Specializing in Wastewater Process Environmental Compliance including Aerators, Bioreactors, Slurry System, Rotary Screens, Flocculation and Pilot Units, Sequential Batch Reactor, Sludge Disposal and Air Flow Feeders
About Integrated Engineers, Inc: Engineering
Company Biography Integrated Engineers, Inc was established by David Wensloff, P.E., in 1994 and based upon his vision, that environmental compliance should be effective, simple and affordable for industries. Integrated Engineers` approach to water & wastewater systems is unique in that we evaluate the entire wastewater process. We perform a comprehensive evaluation of the client`s system including engineering aspects, equipment and chemistry. We are proud to offer our clients the expertise of a broad network of experienced professionals, equipment manufacturers, and chemical suppliers, which we utilize to provide state of the art, cost effective solutions that work! This is achieved by understanding our client`s needs, evaluating the many water and wastewater treatment alternatives, and providing a solution that has the best long term environmental advantages at a reasonable price. Integrated Engineers applies a comprehensive analysis to the complete water and wastewater system, its operation and costs. Our evaluations include: existing equipment analysis, chemical usage and costs, maintenance, compliance, and ease of plant operations. We consider every aspect of the system from the operator`s viewpoint all the way through the management considerations and legal compliance. How Integrated solves problems? It is crucial to take the time to fully understand the client`s needs for the short and long term including growth and changes in their internal processes. By keeping up to date with the ever-changing environmental compliance regulations, we offer wide spectrum solutions knowing that any change internal to a facility can potentially impact the future environmental liability to our clients. Knowing this, we evaluate solutions for our clients based on capital and operating costs in conjunction with their expected growth, future plans and pending environmental regulations. Areas of Expertise Water and Wastewater Process Optimization Reduction in Effluent BOD/FOG/TDS/EC levels Environmental Regulatory Compliance Assisting Clients with Regulatory Agencies Negotiations Engineering Water and Wastewater Equipment Water and Wastewater Controls and Control Systems Mechanical/Electrical Chemicals and optimization of their uses Engineering & Consulting Services Water and Wastewater System Evaluations Feasibility Analysis Water and Wastewater System Renovation New Water and Wastewater System Design & Installation Water and Wastewater System Start-ups & Troubleshooting Water and Wastewater Process Engineering Waste Minimization Studies Sludge Disposal Studies Regulatory Compliance Water and Wastewater Treatability Studies Surcharge Reduction Studies Operator & Management Training of Water & Wastewater Treatment Contracting As General Engineering Contractors, we provide contracting service specific to industrial and municipal wastewater. We specialize in turnkey projects (design/build/startup), but get into several other levels including subcontracting as consultants, installation of parts of the equipment, startup assistance, design review, constructability, and process confirmation. On large projects, we often subcontract to perform the treatibilities, develop the process, scope of work, and generate the bid specifications. Often we win the bid as the contractor and if not have been retained to fix many projects so they work.
Integrated Engineers, Inc was established by David Wensloff, P.E., in 1994 and based upon his vision, that environmental compliance should be effective, simple and affordable for industries. Integrated Engineers` approach to water & wastewater systems is unique in that we evaluate the entire wastewater process. We perform a comprehensive evaluation of the client`s system including engineering aspects, equipment and chemistry. We are proud to offer our clients the expertise of a broad network of experienced professionals, equipment manufacturers, and chemical suppliers, which we utilize to provide state of the art, cost effective solutions that work!
This is achieved by understanding our client`s needs, evaluating the many water and wastewater treatment alternatives, and providing a solution that has the best long term environmental advantages at a reasonable price.
Integrated Engineers applies a comprehensive analysis to the complete water and wastewater system, its operation and costs. Our evaluations include: existing equipment analysis, chemical usage and costs, maintenance, compliance, and ease of plant operations. We consider every aspect of the system from the operator`s viewpoint all the way through the management considerations and legal compliance.
It is crucial to take the time to fully understand the client`s needs for the short and long term including growth and changes in their internal processes. By keeping up to date with the ever-changing environmental compliance regulations, we offer wide spectrum solutions knowing that any change internal to a facility can potentially impact the future environmental liability to our clients. Knowing this, we evaluate solutions for our clients based on capital and operating costs in conjunction with their expected growth, future plans and pending environmental regulations.
