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No.AOS-8G10

VOLUTE Dewatering Press Application Information ES-SA & TA Series Ver.2.0

2008, June / Hirose

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Table of Contents

CChhaarraacctteerriissttiiccss ooff EESS--SSAA SSeerriieess

11.. SSyysstteemm OOuuttlliinnee

1-1 ES Series Model Number Legend 1-2 Structure of The System 1-3 Parts Outline

① Volute Cylinder ② Flow Control Tank ③ Flocculation Tank ④ Control Panel

1-4 Flow Chart

22.. DDeessiiggnn CCrriitteerriiaa

2-1 Suitable Sludge for Volute Process 2-2 Conditions of Pre-Process of Sludge 2-3 Performance 2-4 Control Panel 2-5 Electrical Interfaces

① Electrical Compartment Table ② Block Diagram ③ Skeleton

2-6 Standard Specification 2-7 Nozzle List 2-8 Weight List

33.. CCrriitteerriiaa ffoorr tthhee DDeevviicceess PPrreeppaarreedd bbyy CCuussttoommeerrss

3-1 Sludge Feed Pump 3-2 Polymer Feed Pump 3-3 Water Supply

44.. RRuunnnniinngg CCoosstt

4-1 Calculation for Chemical Cost 4-2 Calculation for Cleaning Water Cost 4-3 Calculation for Power Cost

55.. CCoonnssuummaabbllee PPaarrttss

5-1 Consumable Parts and Life Span 5-2 How to Exchange

66.. OOtthheerrss

6-1 Others

(3/19)

11.. SSyysstteemm OOuuttlliinnee

11--11 EESS SSeerriieess MMooddeell NNuummbbeerr LLeeggeenndd ((NNoommeennccllaattuurree))

ES-202/SA-CE **EESS--220022 mmooddeell wwiitthh aa ssiinnggllee FFllooccccuullaattiioonn TTaannkk,, WWaatteerr--LLeevveell AAddjjuusstteerr,, aanndd wwiitthh CCEE mmaarrkkiinngg.. EESS –– (( )) (( )) (( )) // (( )) -- (( )) AA BB CC DD EE FF AA:: MMooddeell SSeerriieess NNaammee BB:: SSiizzee ooff CCyylliinnddeerrss

1100 110000 φφ 1133 113300 φφ 2200 220000 φφ 3300 330000 φφ

CC:: NNuummbbeerr ooff CCyylliinnddeerrss

11 OOnnee CCyylliinnddeerr 22 TTwwoo CCyylliinnddeerrss 33 TThhrreeee CCyylliinnddeerrss

DD:: MMoottoorr’’ss PPoossiittiioonn ““NNoottee:: AAddaapptteedd oonnllyy ffoorr 330000 mmooddeell””

NNoonnee IInnlleett SSiiddee FF OOuuttlleett SSiiddee

EE:: SSppeecciiffiiccaattiioonnss ooff FFllooccccuullaattiioonn TTaannkk((ss)) ““NNoottee:: TTAA iiss aaddaapptteedd oonnllyy ffoorr 330000 mmooddeell””

SSAA OOnnee FFllooccccuullaattiioonn TTaannkk wwiitthh WWaatteerr--LLeevveell AAddjjuusstteerr TTaannkk TTAA TTwwoo FFllooccccuullaattiioonn TTaannkk wwiitthh WWaatteerr LLeevveell AAddjjuusstteerr TTaannkk

FF:: CCoonnffoorrmmeedd MMaannuuffaaccttuurriinngg SSttaannddaarrdd

Table-1 Specifications Throughput (kg-DS/h)

Model Waste Activated Sludge 2,000~4,000 mg/L

DAF Sludge, Thickened Sludge

6,000~35,000 mg/L

D/No. of Cylinder

ES-101SA 2 ~ 3 kg-DS/h 3 ~ 5 kg-DS/h 100 φ × 1 ES-131SA 4 ~ 5 kg-DS/h 6 ~ 9 kg-DS/h 130 φ × 1 ES-132SA 8 ~ 12 kg-DS/h 12 ~ 18 kg-DS/h 130 φ × 2 ES-202SA 12 ~ 18 kg-DS/h 18 ~ 30 kg-DS/h 200 φ × 2

ES-301SA/TA 18 ~ 30 kg-DS/h 36 ~ 50 kg-DS/h 300 φ × 1 ES-302SA/TA 36 ~ 60 kg-DS/h 72 ~ 100 kg-DS/h 300 φ × 2 ES-303SA/TA 54 ~ 90 kg-DS/h 108 ~ 150 kg-DS/h 300 φ × 3

(4/19)

11--22 SSttrruuccttuurree ooff tthhee SSyysstteemm Volute Dewatering Press has been developed mainly for the purpose of dewatering the organic sludge.

