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Contract for complete wastewater treatment for sugar producer in Croatia

H+E, one of the leading providers of industrial process and wastewater treatment on the international market, has been awarded a contract for a complete wastewater treatment for a sugar producer in Croatia.

Having designed and built more than 40 treatment systems for sugar production worldwide, including plants in Lithuania, Egypt and Chile, H+E has a huge amount of experience with the rather unusual requirements of this type of wastewater.

The sugar industry uses flume water circuits for the cleaning of the delivered sugar beet. Many companies use the so-called alkaline mode of operation. This involves adding lime to the water, which reduces odour pollution, improves the settleability of the washed-off soil and reduces corrosion in the pipelines, thereby also minimising maintenance costs.

But using lime also results in wastewaters with high calcium content and a strong tendency to precipitate lime-containing solids. These precipitates lead to extensive operational problems in anaerobic wastewater treatment and to clogging of the membrane aerators in aerobic wastewater treatment, thus considerably reducing the capacity of the treatment plant.

But, H+E offers solutions to these problems that were specifically developed to deal with the issues resulting from the use of lime in sugar industry wastewater. These technological innovations include ANAFIT®.CS, one of the water treatment solutions from our ANAFIT® product range. Based on the anaerobic contact sludge process, ANAFIT®.CS is a reliable, proven and effective process for the treatment of the calcium-rich, organically highly loaded wastewaters from the sugar industry.

H+E also offers other process technologies for wastewater from the sugar industry: For example, the BIOFIT®.N treatment for nitrification/denitrification in an aerobic stage. Here, H+E’s specially developed aerators are used which, even at high calcium concentrations, reliably supply oxygen over years without requiring any maintenance.

In Croatia, industrial companies have faced stricter quality requirements in recent years following accession to the EU. Due to this, the client decided to invest in a new treatment plant including anaerobic and an aerobic stages. We arranged a visit to a nearby reference plant, which helped to convinced the customer of our experience and expertise.

The wastewater treatment plant will go into operation for the 2017/18 sugar campaign.

This project has recently been the subject of an article published in the International Sugar Journal. You can download that article here.

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Aerobic Wastewater Treatment Plant in Scandinavia

H+E, one of the leading international providers of industrial process and wastewater treatment solutions, has been awarded a contract to refurbish an existing Aerobic Wastewater Treatment System in Scandinavia.

The existing wastewater ponds have the disadvantages of both consuming large amounts of energy and, at the same time, not meeting the necessary treated wastewater quality requirements. Therefore the decision was made to replace the essentially redundant equipment with up-to-date technology.

H+E has extensive experience in the sugar industry and has been a leading provider of wastewater treatment systems for the companies throughout the sugar industry for many years. Our unique technology and energy-efficient solutions, developed to meet the specific demands of the sugar industry, were the main factor in the Client’s decision to choose H+E.

Our aerobic BIOFIT®.N process (one of a number of BIOFIT processes) uses combined denitrification and nitrification stages to safely and efficiently remove nitrogen. This compact solution has been proved many times in the sugar industry to be a reliable and highly efficient method for treating wastewater. It uses a particular type of fine bubble membrane aeration of the activated sludge basin that results in a substantial reduction of energy consumption, and therefore leads to a rapid return on investment for the client. But also, it can be easily integrated with the existing equipment, which again, reduces a total investment costs.

The aerobic BIOFIT®.N system will start operation right on schedule for the 2017/2018 campaign.

H+E has also developed the two-stage ANAFIT-CS system, which is particularly suited to wastewater with a high calcium concentration, commonly seen within the sugar industry. It operates reliably and dependably, avoiding operational problems which, are often caused by calcium carbonate clogging, as commonly seen in other treatment processes.

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Wastewater Treatment for new Waste-to-Energy Plant

H+E has just delivered to the client’s site the Pre-assembled parts of a Treatment Plant to handle wastewater from a new highly efficient Waste-to-Energy Plant that uses Refuse-Derived-Fuel (RDF) to produce electricity and at the same time minimise overall CO2 emissions to atmosphere.