As General Engineering Contractors, we provide contracting service specific to industrial and municipal wastewater. We specialize in turnkey projects (design/build/startup), but get into several other levels including subcontracting as consultants, installation of parts of the equipment, startup assistance, design review, constructability, and process confirmation.
On large projects, we often subcontract to perform the treatibilities, develop the process, scope of work, and generate the bid specifications. Often we win the bid as the contractor and if not have been retained to fix many projects so they work.
Water and Wastewater Systems and Equipment
Wastewater Experts: We can give you the total solution for your whole problem. Engineering Licensed Engineers Licensed Contractors System Evaluation Process Engineering Plant Construction Water and Wastewater Equipment Customized Equipment Packaged Biological Systems (BioReactors) Clarifiers Screens Plate Presses Aerators Custom Control Panels Chemical Feed Systems Tanks/Pump/Contols Flow Meters/ph Controllers Water and Wastewater Chemicals FloccinAgents Metal Grabbers Microbes Enzymes Anti-foaming Agents De-foaming Agents Aerators These aerators have the best efficiency for oxygen transfer and pumping rate capacity of any aerator on the market. These units have a certified SAE oxygen transfer efficiency of 2.8 lbs Oxygen/hp-hr in dirty water (over 5.0 in clean test water conditions). In addition and just as important is the amount of water an aerator moves. These units pump 3,500 gpm/10 hp (aspirating aerators pump 300 gpm/10 hp and mechanical splashers do 450 gpm/10 hp). The importance with the pumping rate is the contact frequency of the oxygen with the BOD and bacteria so the food gets to the bugs. Power savings: the potential power savings yields a good payback with replacement of aerators and there is often a rebate from the local electric company to offset the capital costs further decreasing the payback period. BioReactors A BioReactor is a biological wastewater treatment system used to degrade high levels of BOD. This is achieved with the use of a series of tanks, blowers, and pumps that specially designed to maintain an aerobic biomass (population of bacteria that eat the organic constituents that makeup the BOD). A Bioreactor gives industry an option to treat BOD in an economical and reliable manner. Packaged 1,500 gpd unit The BioReactor can decrease BOD 80-98% and has an estimated area footprint of 36-45 square feet per 1,000 gallons of water treated per day. It basically runs itself. Maintenance is 20 min/day; the pH controller needs calibrating, the return sludge needs to be monitored, and the solids coming off the screen need to be managed. Operational costs depend on the size of the system. Costs include electricity, chemicals and labor which averages $0.002 per gallon treated or $0.04 per pound of BOD reduced. Small 25,000 gpd facility A BioReactor starts by screening out all of the larger particulates. The wastewater is flow equalized and pH adjusted to 7-8 in an equalization chamber. Aeration starts in the following chamber where blowers supply air as well as mixing energy to the wastewater. The BOD levels are reduced as the bacteria ``eat`` the BOD. A clarifier follows the aeration chamber where the solids settle to the bottom, and get returned to seed`` the incoming wastewater with healthy bacteria. The clarified effluent then flows out of the BioReactor. Depending on the site requirements, the treated water can be used for irrigation, land applied, water-reuse, or discharged to the Publicly Owned Treatment Works (POTW) Medium 60,000 gpd facility A BioReactor starts by screening out all of the larger particulates. The wastewater is flow equalized and pH adjusted to 7-8 in an equalization chamber. Aeration starts in the following chamber where blowers supply air as well as mixing energy to the wastewater. The BOD levels are reduced as the bacteria ``eat`` the BOD. A clarifier follows the aeration chamber where the solids settle to the bottom, and get returned to seed`` the incoming wastewater with healthy bacteria. The clarified effluent then flows out of the BioReactor. Depending on the site requirements, the treated water can be used for irrigation, land applied, water-reuse, or discharged to the Publicly owned Treatment Works (POTW) Clarifiers This unit is a Lamella plate clarifier with a design rated at 125 gpm for use in a Bioreactor system. It is used for clarification of bio-solids prior to discharge to the fields. The clarifier included dual mixing chambers for addition of a coagulant and then a flocculant for settling aids used during start up of the aerobic biomass or system upsets from the plant sanitizing operations, etc. Filter Presses No matter what size filter press you are interested in -- new or used. Whether it is one item or part of a complete package, we can find the items for you. If you are looking for a small unit such as the 1 cu ft for a smaller industrial setting or if you are looking for some thing a little larger. Manual or fully automated we will help you select what is right for your setting and budget. Rotary Screens Features of the Integrated Engineers Internally-fed Rotary