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Case Study: TASKMASTER® Grinder Ends Septage Headache
The Broward County Wastewater Treatment Plant in Pompano Beach, Florida is a regional facility processing 80 million gallons of wastewater every day. Adjacent to the plant and across the street is a septage receiving area used for pre processing and receiving septage from haulers. Proper treatment of this septage was a problem for the facility.
Every day, haulers with an average capacity of 4000 gallons per tanker truck continually arrive at the pre-treatment area and dump the effluent from septic tanks, portable toilets and other septage systems into a discharge bay. The septage then needs to be processed so that it passes smoothly through the pumps to the treatment facility. According to Supervisor of Plant Management, Curtis Preece, "Previously a large bar screen captured the incoming debris which was then removed to a dumpster. Maintenance of the screen was costly because it had so many moveable parts. This also contributed to a lot of down time."
I knew there had to be a better way." Preece continued. He attended a trade show and found exactly what he was looking for. "A light went on in my head when I saw the TASKMASTER® TM8500," he said.
The TASKMASTER is a rugged workhorse of a grinder. The unit's twin shaft mechanism is especially rugged due to the use of "cutter cartridges" instead standard individual cutter and spacer disks.
This design gives it the extra strength needed to successful process these tough septage materials. Says Mr. Preece, "We installed it and did away with the bar screen altogether. It does the job completely"
The unit has offered day-in and day-out dependability and performance. The TASKMASTER'S powerful size reduction capabilities facilitates further processing at the plant, protects downstream process equipment and ensures that systems run smoothly.
"We're very pleased with our choice," Preece concluded. "Maintenance is non-existent and we've saved a lot of money."
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ChemScan Mini On-Line Monitoring Units
WWTP installs new affordable ortho-phosphorus analyzer to help contain escalating chemical costs. - By Dave Marsh
Wisconsin’s Department of Natural Resources recommended a reduction in the state’s phosphorus limit from 1 ppm to 0.05 ppm for inland lakes and streams (0.5 ppm for the Great Lakes) in efforts to improve water quality and reverse eutrophication of state’s lakes and rivers. These new limits when adopted will force many WWTPs to spend more on chemicals and invest in new equipment.
In anticipation of more stringent regulations, operators of Sheboygan’s Waste Water Treatment Plant recently installed the ChemScan Mini oP Online Analyzer manufactured by ASA Analytics. The Mini oP is a dedicated ortho-Phosphorous analyzer that Sheboygan uses to continuously monitor the ortho-phosphorus levels in the final effluent and through its SCADA system automatically controls the Ferric Chloride (FeCl3) feed rate.
“I’m confident we can meet the lower phosphorus limits,” said Dale Doerr, Sheboygan Regional WWTP Wastewater Superintendent. “But that means our annual Ferric Chloride costs will dramatically increase. In 2009, we spent $160,000 on Ferric Chloride. However, in order to meet the new limits we expect the costs for ferric chloride will increase to $500,000. Obviously this will make it even more critical that we control our processes and use chemicals more judiciously, which was our thinking behind installing the new Mini oP online analyzer.”
Doerr had been researching options for monitoring ortho-Phosphorus but he couldn’t justify the cost until the introduction of the Mini oP. “Our Mini oP was only $12,000, said Doerr. “The next closest solution cost $6,000 more so we were willing to give it a shot. We only have to save 8% on our annual chemical costs to pay for it. From what we have seen it gives us a better phosphorus result, and it should pay for itself in one year.”
Doerr faces the additional challenge of managing a plant that is only staffed 12 hours a day, which meant that during the un-staffed hours the process might not have been receiving optimal levels of ferric chloride.
“Before we installed the Mini oP, the operators would draw ortho-Phosphorus grab samples three times a day,” said Doerr. “And based on the results they would either turn on or turn off the Ferric feed to the basins. That worked fine when operators were on duty, but whatever the feed rate setting was when the operator left at 6:00 PM, it would remain at that feed rate setting until 6:00 AM the next morning. Ferric chloride might have been fed all night when it was not needed; and it might not have been fed when it was needed.
Now the Mini oP automatically optimizes our use of Ferric 24/7.” The Sheboygan plant operators are accustomed to fluctuating phosphorous levels and add FeCl3
to complement the plant’s Biological
Phosphorus Removal process. “We take a lot of hauled in waste and most of it is cheese processing waste, high in phosphorus,” said Doerr. “Fluctuations have more to do with how much phosphorus is coming in, than how well the BPR is running.”
Doerr said that tighter government regulations are forcing many plant operators to seek out new methods and technologies for better phosphorus control. “We run this plant like a business and we’re proud to have the second lowest rates of all Wisconsin wastewater treatment plants serving 50,000 and more. But it’s something we’re always working to improve”, said Doerr who began working in wastewater treatment as a plant operator trainee and later went to school to earn a MBA. “If some new system or technology is going to reduce our costs and improve our bottom line, we’re going to take a serious look at it.”
The new ChemScan Mini oP Analyzer is dedicated to analyzing samples of a single parameter, ortho-Phosphorous, from a single sample point, making it an affordable option for controlling the rising costs of meeting tighter phosphorus limits. The Mini oP Analyzer was designed with many of the time tested features of larger ChemScan Analyzers. Its flow paths are designed with larger orifices that avoid plugging, it can operate for three months without replenishing the reagent, and any analyzer component can be replaced in less than five minutes.
“We’ve continued to check the Mini oP against grab samples and it has been consistently accurate. It’s been dead on since we installed it,” said Doerr. “We’ve been on the cutting edge of technology and we’ve tested out many new products and technology. We have a culture that is not afraid of trying new equipment and technologies. If we believe something can benefit our operations we don’t feel we have to wait for someone else to prove it. The Mini oP is working out well for us. We have two process trains and it looks like we’ll be investing in a second Mini oP for our second train.”
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