Volute Dewatering Press is the combination of the following devices;

････････････････ Heart of the system. Thickening and dewatering of sludge. ■Volute Cyl inder ■Flow Control Tank ････････････････ A necessary amount of sludge is measured by V weir. ■Flocculation Tank ････････････････ The sludge is made to react with chemical in this tank. ■C o n t r o l P a n e l ････････････････ Control Panel includes features of Manual/Auto operation.

Figure-1 System Structure

Control Panel

Flocculation Tank

Flow Control Tank

Volute Screw Cylinder Dewatering Zone (SUS)

Volute Screw Cylinder Thickening Zone (Resin)

(5/19)

11--33 PPaarrttss OOuuttlliinnee ① Volute Cylinder ①-1 Structure The moving rings and fixed rings are arranged in layers one after the other and the

screw pitch narrows from thickening zone towards the dewatering zone.

Figure-2 Volute Cylinder Structure

①-2 Dewatering Principle The former part of Volute plays thickening role and the latter part plays dewatering role. In the thickening zone, the rings are made of resin. Filtration part separates sludge from filtrate water as it is like a bar screen. In the dewatering zone, the rings are made of stainless steel. The screw pitch narrows from thickening zone towards the dewatering zone, thus making the pressure in the dewatering drum to increase. The End Plate (Figure-2, E) increases the inner pressure even more, thereby dewatering sludge and discharging the cake with solid content of approx. 20%.

Figure-3 Volute Cross Section ①-3 Self-Cleaning Structure

The screw passes through the filtration part and continuously pushes the moving rings up and down with its edge in accordance with its rotation. This causes the moving rings to move continuously, thereby cleaning the gaps in the filtration part to prevent clogging.

Screw

Fixed Ring

Moving Ring

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② Flow Control Tank Sludge from a storage tank is regulated to adjust feed sludge volume supplied to the flow control tank by the sludge feed pump, and constant amount exceeds V weir and it flows into the focculation tank. The sludge of the remainder returns from the water level adjustment pipe back to the storage tank.

Figure-4 Flocculation Tank

③ Flocculation Tank In the Flocculation Tank admixing of the chemical substance is carried out in order to form flock. The flock is then transferred to the Volute drum where instantaneous gravity thickening takes place at the same time and then the flock moves through the thickening zone.

④ Control Panel Control Panel has the function not only for manual operation but also for fully automatic unattended operation with 24 hours timer for the attached facilities. Water level control is possible as well by means of receiving operation signal from a sludge storage tank. *Circuit of sludge pump and chemical feed pump is included in the Control Panel.

Figure-5 Control Panel

Water Level Adjuster

V weir

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11--44 FFllooww CChhaarrttss

Flocculation Tank The sludge is supplied at constant quantity

through V-weir into the Flow Control Tank. Admixing of the chemical substance with is

carried out in the Flocculation Tank in order to form flock.

Volute Cylinder Thickening instantly in the thickening zone. Dewatering occurs in the dewatering zone

due to high pressure inside the drum and pressure from the End Plate.

Discharging sludge cake of solid content higher than 20%.

Figure-7 Flow Charts

Flocculation Tank

Volute Drum

LS

M

M

N-3 Filtrate

N-1 Sludge Inlet

N-4 Chemical Inlet

N-5 Water supply

N-2 Sludge Over Flow

Volute Cylinder

Flocculation Tank

Sludge Inlet

Chemical Inlet

Water Supply

Sludge Over Flow Filtrated Outlet Model “SA”

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22.. DDeessiiggnn CCrriitteerriiaa The following Design Criteria should be met when you install Volute Dewatering Press in your WWTP facility design.

22--11 SSuuiittaabbllee SSlluuddggee ffoorr VVoolluuttee PPrroocceessss 1) Organic Sludge. 2) Feed sludge concentration should be about 0.2 ~ 3 %.