Screens Integrated Engineers Internally-fed Rotary Screens use a cylindrical drum mounted horizontally on four shaft mounted trunnion wheels that are supported on pillow block bearings. The rotating screen is slotted wedge wire screen with sized ranging from 0.075 to 0.010-inch openings. Rotary Screen sizes range from 1`-6`` long and 1`-6`` in diameter to 8`-0`` long and 4`-0`` in diameter. Flows are dependent on rotary screen open area and size. Method of OperationThe influent enters a collection/diversion box, which extends 2/3 the length of the drum, where the flow is evenly distributed onto the sidewalls of the drum. Solids are retained on the rotary screen surface as the liquid flows by gravity through the rotating screen openings. Splashguards direct the liquid filtrate to a central drainage area, and the solids are transported axially, by flights, to the open end of the drum. The rotation of the drum allows the entire screening surface to be continuously or intermittently washed by a fixed external spray bar fitted with a bank of fanjet, spray nozzles. Materials of Construction All 304 stainless steel construction including the frame, legs, drainage pan, discharge chute and screen Channel base in 304, stainless steel TEFC motor and gear drive Stainless steel, direct drive wheel UHMW polyethylene trunnion shaft mounted on pillow block bearings Internal flights External spray bar with optional reuse pump/filter Nema 4 Control panel /w starter and spray bar timer. Spray bar has delay off time to fully rinse the screen prior to shutdown.
Wastewater Experts: We can give you the total solution for your whole problem.
Water and Wastewater Equipment
Water and Wastewater Chemicals
These aerators have the best efficiency for oxygen transfer and pumping rate capacity of any aerator on the market. These units have a certified SAE oxygen transfer efficiency of 2.8 lbs Oxygen/hp-hr in dirty water (over 5.0 in clean test water conditions). In addition and just as important is the amount of water an aerator moves. These units pump 3,500 gpm/10 hp (aspirating aerators pump 300 gpm/10 hp and mechanical splashers do 450 gpm/10 hp). The importance with the pumping rate is the contact frequency of the oxygen with the BOD and bacteria so the food gets to the bugs.
Power savings: the potential power savings yields a good payback with replacement of aerators and there is often a rebate from the local electric company to offset the capital costs further decreasing the payback period.
A BioReactor is a biological wastewater treatment system used to degrade high levels of BOD. This is achieved with the use of a series of tanks, blowers, and pumps that specially designed to maintain an aerobic biomass (population of bacteria that eat the organic constituents that makeup the BOD). A Bioreactor gives industry an option to treat BOD in an economical and reliable manner.
Packaged 1,500 gpd unit The BioReactor can decrease BOD 80-98% and has an estimated area footprint of 36-45 square feet per 1,000 gallons of water treated per day. It basically runs itself. Maintenance is 20 min/day; the pH controller needs calibrating, the return sludge needs to be monitored, and the solids coming off the screen need to be managed. Operational costs depend on the size of the system. Costs include electricity, chemicals and labor which averages $0.002 per gallon treated or $0.04 per pound of BOD reduced.
Small 25,000 gpd facility A BioReactor starts by screening out all of the larger particulates. The wastewater is flow equalized and pH adjusted to 7-8 in an equalization chamber. Aeration starts in the following chamber where blowers supply air as well as mixing energy to the wastewater. The BOD levels are reduced as the bacteria ``eat`` the BOD. A clarifier follows the aeration chamber where the solids settle to the bottom, and get returned to seed`` the incoming wastewater with healthy bacteria. The clarified effluent then flows out of the BioReactor. Depending on the site requirements, the treated water can be used for irrigation, land applied, water-reuse, or discharged to the Publicly Owned Treatment Works (POTW)
Medium 60,000 gpd facility A BioReactor starts by screening out all of the larger particulates. The wastewater is flow equalized and pH adjusted to 7-8 in an equalization chamber. Aeration starts in the following chamber where blowers supply air as well as mixing energy to the wastewater. The BOD levels are reduced as the bacteria ``eat`` the BOD. A clarifier follows the aeration chamber where the solids settle to the bottom, and get returned to seed`` the incoming wastewater with healthy bacteria. The clarified effluent then flows out of the BioReactor. Depending on the site requirements, the treated water can be used for irrigation, land applied, water-reuse, or discharged to the Publicly owned Treatment Works (POTW)
This unit is a Lamella plate clarifier with a design rated at 125 gpm for use in a Bioreactor system. It is used for clarification of bio-solids prior to discharge to the fields. The clarifier included dual mixing chambers for addition of a coagulant and then a flocculant for settling aids used during start up of the aerobic biomass or system upsets from the plant sanitizing operations, etc.
