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The plant wastes sludge to the digesters at 7,000 GPD at one percent solids. Centrifugal pumps transfer material from the digesters to a mixing tank for chemical treatment with a ferric chloride polymer blend. The blended slurry then enters the JVap unit via diaphragm pumps. During the batch process, the filter plates are clamped tightly together in a specially designed filter press. Slurry enters the filter chambers, where initial filtration takes place and free liquid is removed. Filtrate flows through the filter cloths, leaving a filter cake. After filtration, the vacuum/drying cycle begins. The feed pumps stop, the feed and filtrate valves close, and the reduction chamber diaphragms are pressurized to 100 psi to squeeze the filter cake and remove as much water as possible. Hot water at 180 degrees F is circulated in a closed loop behind the diaphragms to heat the filter cake. At the same time, a vacuum is introduced to the filter chambers, causing water remaining in the filter cake to boil off at a low temperature. Cycle time can be adjusted to reach the desired moisture content. At the end of the drying cycle, a pathogen kill cycle begins. The vacuum is turned off, raising the boiling point within the unit, thus raising the material temperature to meet U.S. Environmental Protection Agency time and temperature requirements for pathogen destruction.
By drying the material at low temperature, the J-VAP unit conserves energy. Air exhaust from the unit is minimal, requiring no air-quality permits. Mountain City cools the vapor from the unit using plant effluent passed through a heat exchanger. Condensate returns to the head of the treatment plant.
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Results The J-Vap system proved more cost-effective than other drying systems and had significant advantages over belt presses, another option the city considered. More efficient solids handling has also led to process improvements. Before the facility upgrade, solids residence times in the plant's aerobic digester was brief, and the digester essentially served as a storage tank. Since the upgrade, digester residence times have increased to 15 days, and in the future Mountain City hopes to achieve the 30-day residence time required for complete digestion.In the end, more efficient solids processing with the J-Vap system has helped Mountain City improve its treatment plant operations and facilitated the community's opportunity for growth and prosperity.
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