【Explanation】 1)100% Inorganic Sludge is difficult to dewater due to structural matter of Volute Screw.

In case of high ratio of inorganic sludge among organic sludge is difficult to show good performance as usual. In such case, please ask us for our free beaker test just before your design work and procurement.

2) Under the condition of sludge concentration is below 0.2%, process speed tends to decrease a little and then performance tends to show a worse performance. In case when sludge concentration is over 3.0%, there is possibility that it could not show standard performance as well. High concentrated sludge prevents enough agitation in Flocculation Tank and then enough reaction between sludge and chemical.

22--22 CCoonnddiittiioonnss ooff PPrree--PPrroocceessss ooff SSlluuddggee 1) Always agitate sludge to keep steady solid concentration. 2) ｐＨ of the sludge should be in the range of 6 ~ 8. 3) Screen would be required in case when rubbish, dead leaves, fur, straw and fiber

are included in sludge. 【Explanation】

1) and 2) In case of big range of concentration, it is difficult for the system to get steady performance because frequent adjustment for quantity of chemicals is required.

22--33 PPeerrffoorrmmaannccee

1) Standard Throughput 100 φ × 1 pc ~ 3 kg-DS/h (surplus sludge) ~ 5 kg-DS/h (floating floth) 200 φ × 1 pc ~ 9 kg-DS/h (surplus sludge) ~ 15 kg-DS/h (floating floth) 2) Water content of sludge cake is below 85% in case of dewatering surplus sludge

from biological treatment. 3) Chemicals for the right performance can be selected from Polyferric Sulfate and Polymer

Coagulant depending on sludge property.

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【Explanation】 1) Throughput is influenced by sludge property (quality and concentration).

Table-2 Standard Performance (per one cylinder).

Quality Concentration D Easy Dewatering Difficult Dewatering

φ100 3 kg-DS/h 4kg-DS/h 0.6 ~ 1.0 % φ200 9 kg-DS/h 12kg-DS/h φ100 4 kg-DS/h 5kg-DS/h

1.0 ~ 3.0 % φ200 12 kg-DS/h 15kg-DS/h

2) The use of standard polymer coagulant such as Anion and Cation easily achieves 85%

or lower water content of sludge cake. When water content of sludge cake is the highest priority of a client, it is possible to achieve a better performance by selecting a more suitable polymer coagulant.

3) In case of flocculated sludge, add Anion 2.5 ~ 3.0%(liquid conversion against DS) and Cation 2.5 ~ 3.0% (liquid conversion against DS). In case of activated sludge, add Polyferric Sulfate 15% and in Amphibious 2.5 ~ 3.0% (liquid conversion).

22--44 CCoonnttrrooll PPaanneell 1) The speed of Volute motor and Flocculation Tank Agitator is controlled by the

inverter inside the Control Panel. 2) Switch and Indications in Control Panel are for common use up to screw number 1pc ~

5pc. 3) Circuit for a sludge feed pump, a chemical feed pump (Anion, Cation and Polyferric

Sulfate) are pre-installed. 4) 24hr Timer is pre-installed. 5) “Receiver for stop signal from outside” is pre-installed. 6) Dispatch by “Dehydrator collective trouble”

*Motor capacity of each item is referred to the attached Skeleton. 【Explanation】 1) Volute motor speed is controlled by the inverter to adjust a process speed easily. In

case when Volute Screw are more than 2 pieces, thermal switch are equipped at the secondary inverter.

Flocculation Tank Agitator is controlled with the inverter for correct reaction of sludge and polymer.

2) For 3),4),5),6), please refer to Figure-8 Electrical Compartment Table, Figure-9 Block Diagram, Figure-10 Skeleton.

