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NEWSSeptember 2013

Inside this issue:

Huber Sludge Products 2

BS EN ISO 14001:2004 2

Huber Sludge Screens -Two Stage Approach 3

Treatment of effluent containing solids- the suitability of Huber Wash Drum RoFAS or SludgeAcceptance Plant Ro3 4

Imported / Septic Tank Sludge 5

RoS2S Disc Thickener 6

RoS3Q Screw Press Dewaterer 7

Industrial Sludge - Case StudyDairy Crest Davidstow Creamery in Cornwall 8

Anaerobic Digestion 8

STOP PRESS 8

www.huber.co.uk

The Newsletter of Huber Technology UK

Welcome to the HuberTechnology newsletter for 2013. Huber Technology has a long and successful history spanning over 150 years,supplying market-leading products for waste water treatment.

In the UK, we have been serving our customers for over 20 years, providing a widerange of waste water treatment solutions for a variety of applications; from inletscreens and screenings handling through to tertiary disc filters prior to finaldischarge.

One area where Huber has really excelled is in the provision of innovative stainlesssteel products for municipal and industrial sludge treatment. These are used toreduce processing and transportation costs as well as helping to meet ever morestringent disposal requirements.

In a recent report by UKWIR (Ref No. 13/SL/11/6) they identified that watercompanies who implement primary sludge concentration at small WWTWS- canachieve faster paybacks on their investments. The report compares a range oftechnologies and discusses the features of some of Huber’s equipment.

In this edition we will be outlining our sludge products and describing where theyare used and the benefits they are bringing to customers.

We hope you enjoy reading this newsletter and welcome your feedback. We willbe more than happy to provide further information about any of our products andtheir applications, and to discuss your specific requirements.

Best Wishes

Steve MorrisManaging Director

UK Installation of 2 x ROS2

“UKWIR Report identified thatwater companies whoimplement primary sludgeconcentration at smallWWTWS can achieve fasterpaybacks on their investments”

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Sludge ScreeningRo3 - Sludge Acceptance Plant

SP4 - StrainPress - pressurised sludge screen

RoFAS - Sludge Screen

Sludge ThickeningRoS2S - Disc Thickener

RoS2 - Drum Thickener

DB - Drain - Belt/ Gravity Belt Thickener

Huber Sludge Products

Earlier this year Huber had an EnvironmentalManagement System audit. CCAS are pleased tocertify that the Environmental ManagementSystem of Huber Technology has been assessedand registered as meeting the requirements of BS EN ISO 14001:2004

The scope of approval covers Design, Assembly ,Supply, Installation & Commissioning of EffluentTreatment Plant Equipment and After Sales Service

Huber Technology has now achieved theOrganization Carbon Footprint Standard ISO14064 and will continue to strive and reduce ourimpact on the environment. We are continuallylooking for new innovation to make the world abetter place for everyone.

Sludge DewateringRoS3 - Drum Dewaterer

RoS3Q - Q Series Horizontal drum dewaterer

BS - Belt Press Dewaterer

Combi - Combined GBT & Belt Press Dewaterer

Sludge DryingBT - Low Temperature drying plant

BS EN ISO 14001:2004

This is to certify that the Environmental Management System of

Huber Technology

Location:

Units C & D Brunel Park, Bumpers Farm Ind. Est., Chippenham, Wiltshire, SN14 6NQ

Has been assessed and registered as meeting the requirements of

BS EN ISO 14001:2004

Scope of Approval:

Design, Assembly, Supply, Installation & Commissioning of Effluent Treatment

Plant Equipment and After Sales Service

EAC: 18 NACE: DK 29.2

for Chamber Certification Assessment Services Limited

Registration Number: 2009/536 Re-issued: 26 June 2012

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ate of initial approval: 15 June 2009 Expiry: 25 June 2015

This is to certify that the Quality Management System of

Huber Technology

Location:

Units C & D Brunel Park, Bumpers Farm Ind. Est., Chippenham, Wiltshire, SN14 6NQ

Has been assessed and registered as meeting the requirements of

BS EN ISO 9001: 2008

Permissible Exclusions: None

Scope of Approval:

Design, Assembly, Supply, Installation & Commissioning of Effluent

Treatment Plant Equipment and After Sales Service

EAC: 18 NACE: DK 29.2

for Chamber Certification Assessment Services Limited

Registration Number: 2009/536

Reissued: 03 December 2012

Date of initial approval: 11 December 2009 Expiry: 10 December 2015

Previous CB: UL

SP4 RoS3 (right)

