Industrial wastewater treatment results in an undesirable, yet unavoidable by-productsludge. The methods facilities employ to handle and dispose of sludge has a material impact on operating expenses as excess water in solids directly influences haul-off costs. Its critical to remove as much water from the waste as possible, since more water equals greater disposal fees. Many of our customers have experienced that.

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There are numerous ways to dewater sludge, each with its own benefits. Two of the more popular methods include a vacuum system and a filter press. Its a common, but unfounded belief, that a vacuum filter supports a more automated process. This is untrue. A vacuum system targets lower solids, and results in more water in the sludge, leading to higher haul-off costs. Its also a pricier system to operate, with pre-coat costs. The maintenance of vacuum seals and the systems many moving components add to expenses.

Dewatering by way of filter press targets higher solids and yields less water in the waste for lower haul-off costs. A filter system also has lower operational costs and supports automatic stage fill sections. Filter press dewatering delivers great value to facilities and reduces the volume of materials destined for the landfill, making it a very eco-friendly option.

The MacDermid Envio Press Manager is a process that reacts to the variable characteristics of the precipitate and rapidly fills the press by integrating feed pressure, feed flow rate, and feed volume. The system continuously adjusts feed pressure to maintain the maximum feed volume.  The press fills uniformly and provides optimal dewatering by preventing premature plate surface blinding that causes soft cakes. The MacDermid Envio Press Manager results in the highest filter cake solids possible, produced in the shortest amount of time.

Industrial facilities have many viable options when it comes to dewatering sludge. A centrifuge, belt press, geo-textile, and rotary vacuum are all techniques that can be utilized. The goal of each is to separate sludge into liquids and solids, eliminating as much water from the by-product as possible to reduce disposal costs. The MacDermid Envio Press Manager proves to be the superior technique for lowering expenses by optimizing wastewater sludge reduction and management. To learn more about our dewatering techniques, contact a MacDermid Envio professional today.

 

Written by a MacDermid Envio Solutions Subject Matter Expert

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How Sludge Filter Presses Work And Their Benefits

Sludge filter presses are a type of dewatering equipment designed specifically for removing water from sludge. They consist of a series of filter plates that are compressed, allowing water or filtrate to pass through while retaining the dewatered solids or filter cake.

This blog post will discuss how sludge filter presses work and their main advantages, including:

• The basic mechanics of sludge filter presses
• Types of filter plates and frames used
• How the dewatering process occurs
• The benefits of high percent solids capture
• Other key advantages
• Factors to consider when choosing a sludge filter press
• Tips for effective operation and maintenance

How Sludge Filter Presses Work

The basic components and mechanics of a sludge filter press are:

• Filter plates These consist of a filter cloth or membrane sandwiched between rigid plates. The filter media separates solids from liquids under pressure.
• Slurry feed The slurry or sludge to be dewatered is fed into the space between the plates.
• Hydraulic frame The plates are secured in a frame that can be tightened hydraulically. As pressure is applied, water passes through the filter media but solids are captured.
• Filtrate discharge The filtered water or filtrate drains out of the end of the filter press.
• Cake discharge The dewatered solids or filter cake builds up between the plates and is discharged when the press is opened.

Types of Filter Plates

There are two main types of filter plates in sludge filter presses:

• Frame plates Provide structure but have no filter media. They separate the active filter plates.
• Filter plates Contain the filter cloth or membrane to separate solids and liquids. Common types include:
• Flat plates Simple and basic style with a flat surface area.
• Tortional plates Have grooves to increase the surface area for filtration.
• Membrane plates Use advanced filter membranes instead of cloths.

How Dewatering Occurs

As pressure is applied in the filter press between cycles:

• Water in the slurry is forced through the small openings in the filter media.
• Solids in the slurry accumulate on the surface of the filter cloth or membrane.
• The solids build up to form a filter cake, which becomes denser and holds together as more water is removed.
• The filtrate flows out through channels to be discharged or collected for reuse.

Benefits of High Percent Solids Capture

• Water recovery Up to 99% of water can be removed, allowing for recycle and reuse.
• Reduced volume A thicker filter cake takes up less space, lowering disposal costs.
• Lower energy costs Less sludge means less energy needed for heating and pumping.
• Reduced chemicals Thicker sludge requires less polymer addition for dewatering.
• Compliance with regulations Many wastewater discharge limits based on total solids.
• Cost savings Higher dewatered solids content directly correlates to lower operating expenses.

Other Key Advantages of Sludge Filter Presses

• Ability to handle a wide range of sludges and slurries
• Continuous or batch operation modes available
• Simple and robust design requires little maintenance
• Modular design for ease of installation and expansion
• Compact footprint conserves space
• Flexibility to optimize cycle times and pressures based on application needs

Factors to Consider When Choosing

When selecting a filter press, consider:

For more information, please visit filter press for sludge dewatering.

• Flow rates and throughput needs
• Final dewatered solids content required
• Space and facility footprint available
• Capital and operating costs
• Type of sludge or slurry to be dewatered
• Disposal and reuse requirements
• Level of automation desired

Tips for Operation and Maintenance

• Start slowly and work up to maximum operating pressure.
• Allow a dwell time at pressure for best dewatering results.
• Apply vacuum to the filtrate chamber where possible.
• Flush and rest the press between cycles for optimal performance.
• Inspect and replace seals, gaskets and worn parts as needed.
• Replace filter cloths and membranes when flow rates begin to decrease.