order to
keep disposal costs down this (liquid) sludge has to
be drained from water, leaving (drained) wastewater
and (still wet) sludge.
With increasing disposal costs for (wet) sludge it
would be more favorable to turn this sludge into a
valuable product, putting an end to this drainage of
profts.
With new developed technologies in the feld of
wastewater treatment, sludge dewatering, sludge
drying, as well as for their recycling (mentioned above)
their application does not only reduce disposal costs.
They produce proft!
The required equipment is easy to operate and the
anticipated investment costs are low. In many cases
savings in disposal costs alone result in an amortization
of the investment costs in less than 3 (three) years!
Wastewater can be purifed to a degree where it can
be recycled! Sludge is turned into a valuable product
for sell or use!
Industrial
sewage
sludge
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Introduction
For economic reasons, modern meat industry cant
avoid factory farming. The concentrations of extre-
mely large numbers of animals to be breed or fattened
up on one place makes the traditional discarding of
slurry diffcult or even impossible limitation of land for
spreading slurry per hectare and year as well as sto-
rage capacity for up to year).
In several cases breeders are not allowed to incre-
ase their meat production since their slurry disposal
reached its limit.
Main problems
Z high COD and BOD5 loads
Z high loads of phosphates and nitrogen com-
pounds
Z odor emissions
Advantages
Z Dried slurry would be an excellent fuel with a calori-
c value of approx. 4,500 kCal/kg dry matter (approx.
18,800 kJ/kg).
Z Beside of thermal utilization slurry in its dried state
can be also used as natural fertilizer which is stabile
and easily stored over a long time period, and can be
easily dosed and spread on demand during growing
season.
Z Of course, transport is more efcient without the
burdening
Solution
The above mentioned system turns a problematic
object (slurry) into a valuable product, either into
energy or into a customer friendly fertilizer, which can
be exactly dosed and evenly spread. The system had
been developed based on the fnding that the main
part of COD and BOD5 loads result from the solids.
In separating the solids, COD and BOD5 loads drop
drastically. The remaining loads in the water fraction
can be easily (biologically) decomposed.
Slurry
(Manure)
(from pig, cow
and poultry)
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Description of technology
The slurry with an approx. 5% DS is pumped into a
collecting tank. From here it is pumped off into pre-
dewatering/pre-thickening cylinders where it is de-
watered by mere gravitation up to 23-24% DS. The
pre-dewatered slurry falls on a belt press where it is
dewatered to 26-28% DS. Filtrates and flter washing
water are pumped into a Quick Sedimentation Unit
in order to separate remaining solids from the water
fraction. After this step sludge and water fraction
are separately treated according to the local require-
ments.
With their loads drastically reduced the fltrate water
can be spread onto cultivated areas. For the dischar-
ge into water bodies (streams) it would pass in a fnal
step a biological trickling flter. If required/mandato-
ry this step can be combined with a denitrifcation
process. Alternatively the water can be used as wash
water.
The solids are formed to pellets with a diameter of 8
mm and afterwards dried by off- heat up to 95-98%
DS.
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Waste Water Treatment | 12 Waste Water Treatment | 12
The caloric value of dried slurry is so high, that
only a small part of the heat energy from the sub-
sequent incineration is needed for the drying of the
sludge.
The remainder can be converted into electrical energy
by a steam turbine.
Since the system is completely enclosed no odor
emissions are leaving the plant.
Electrical power generation is already economical at
a slurry volume from 8.000 - 10.000 animals (cattle,
hog).
Additional advantages
Z Extremely low space requirement in comparison
to conventional wastewater treatment systems
(~10%)
Z Cutting investment costs into half
Z Low operating cost
Z Nearly 100% usage of (the former) sludge
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Instead of disposing into landlls or ocean dumping com-
mon steel mill wastes (furnace sludge, sinter sludge and
dusts) mixed with two other organic wastes can reprocess
millions of tons of ferrous wastes per year! With this system
three organic wastes are converted into a valuable product!
The nal product is an absolutely dry, dust free and abrasion
resistant briquette, ready to be melt down.
Steel Mill Waste
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For any further information
please contact us:
IPH GmbH
DI FRIEDRICH JAROSCH
Pretschgasser 12
1110 Wien Austria
T +431 768 31 42
F +431 768 31 42
M +43 664 338 91 95
fjarosch@chello.at
www.environment-waste.com
Thank You.