Centrifuges
Decanter centrifuge
LYNX drilling mud decanter centrifuges from Alfa Laval remove unwanted solids and fine particles from virtually all kinds of used drilling mud, including those based on water/synthetics and conventional oil-based drilling fluids. It removes the vast majority of fine particles down to sizes of around 5 microns. Less mud is wasted, and removing solids in very dry form also leads to lower costs for transporting and disposing of waste. Additional savings stem from opportunities for automatic, unattended operation. Units have been designed for reduced power consumption in relation with process flow. A variety of sizes are available, with solids capacity from 11,000 up to 154,000 pounds per hour. 866/253-2528; www.alfalaval.us.
Thickening centrifuge
The THK thickening centrifuge from Centrisys is designed to thicken waste-activated sludge without polymer. The system produces up to 8 percent cake solids running at flow rates of up to 1,000 gpm. Applications include secondary sludge, primary sludge, oxidation ditch sludge, digested sludge and MBR sludge. 877/339-5496; www.centrisys.us.
Horizontal sludge-dewatering system
The horizontal sludge-dewatering system from In The Round Dewatering has a stainless steel drum with perforated plastic tile lining. The drum is mounted on a roll-off frame for easy transportation and unloading. Water trays have been configured to allow for containment of discharge water. A typical batch of sludge consisting of 18,000 to 25,000 gallons is mixed with polymer before being filtered in the rotating drum. The drum is driven by a 1/2 hp variable-speed electric motor with a heavy-duty chain and sprocket. The turning eliminates crusting and wet pockets, producing uniform, consistent results. The dewatered material dumps easily, and the drum is self-cleaning. The sludge is ready for disposal after one night. 317/539-7304; www.itrdewatering.com.
Centrifugal separator
The centrifugal action separator from LAKOS removes sand or grit from water or oil, protecting pumps, valves, tanks and piping from abrasive solids. The centrifugal action has no moving parts to wear out or replace. It can be used as primary filtration for desanding, which extends operating cycles and protects other equipment. It can be used as secondary recovery, which protects high-pressure pumps and finer filters used in waterflood injection techniques. It can also be used in produced water, removing sand prior to reinjection or disposal, or to protect downhole applications, extending the life of production well PCP and ESP pumps. 800/344-7205; www.lakos.com.
Frac sand washing/dewatering unit
The KISA/PHOENIX Bucket Wheel from PHOENIX Process Equipment is used for washing and dewatering frac sand, providing over 99 percent solids recovery, even from dilute slurries such as dredger spoils. Dewatered solids are readily conveyable and stackable, having considerably lower residual moistures than dewatering screws. Capacities up to 17,500 gpm and solids throughputs up to 1,760 short tons per hour are achievable on a single machine. The wheel is equipped with multiple buckets, and slotted elastomer sieve mats are bolted into the bucket bottoms providing consistent drainage area. Siphon pipes are mounted beneath the buckets, withdrawing water from the sand cake as the bucket lifts from the slurry bath. 502/499-6198; www.dewater.com.
Belt Presses
Belt filter press
Belt filter presses from Bright Technologies are constructed of 304 stainless steel with a radius wedge and high performance drainage roll that allow for high throughput rates and increased total solids output. A pneumatic steering and tensioning system integrate a high degree of safety and ease of operation and control of the unit. The turnkey system allows for ease of installation along with operator-friendly controls. The PLC coupled with touch-screen controls easily integrate into new and existing wastewater treatment facility SCADA control systems. 800/253-0532; www.brightbeltpress.com.
Slurry Separation Equipment
Single-shaft macerator
The Rotorrake compact, non-clogging, single-shaft macerator from Boerger grinds very coarse solids and stringy material for the protection of downstream equipment. It incorporates reversible-flow direction and extraction of hard substances with throughput volumes of up to 4,000 gpm. Solids-laden liquids are fed through angled counter blades, which capture and chop the solids. Macerated solids continue to flow with the liquid, and foreign materials accumulate in the debris collector. It can be used as a stand-alone machine or with a pump or other peripheral machines. 844/263-7437; www.boerger.com.