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22--55 EElleeccttrriiccaall IInntteerrffaacceess ① Electrical Compartment

Volute Control Panel

①Dewatering Press COS Manual・OFF・ON

②Volute CS OFF ・ON

③Agitator CS OFF ・ON

④Polymer Pump CS OFF ・ON

⑤Sludge Pump CS OFF ・ON

Condition Indication

①Power Receiving White Pilot Lump

②Trouble Orange Pilot Lump

Main Device Load

① Volute Drive

② Flocculation Tank Agitator

③ Electric Valve

Detector

① Flocculation Tank-Full

① Sludge Pump（B）

② Polymer Feed Pump

Control Center

Continuing Control Panel

Ａ

Ｃ

Relation Device Detector

（when required）

① Chemical Tank Level

Decreasing

・Polymer Coagulant

② Sludge Storage Tank

Level Decreasing

Power Supply（200V・Triphase）

Chemical Unit

Ｂ

Volute Control Panel

（ES-SA Series） Ｂ’

Relation Device Load(Ｂ’)

① Sludge Pump

※choose one

Ｂ’

Power Supply（200V・Triphase）

Solid line AMCON’s arrange

Dotted line Customer’s arrange

Figure-7 Electrical Compartment Table

Content of Ａ is as below

1） Outside starting signal(when required）

Contents of Ｂ are below

1）Lump sum trouble

2）On operating signal

Contents of Ｂ’are below

1）Lump sum trouble

2）On operating signal

3）Operation order for sludge

Pump

Content of Ｃ is below（when AF series adopted）

1）Chemical auto dissolving device interlock signal

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② Block Diagram

Figure-9 Block Diagram

Figure-8 Block Diagram

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.

③ Skeleton

Figure-10 Skeleton

Figure-9 Skeleton

Volute Motor

No.1 No.2 No.3

Flocculation Tank Agitator

Motor

Flocculation Tank Agitator

Motor Chemical

Pump Chemical

Pump Sludge

Feed Pump Total

(kW/h)

ES-101 0.1 0.1 0.2 + A + C ES-131 0.1 0.1 0.2 + A + C ES-132 0.1 0.1 0.1 0.3 + A + C ES-202 0.2 0.2 0.4 0.8 + A + C ES-301 0.4 0.4 0.2 0.8(1.0)+A+(B)+C ES-302 0.4 0.4 0.4 0.2 1.2(1.4)+A+(B)+C ES-303 0.4 0.4 0.4 0.75 0.2

A

B

C

1.95(2.15)+A+(B)+C

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22--66 NNoozzzzlleess Table-3 Nozzle List

Model Items ES-101SA ES-131SA ES-132SA ES-202SA ES-301SA/TA ES-302SA/TA ES-303SA/TA

Caliber 50A 50A 50A 50A 50A 50A 65A Standard Socket Socket Socket Socket Socket Socket Socket Sludge Inlet Material SUS SUS SUS SUS SUS SUS SUS Caliber 80A 80A 80A 100A 125A 150A 150A

Standard Socket Socket Socket Socket Socket Socket Socket Filtrated Water Outlet

Material SUS SUS SUS SUS SUS SUS SUS Caliber 20A 20A 20A 20A 20A 20A 20A

Standard Union Socket Union Socket Union Socket Union Socket Union Socket Union Socket Union Socket Water Inlet Material PVC PVC PVC PVC PVC PVC PVC Caliber 20A 20A 20A 25A 25A 40A 40A

Standard Union Socket Union Socket Union Socket Union Socket Union Socket Union Socket Union Socket Chemical Inlet

Material PVC PVC PVC PVC PVC PVC PVC Caliber 20A 20A 20A

Standard Union Socket Union Socket Union Socket Chemical Inlet

Material PVC PVC PVC Caliber 100A 100A 100A 100A 100A 100A 100A

Standard Socket Socket Socket Socket Socket Socket Socket Sludge Over Flow Material SUS SUS SUS SUS SUS SUS SUS Caliber 40A 40A 40A 40A 50A 50A 50A

Standard Ball Valve Ball Valve Ball Valve Ball Valve Ball Valve Ball Valve Ball Valve Flocculation Tank Drain

Material PVC PVC PVC PVC PVC PVC PVC

22--88 WWeeiigghhtt Table-4 Weight

Model Items ES-101SA ES-131SA ES-132SA ES-202SA ES-301SA/TA ES-302SA/TA ES-303SA/TA

840 1370 1620 Empty Weight（kg） 190 205 275 420

900 1420 1900

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33.. CCrriitteerriiaa ooff tthhee DDeevviicceess PPrreeppaarreedd bbyy CCuussttoommeerrss Volute Dewatering Press needs a “Sludge Feed Pump” and a “Polymer Feed Pump”. 33--11 SSlluuddggee FFeeeedd PPuummpp

The Sludge Feed Pump capacity should be decided by the throughput. Please refer to the table below.