RoS2 Disc ThickenerSludge Dryer (right)

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Huber Technology,for the past 20+ years have beenthe largest supplier of sludge screens into the UKmarket with over 735 units sold to date. There aretwo types of well-established and recognised sludgescreens supplied by Huber. These are the gravityRo3 Sludge Acceptance Plant (475 sold to date)and the pressurised SP Strainpress® screen (272units sold to date). The versatility of having thesetwo types of screens in our portfolio enables Huberto provide the best possible technical and whole lifecost solution to our clients as each screen hasdifferent characteristics which may well be suitedfor different sludge types and applications.

Huber Sludge Screens – Two Stage Approach

We are always assessing the market and we havefound that the nature of the sludge has changedover the last 20 years. In recent years in particular,Huber have noted an increase in the solidsconcentration of the screenings contained withinthe sludge and this has become more of an issue.The results of this increase will limit the screenscapabilities not necessarily on its hydraulic capacitybut on its solids removal capacity. In theseinstances, Huber have developed an option toincrease its integral screenings conveyor capacityto over double that has been supplied in the past.This enables us to meet the ever changingcharacteristics of the sludge now being found inthe UK’s treatment plants. Clients in conjunctionwith ourselves,are now combining the Ro3 SludgeAcceptance Plant unit in series with the SPStrainpress® Pressurised Sludge Screen. They havefound that this gives a good combination to fulfilthe large screenings handling capacity requirementnow necessary with very fine 2 dimensional sludgescreening. This will reduce not only the plantoperational input required by reducing de-raggingof pumps and aeration systems but also areduction in maintenance of the basic sludgescreens themselves.

Written by Nick Hunt- Sales Director

”Huber continueto strengthentheir range ofsludgeinstallations inWales” said AdrianHeneghan ASMWales,

Northern Ireland Ro3Installation

South Wales SPinstallation

The Huber RoFAS wash drum and the Ro3 SludgeAcceptance Plant are both capable of handlingeffluent containing solids that require separation,but there are instances where the standard versionof one machine may be more appropriate for anapplication than the other.

The standard screening apertures shape and sizeoffered by the raked bars in the Ro3 are able topass more viscous liquid, such as older septicsludge, that might otherwise lead to pulsedoperation and therefore longer off- load durationsif the high level in the unit kept being reached(“thicker” fluids do not flow through smallerapertures as quickly)

Other factors that may lead to the Ro3 being themost suitable for an application include;

4 Low wash water requirement

4 Integrated screenings washing and press zone(though the raised RoFAS may be used inconjunction with a screenings handlingmachine positioned under its discharge chute)

4 Integral emergency bypass and itsimperviousness to hair – pinning by finerfibrous materials

The perforated drum of the RoFAS is very robustand able to accept larger solids (e.g. rocks etc) thatmight otherwise damage screening components(however the Ro3 may have a stone trap installedimmediately upstream of the unit to remove suchlarge items from the feed ). If a high throughput of very thin liquid containing high solidsconcentrations and /or particularly large solids isrequired, then the RoFAS offers a very robustsolution. It may accept any ratio of grit, large ragsand hardened grease deposits

Other potential advantages of the RoFAS include;

4 Greater solids removal rate

4 Smaller screening apertures provide a greatersolids capture rate

4 Option for multiple vehicles dischargingsimultaneously

Though the Ro3 inlet basket is protected from overtopping by level control when operated inautomatic mode as per the control philosophy, thefully enclosing drum of the RoFAS providesguaranteed retention of solids should theautomatic operation be compromised for anyreason (e.g. inadvisable operation in hand mode bytanker drivers).

It should also be noted that while 6mm bar spacingin the Ro3, a 6 mm perforated plate in the RoFAStend to be offered as standard in the UK; both unitsmay be fitted with different aperture sizes to suit

a customer’s requirements.

Written by Jason Sims Process Development

Manager

Treatment of effluent containing solids-the suitability of Huber Wash Drum RoFASor Sludge Acceptance Plant Ro3

“Greater solidsremoval rate”

Scottish RoFASinstallation

“Low wash waterrequirement”

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Over the last 25 years Huber Technology havesupplied approximately 475 Ro3 Sludge Screensthroughout the UK and Ireland.