Pre-assembly showing pH adjustment stage on the left and IBC level control on the right

 IBC level control Cabinet

The Problem: Wastewater is produced from a number of different sources from this type of plant and has to be carefully treated before it can be safely discharged to foul sewer. Even then, that discharge must be constantly monitored to ensure that its quality is within the prescribed limits. The wastewater can contain very variable concentrations of both suspended solids and chemicals.

The Solution: Solids accumulated from a range of sources will be removed in two settlement stages, operated in parallel to give the plant maximum flexibility and ensure that it is always available. It is anticipated that the incoming wastewater quality will vary significantly and chemical treatment will therefore be required. This will be done completely automatically. The chemicals used for this will be delivered directly from 1m3 Intermediate Bulk Containers (IBC’s). For each chemical, two IBCs will be connected via H+E’s automated delivery system, developed in-house. In this system, the chemical from each IBC is completely consumed and only then does the system switch automatically to the standby IBC. Thus, the only operator involvement is to change the empty IBC for a new, full one from time to time. Chemical handling and the associated risks are thereby largely avoided.

Prior to discharging the treated wastewater to foul sewer its pH, temperature and flow rate are monitored.

Pre-assembly: Following completion of the design phase, the system will be both manufactured and pre-assembled in H+E’s factory. This enables our client to also attend and witness the testing and enables us to ensure that it will function as required immediately on start-up. It also means that, once the equipment has been delivered to site, we can install it very quickly, which has significant benefits for our client.

Once installation is complete, we will commission the system and train the client’s staff and then, if the client wishes, provide long-term service and support for the lifetime of the plant. Typically, for this type of plant, lifetime can be expected to exceed 25 years.

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New £1 million Industrial Wastewater Treatment Plant

New £1 million Industrial Wastewater Treatment Plant

H+E are currently designing & building a Treatment Plant to handle wastewater from a process plant that uses a mixture of highly concentrated acids including Hydrofluoric and Nitric acids, and also contains a range of soluble metals.
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This particularly highly-sensitive application has demanded that all equipment within the overall plant be both designed and manufactured to an unusually high standard, with a target 40 year minimum design life. It also includes the supply of documentation to a very high standard.

 

The Solution: This involves neutralising the wastewater with calcium hydroxide in order to precipitate the fluoride as calcium fluoride. The pH of the incoming wastewater can be very low (less than 1) so the neutralisation is done in two separate steps, after which the solids produced are flocculated before being separated from the wastewater in one of our Tube Settlers, a highly efficient lamella clarifier design that has been a standard product used in literally hundreds of applications.

A typical pre-assembled chemical dosing systemFollowing settlement, the clarified wastewater flows into a TOVEKO continuous gravity sand filter, the purpose being to remove any final traces of fine solids that were not removed in the Tube Settler. Then the wastewater is cooled if necessary (it can sometimes be too warm to discharge directly to sewer), and has its quality monitored continuously before being mixed with various other non-toxic wastewater streams being discharged from the site. The final, mixed wastewater stream then has its quality monitored again before being discharged to foul sewer.

The sludge formed by the settling solids is transferred to a separate sludge holding tank, which automatically removes excess water that accumulates as the sludge settles further in the quiescent conditions provided, before it is finally pumped from the tank for final dewatering, producing a solid that can be disposed off-site.

The plant’s control system is unusually sophisticated, and features a far greater degree and depth of continuous control and monitoring than is normal for this type of wastewater in a more “standard” industrial environment.

 

img_0057Pre-assembly: The plant as a whole is being both manufactured and pre-assembled to a very high level and will be extensively inspected and Factory Tested prior to being delivered to site. Pre-assembly has been an integral part of our culture for a substantial time now, mainly because it enables us to control the quality of what we deliver and also because testing in our factories is so much more efficient than doing so on site.

You can find further information about H+E’s Tube Settlers and TOVEKO filters in the Downloads section.

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H+E UK Provides Process Water System for Pembroke Power Station

The power station at Pembroke in South Wales is, at 2,160MW, the largest combined cycle gas turbine (CCGT) power plant in the UK. It was recently built for RWE npower. Following a number of previous contracts with both RWE and the main contractor, Hager + Elsässer was chosen to design and supply the process water system to feed the gas turbines.

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