Industrial shredder
Monster Industrial Shredders from JWC Environmental homogenize drill cuttings and slurries so material is properly sized before it enters dewatering systems. This makes dewatering more efficient and protects the system from damage. The dual-shafted grinder includes through-hardened steel cutters, high-pressure seals, a removable cutter cartridge and an auto-reversal feature. They shred solids such as wood, rags, rocks and plastics. 800/331-2277; www.jwce.com.
Shakers
Shaker material removal system
The Total Clean System from DEL Tank & Filtration Systems processes drilling waste, taking the initial flow directly from the trucks, tanks or pits and pumping it over the scalping shaker where all the oversize debris, usually 8 to 10 mesh material, is removed. The remaining slurry is then pumped to the primary hydrocyclone/shaker units, where typically the sand fraction, +74 microns, is removed. Any solids remaining in the primary hydrocyclone overflow and screen underflow then flow through the tilted plate baffle section of the V-Tank. The remaining solids settle and are conveyed to the pump suction of the recycle pumps by the shaftless auger, then through additional sets of recycle hydrocyclone/shaker units for additional removal, down to +37 microns in some cases. The effluent overflow can then be treated with polymer and pumped to a clarifier/thickener tank, where the remaining solids will settle and the thickened underflow can be pumped to centrifuges for final solids removal. 800/468-2657; www.deltank.com.
Filtration Systems
Open-top roll-off dewatering unit
The ADS 30-yard open-top roll-off dewatering unit from AQUA-Zyme Disposal Systems can be filled with 22,000 to 25,000 gallons of liquid waste at 1 to 2 percent solids in about two hours. After draining 24 hours, the unit can be hauled to a landfill or other permitted facility for disposal. Sludge volume can be reduced by 80 percent, with reductions to 98 percent in BOD, COD, FOG and TSS. Effluent is clear and sewerable. The unit has few moving parts and includes a roll-over tarp system; side, floor and center screens; 1/4-inch floor plate; seven-gauge side plates; four door binder ratchets; eight drain ports; two inlet ports; and a long-handle scraper. The average life span of the unit is 12 to 14 years. It can be hauled with a standard-capacity roll-off truck. Units are also available in 15-yard sizes. 979/245-5656; www.aqua-zyme.com.
Dewatering container
Roll-off dewatering containers from Bakers Waste Equipment provide a one-step process for dewatering all types of liquid waste, including septic waste, grease sludge, grit, hazardous waste, lagoon sludge, fly ash and more. Liquid waste is pumped into the containers, allowing the liquids to drain through filtered walls and floors. The liquid is collected in a sump area behind the walls and floors, staging it for discharge out one of the side drain ports. 800/221-4153; www.bwe-nc.com.
Dissolved air treatment system
The Integrated Treatment System (ITS) from Ecologix Environmental Systems prepares flowback and produced water from fracking operations for reuse. The dissolved air flotation design on a mobile frac tank chassis grants rapid deployment for an on-site or near-well operation. Processing wastewater at rates up to 31,000 bbl per day, it efficiently removes 99.99 percent of suspended solids, oils and grease, and other insoluble contaminants that would otherwise restrict water reuse. 888/326-2020; www.ecologixsystems.com.
Dewatering container filter
Sludge Mate container filters from Flo Trend Systems can dewater a variety of sludge and waste such as alum, ferric, lagoon and digested sludge, septic tank, grease-trap and slaughterhouse waste, wastewater residual and sump bottoms. The closed-system design provides total odor control, no spillage, reduced maintenance and weather independence. They have 10-gauge reinforced walls and a seven-gauge carbon steel floor. Options include peaked roofs with gasketed bolted-down access hatches, drainage ports, inlet manifolds, floor filters and side-to-side rolling tarps. They dewater on site; are available as roll-offs, trailer and tipping-stand mounted; and range from 5 to 40 cubic yards. 713/699-0152; www.flotrend.com.
Skid-mounted filter press
Kompress skid-mounted belt filter press systems from Komline-Sanderson are available in 1-, 1.5- and 2-meter versions with feed pump, polymer system, control panel, belt wash-water pump, interconnecting piping, drain pan, and air compressor or hydraulic power unit for belt steering and tensioning. The system only needs to be off-loaded, anchored in place and connected to utilities. It is available in two- or three-belt designs and can achieve feed rates above 200 gpm. 800/225-5457; www.komline.com.