Table-5 Sludge Feed Pump Required Capacity

(Sludge Concentration 1.0%)

* Calculation Sample 【Conditions】 Volute Model: ES-101SA Throughput: 3 kg-DS / h Sludge Concentration: 10,000 mg / L 【Selection Method】 “Throughput (kg-DS / h) ÷ Sludge Concentration (mg / L)” 【Calculation】 Pump Dosage : 3 kg-DS / h ÷ 10,000 mg / L = 0.3 m3 / h Pump Capacity : 0.3 m3 / h ÷ 60 min = 5.0 L / min 【Required Capacity】 Required pump capacity is 5.0 L / min.

*Note _Please select a pump which has capacity exceeding the figure described above in the

“Table-5” and the “Calculation Sample”. _Please select a pump in consideration for pump head. _For selections and details, please contact pump supplier.

Sludge Feed Pump shall be out of AMCON’s scope.

ES101SA ES131SA ES132SA ES202SA ES301SA /TA

ES302SA/TA

ES303SA/TA Model

Items 3 kg-DS/h 4 kg-DS/h 8 kg-DS/h 18 kg-DS/h 27 kg-DS/h 54 kg-DS/h 81 kg-DS/h

Required Capacity ( L / min )

5 7 14 30 45 90 135

(15/19)

33--22 PPoollyymmeerr FFeeeedd PPuummpp Polymer Feed Pump shall be out of AMCON’s scope.

The polymer feed pump capacity should be decided by the throughput and addition ratio. Please refer to the table below.

Table-6 Polymer Feed Pump Required Capacity

(Dilution Rate 0.1 %, Adding Rate 1.0 %)

* Calculation Sample 【Conditions】 Volute Model: ES-101SA Throughput: 3 kg-DS / h Sludge Concentration: 10,000 mg / L Dilution Rate: 0.1 % Adding Rate: DS of 1.0 % Polymer Density: 1 g / cm3 【Selection Method】 “Throughput (kg-DS / h) × Adding Rate (%) ÷ Dilution Rate (%) ÷ Density (g / cm3)” 【Calculation】 Polymer Dosage : 3 kg-DS / h × 1.0 % ÷ 0.1 % ÷ 1.0 g / cm3 = 30 L / h Pump Capacity : 30 L / h ÷ 60 min = 500 ml / min 【Required Capacity】 Required pump capacity is 500 ml / min. *Note _Please select the flow adjustable pump or equipment. _Please select a pump which has capacity exceeding the figure described above in the “Table-6” and the “Calculation Sample”.

_Please select a pump in consideration for pump head. _For selections and details, please contact a pump supplier. _Capacity would be different depending on sludge concentration. _Adding rate is depending on the kind of sludge. In case of concentrated sludge, add Anion 0.5% ~ 1.0%，Cation 0.5% ~ 1.0% against DS. In case of activated sludge, add Cation 0.5% ~ 1.0%.

ES101SA ES131SA ES132SA ES202SA ES301SA /TA

ES302SA/TA

ES303SA/TA Model

Items 3 kg-DS/h 4 kg-DS/h 8 kg-DS/h 18 kg-DS/h 27 kg-DS/h 54 kg-DS/h 81 kg-DS/h

Required Capacity ( L / min )

0.5 0.7 1.4 3.0 4.5 9.0 13.5

(16/19)

33--33 WWaatteerr SSuuppppllyy

Necessary water pressure for showering is 0.1 ~ 0.2Mpa. Thus, only normal water pressure is fine.

The filtration part of Volute Dewatering Press is designed as “clog-free”, making rinsing water unnecessary. However, shower is equipped to clean leaked sludge on the Cylinder by automatic operation. Approximate shower water consumption is listed in the Table-7.