Huber supply these units in a range of sizes, withthe most popular being:

780mm x 6mm for flows of27ltrs /sec @ 3%ds and18ltrs /sec @ 6%ds

1000mm x 6mm for flows of45ltrs /sec @ 3%ds and30ltrs /sec @ 6%ds

These machines are fitted witha 273mm diameter auger asstandard and the auger iscapable of transporting 1.6m3 /hour of screenings.

The above flows are guidelinesand will vary depending on thescreenings loading in thesludge.

Up until approximately 5 yearsago, the 780 mm diameterunits were the units used in themajority of applications.However over the last four tofive years, Huber haveexperienced a substantialincrease in screenings loadingsin imported / sceptic sludge. Wehave conducted studies atvarious sites to try tounderstand what has changedand what is required to handlethe increased loadings.

Imported sludge can varytremendously from site to siteand can be made up fromscreened / unscreened sludgefrom outlaying works, prethickened sludge, waste fromsceptic tanks, waste from sewerchokes/ tank and pump station clean downs andwaste from industrial tanks.

This sludge / waste can contain liquids / sludge invarying thickness, oils, fats and grease in varyingconsistencies, screenings, rags, litter, leaves cans,plastics, rubber, stones and bricks, grit in differentquantities, shapes and sizes.

Our studies, carried out at Ballymoney, Cookstownand Strabane, Broadford and Stornoway and otherrural sites throughout the UK, highlighted, that thetankered imports were very highly contaminatedwith screenings.

We feel that this is down to a number of factors:

This probably coincides with charges beingimposed for the emptying of septic tanks andresults in tanks being emptied less frequently,

which obviously results in morescreenings etc being retained inthe tanks and uplifted by thetankers. The type of rag /material has also changed overthe years with more wipes andsanitary material kitchen rollwhich is less bio-degradable.

This results in higher screeningsloading in the imported sludge.As an experiment whenproblems were beingexperienced with the scepticsludge imports through theimported sludge screen atBallymoney, Northern Ireland.The septic sludge imports,which was basically liquor withvery high screenings loading,were diverted and dischargedthrough Huber WAP screeningshandling unit, whilst the minorto major sludge importscontinued to be dischargedthrough the site import screen,without problems.

Following our studies we cameto the conclusion that there islittle point increasing the screenbasket size without increasingthe auger transport rate. Wherehigh screenings loadings arepresent, Huber would suggestusing the larger screen basket,1200 mm diameter with a355mm diameter auger in theunit, this gives a screenthroughput of 80ltrs. /sec.

@3% and 55ltrs./sec@ 6%ds giving a maximumscreenings removal rate of 4m3/ hour.

We have also improved maintenance access onthese units with interlocked side access doors onthe tank sides. This allows easy access for removalof stone grit and a viewing door on the tank lidwith a safety grill to allow the operation and solidsloadings to be viewed safely.

Some examples of Septic / Imported Sludge

Written by Fred Neumann, ASM Scotland and Ireland

“Operations staffare alwaysimpressed withthe operationalfunctionality andflexibility of theHuber TechnologySludge Thickenersand dewaterers”commented FredNeumann ASMScotland &Ireland

Imported / Septic Tank Sludge

Photos showingimported tank sludge

“Imported sludgecan varytremendously fromsite to site”

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At the centre of the RoS2S is an inclined, slowlyrotating filter disc that separates flocculated sludgefrom filtrate. The filter disc consists of a fine meshcover (with roughly square apertures of 0.35 – 0.40mm across) fixed on top of a rigid perforated carrierdisc (with 5 mm dia. holes.) A baffle platedistributes the inflow from the flocculation reactorevenly across the entire filter radius. Flexiblysupported ploughs divide and move the sludgelayer on the disc and open up furrows so thatwater can easily drain through the filter mesh, thusenhancing the filtration effect. As the filter disccontinuously rotates, a scraper pushes thethickened sludge from the disc. The filter mesh isbackwashed with a spray bar.

RoS2S

Disc Thickener Trial Unit

RoS2S outsideoperation

Benefits of the Disc ThickenerLow operation costs as a result of excellentperformance and easy system operation:

4 Unique Design

4 Very small footprint

4 2 sizes available for up to 40m3/hr ofthroughput

4 Low polymer consumption

4 Fully enclosed design

4 Filtrate water can be utilised to wash thedisc

4 Capture rate of 97-99%

4 Low power consumption

RoS2S Disc Thickener

“The RoS2Ssludge discthickener is theideal solution toreduce tankeringcosts on smallsites” explainedRichard Willis at a recentThames WaterInnovation Day

“2 sizes availablefor up to 40m3/hrof throughput”

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The RoS3Q is a screw press with a conical screwshaft and cylindrical sieves consisting of threetreatment zones: inlet and drive zone, three-partthickening and dewatering zone, and press zonewith pneumatic counter – pressure cone.