Recessed-plate filter press
The recessed-plate filter press from McLanahan is designed to treat the underflow of a thickener, clarifier or other waste material, dewatering very fine solids (often -325 mesh) from wash water or industrial processes. Slurry is pressure pumped into recessed chambers wrapped in filter cloth. The resulting solids form dry, easy-to-handle cakes that are discharged from the bottom of the press. These cakes can be transported via truck or conveyor belt, and the water is recycled back to the process for reuse. Units typically require no added polymers or chemicals after the thickener, and no full-time operator is needed. The automated units can be monitored remotely from any computer. 814/695-9807; www.mclanahan.com.
Rotary fan press
The slow revolution of the Prime Rotary Fan Press from Prime Solution (1 to 2 rpm) minimizes the energy required during operation. Depending on the model, the system uses 0.75 to 13 hp. The waterjet design of the filter screen minimizes blockage, reducing the amount of wash water required. Operating the self-cleaning feature once daily uses little wash water, resulting in additional cost savings. It reduces energy use, water consumption and hauling costs to minimize carbon emissions. It offers easy and fast startup and shutdown, and minimal operator attention. Pressure increases as biosolids move slowly through a tapered channel. Friction intensifies as the material compresses against two rotating filter screens. Filtrate drains through the screens. Cake averages 18 to 24 percent solids and reaches up to 60 percent in some applications. 269/694-6666; www.psirotary.com.
Drill-out operation wastewater filter
The Magic Tank System from Resirkulere USA filters returned wastewater pumped by coil and stick rig during drill-out operations for reuse, while at the same time filtering and reclaiming a substantial amount of additional clean oil that would have normally been lost to disposal. It reduces freshwater and fuel consumption, transportation costs, solid waste and waste disposal fees, and increases oil recovery. 701/852-8029; www.resirkulere.com.
Dewatering container
Dewatering containers from Wastequip are designed to reduce the cost of waste disposal by separating liquids from solids. They are ideal for wastewater treatment facilities, manufacturing facilities, spill sites, construction sites, refineries and mines. They have gasketed doors and are hydro tested to ensure they will not leak. Disposable liners and an easy-to-remove shell provide for a quick cleanup. The removable shell also allows the container to be used as a sludge container. Containers can be custom-configured for specific applications and are available in 20- and 25-cubic-yard sizes. 877/468-9278; www.wastequip.com.
Polymers and Polymer Injection
Mobile dewatering truck
The Mobile Dewatering Truck from ABCO Industries Limited conditions incoming sludge with a polymer while the onboard filter system separates solids and liquids. The solids are stored in a holding chamber on the truck while the liquid filtrate – along with its useful bacterial cargo – is returned for normal on-site treatment. The solids on the truck can be disposed of at an approved composting or land application site. The truck can be outfitted with a high-pressure jetting system for clean-out applications and can also be used as a conventional vacuum truck. 902/634-8821; www.abco.ca.
Polymer series
The Alcomer series of polymers from BASF Corporation – Global Oilfield Solutions contains both low molecular weight cationic coagulants and a wide range of molecular weight nonionic, anionic and cationic flocculants. It is designed to help adapt the perfect solution to the condition of drilling mud. The flocculant range establishes a more efficient drilling system with better performance, helps to decrease wear on pump parts and bits, and improves hydraulics. They are ideal for freshwater systems. In particular, Alcomer 80 (nonionic) and Alcomer 120B (anionic) effectively control the conditions of a drilling system. 800/794-1019; www.oilfield-solutions.basf.com.
Dry chemical injector screw
Injector screws from Sodimate transfer dry chemicals into a gas stream, sludge mixer or slurry tank while isolating moisture, heat and condensation from the dry chemical. They can be used in place of isolation devices such as pinch valves, slide gates, rotary airlocks and butterfly valves. Various types and sizes are available depending on the desired discharge rate of the chemical and application. Most injectors are installed with hygroscopic materials, such as quicklime (CaO), magnesium oxide (MgO and polymers. 773/665-8800; www.sodimate-inc.com.
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