Table-7 Shower Water Consumption (Operating Frequency: 15 second / 15 min)

Model Items ES101SA 131SA ES132SA ES202SA ES301SA

/TA ES302SA/

TA ES303SA/

TA

No. of Head 3 3 6 8 5 10 15 Shower Water Consumption

( L / h ) 24 24 48 64 40 80 120

(17/19)

44.. RRuunnnniinngg CCoosstt 44--11 RRuunnnniinngg CCoosstt 【Electric Power Consumption Calculation】 “Volute Model (kW/h) x Operating Cycle (h / day)” 【Polymer Consumption Calculation】 “Throughput (kg DS / h) x Adding Rate (%) x Operating Cycle (h/day)” 【Polymer Dilution Water Consumption Calculation】 “Throughput (kg DS / h) x Adding Rate (%)÷Dilution Rate (%) x Operating Cycle (h/day)” 【Shower Water Consumption Calculation】 “Volute Model (L / h) x Operating Cycle (h / day)” * Calculation Sample 【Condition】 Volute Model: ES-101SA Throughput : 3 kg-DS / h Dilution Rate: 0.1 % Adding Rate : DS of 1.0 % Polymer Gravity: 1 g / cm3 Operating Cycle : 8 h / day 【Electric Power Consumption】 0.2 kW / h x 8 h / day = 1.6 kW / day 【Polymer Consumption】 3 kg DS / h x 1.0 % x 8 h / day = 240 g / day 【Polymer Dilution Water Consumption】 3 kg DS / h x 1.0 % ÷ 0.1 % x 8 h / day = 240 L / day 【Shower Water Consumption】 24 L / h x 8 h /day = 192 L / day

Table-8 Consumption Table Items Consumptions

Electric Power 1.6 kW / day Polymer 240 g /day Polymer Dilution Water 240 L / day Shower Water 192 L / day 432 L /day

(18/19)

55.. CCoonnssuummaabbllee PPaarrttss 5-1 Consumable Parts and Life Span Consumable parts are Moving Rings and Volute Screw and their approximate life span are listed in the Table-8.

Table-9 Life Span of Consumable Parts ( Condition : 40 h / week – operation )

SSiizzee ooff CCyylliinnddeerrss Model D/No. of

Cylinder Moving Ring Volute Screw

100 φ ES-101SA 1 ES-131SA 1 130 φ ES-132SA 2

2.4 years 5,000 h

4.8 years 10,000 h

200 φ ES-202SA 2 ES-301SA/TA 1 ES-302SA/TA 2 300 φ ES-303SA/TA 3

4.8 years 10,000 h

14.4 years 30,000 h

5-2 How to Exchange Consumable For your convenience, “built-up Volute Drum” is available. Standard consumable parts “Volute Cylinder”, “Volute Drum”, “Volute Screw”, and “Moving Ring” in the Table-9 will be delivered. Please exchange these parts accordingly to our manual. Upon request, AMCON provides skilled engineers for maintenance and services for exchanging these parts on site.

Table-10 Standard Consumption Parts Included Parts Note

Parts Volute Drum

Volute Screw

Moving Ring

Fixed Ring

Volute Cylinder ○ ○ *○ *○ Build-Up Part. Volute Drum ○ *○ *○ Build-Up Part. Volute Screw ○ Moving Ring ○ Necessary Pieces.

*AAllll mmooddeellss aarree aaddaapptteedd oonnllyy ffoorr DDeewwaatteerriinngg ZZoonnee

Note: _The life span in the Table-9 is only for your reference, calculated based on the operating conditions of treating excess sludge from biological treatment, producing 15% DS cake, at 8 hours per day. This data is acquired through a research on wearing of Moving Rings and Volute Screw, recorded in the Technical Document.

The life span varies depending on types of feed sludge and quality, especially on inorganic sludge. Moreover, producing sludge cake with solid content higher than approximately 17% may result in a shorter life span.

_Depending on wearing conditions, Moving Rings at thickening zone may have to be exchanged. _As long as Volute continues to operate normally, being confirmed by sludge cake produced and leakage on the Cylinder, the consumable parts do not have to be replaced even after the listed life span.

(19/19)

66.. OOtthheerrss 6-1 Others Data and information described on this document are provided only for your reference. Please ask us if you have any technical concerns or questions. We will respond to each question respectively. We will also judge which sludge is suitable or not and select a suitable model, given appropriate information. Contact Us… AMCON INC. Website : http://www.amcon.co.jp E - m a i l : overseas@amcon.co.jp volute@amcon.co.jp TEL : +81(0)45 540 8580 FAX : +81(0)45 540 8588 1926 Nippa-cho, Kohoku-ku, Yokohama, Japan 223-0057

Squeeze Sludge, Squeeze Cost!!