It is ideal for dewatering of the followingtypes of sludges

4 Primary, Secondary sludges

4 Digested sludge

4 Flotated sludge

4 Membrane sludge

RoS3Q Screw Press Dewaterer

The key features of the RoS3Q include

4 Conical auger shaft

4 Three wedge wire sections with different barspacings

4 Continuous wedge wire inside, cleaned by awiper mounted on auger flights

4 Pressurised feed (0-500mbar)

4 Pressure monitoring / control

4 Easy access through large inspection openings

Benefits of the RoS3Q are:

4 Outstanding energy efficiency

4 Low operator attention required

4 Compact, space saving, stainless steel design

4 Vibration free, virtually noiseless operation

4 Minimum costs for wear parts

4 Totally enclosed

RoS3Q with covers open

RoS3Q

“Outstandingenergy efficiency”

“Low operatorattentionrequired”

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The Dairy Crest Creamery in Davidstow is thelargest producer of mature cheddar and the mostadvanced cheese making creamery in Europe.When an upgrade of the sludge handling facilitywas required, Dairy Crest turned to severalsuppliers of dewatering equipment to dewatertheir sludge’s. Four different sludge streams arisefrom their modern effluent plant and it was initiallythought they might behave differently with regardsto polymer requirements and dewatering potentialso bench trials with each sludge were undertakenand various combinations that may occur weretested. The four streams comprised of; DAF flotate,activated sludge, settled sludge and back-washsludge and they varied in quantity, % dry solidscontent, pH and colour. After bench tests, Huberinstalled their trial plant to get some full scaleresults and attempt to reproduces the results fromthe laboratory work.

18%+ DS cake produced from the mainly DAFsludge with the Atana polymer

The resultant cake is storable and spreadable bymuck spreader and considerably easier to handle.

The RoS3 screw press is totally enclosed, andshowed a vast improvement over the existing beltpress in cleanliness and performance. The screwpress operates at 1 to 6 RPM and requires 14% ofthe power for a centrifuge with none of the highwear, speed, noise and vibration associated with thecentrifuge.

After successful Trials Huber have been pleased toaccept an order from Dairy Crest for 2 offScrewpress units and associated polymer dosingequipment.

Written by Tony Clutten, Process Sales Manager

INDUSTRIAL SLUDGE - CASE STUDYDAIRY CREST DAVIDSTOW CREAMERY

IN CORNWALL

The trial plant is supplied as a complete packageand incorporates; the dewaterer itself, thepolyelectrolyte (poly) dosing unit, the sludge feedpump, the flocculation reactor and the controlpanel. The container also comes with a conveyorthat is positioned under the discharge point fromthe dewaterer and allows cake to be depositedoutside the container.

Various combinations of feed were trialed. Withthe DAF sludge achieving a high throughput of 7m3/h at 3.3% feed solids and a good solids captureratio whereas the biological sludge’s gave a wettercake from a 1-2% DS feed. In all cases, the volumereduction was 4 to 6 times the feed volume thusreducing transport and disposal costs.

Anaerobic DigestionStrainPressIn the anaerobic digestion (AD) sector, the Huberstrainpress is helping our clients reach PAS110quality standard for their digestates. The problemof plastics contaminating digestates can beaddressed using different mesh sizes and pilotplants are available for demonstrating the processfor customers on their specific feedstocks.Digestates from AD are high in nutrients and makeexcellent alternatives to synthetic fertilizers, so theremoval of plastics is an important requirementwhich Huber can help to solve.

STOP PRESSWe received an order from the largestbrewery company in Dublin forscreening their effluent.

Huber are pleased to announce that wehave received an order for our first GritRecycling Plant, which is to be built inWales.

Further data on these two projects tofollow

Trial plant (RoS3 Screw Press)

“It’s good to seeat last that someof our clients haverevisited howimported sludge isdealt with toremove the grosssolids prior tofurther treatment.We understandthe importance ofthis, as failure toadequately screensludge can impactsignificantly onthe ability togenerate powerfrom the sludgetreatment processand also leads tovastly increasedOPEX.” explainedDale Foster at arecent YorkshireWaterpresentation.