No matter what size filter press you are interested in -- new or used. Whether it is one item or part of a complete package, we can find the items for you. If you are looking for a small unit such as the 1 cu ft for a smaller industrial setting or if you are looking for some thing a little larger. Manual or fully automated we will help you select what is right for your setting and budget.
Integrated Engineers Internally-fed Rotary Screens use a cylindrical drum mounted horizontally on four shaft mounted trunnion wheels that are supported on pillow block bearings. The rotating screen is slotted wedge wire screen with sized ranging from 0.075 to 0.010-inch openings. Rotary Screen sizes range from 1`-6`` long and 1`-6`` in diameter to 8`-0`` long and 4`-0`` in diameter. Flows are dependent on rotary screen open area and size.
Method of OperationThe influent enters a collection/diversion box, which extends 2/3 the length of the drum, where the flow is evenly distributed onto the sidewalls of the drum. Solids are retained on the rotary screen surface as the liquid flows by gravity through the rotating screen openings. Splashguards direct the liquid filtrate to a central drainage area, and the solids are transported axially, by flights, to the open end of the drum. The rotation of the drum allows the entire screening surface to be continuously or intermittently washed by a fixed external spray bar fitted with a bank of fanjet, spray nozzles.
Materials of Construction
Floccin AgentsTM
Floccin Agents (Pronounced ``Flockin``) The Floccin line is a series of many products custom designed to remove most contaminants from wastewater such as: BOD TSS Heavy metals Inks, Pigments and Dyes Emulsified Fats, Oil and Grease Phosphates Helps reduce TDS and EC`s vs. other chemistries Our blends encapsulate the contaminants in a barrier, producing an easily disposable waste sludge and water that can often go right down the drain. Each blend provides a multitude of reactions that simultaneously coagulate, break emulsified oils in water, change the pH, encapsulate the metals, and flocculate to separate the solids from the waste stream. For further information select one of the categories. QA/QC Program The Floccin Products are manufactured under stringent guidelines for uniformity, performance, and composition. Each manufacturing step has written procedures that are followed and documented with the corresponding material made that day. Every lot is tested and must pass the QA/QC test(s) before acceptance. All testing is performed onsite in a California state certified lab. Certificates of performance are available to our clients. Floccin Products and Applications The Integrated Engineers blended flocculating agents perform multiple treatment with one product. The blends are designed to break emulsified oils as well as encapsulate the heavy metals or entrained oil in a strong flocculation. All products come in a convenient granular form that virtually eliminates irritating dust. Where the granular form does not work in the waste stream, a powder form is available. The Floccin products are formulated from chemicals that are either NSF 60 approved for drinking water application, FDA approved for direct human contact, or meeting the GRAS status as defined by the FDA. Additional benefits to our clients are that the Floccin products operate over a wide pH range, generate a high shear strength floc and sludge, require no additional chemistry to dewater, simplify the operations by using just 1 product, and reduced operating costs..... Floccin-A This is a general flocculating agent blend that works well in many industries, including ink removal in corrugated box manufacture, paint, pressure washing, etc. The product does not affect pH. Floccin-B, BK This is a blend that is used to raise the pH of low pH wastestreams such as metal finishers, acid washing operations and similar processes. Floccin-D This blend has an enhanced capability for color removal as well as oil/grease reduction. Applications are for color removal, emulsified oil reduction and other similar processes. This product does not affect pH. Floccin-E This blend has the same applications as Floccin-D, however it has been enhanced to work well at slightly higher initial pH. This product will drop the pH slightly. Floccin-F This blend is used primarily for the treatment of wastestreams with soluble organics such as benzene, xylene, toluene and other industrial soluble organics. Floccin-G This blend works well with stronger emulsions, higher % solids and hard to treat water(s). Floccin-H This blend is essentially the same as Floccin I, but is enhanced to work better for dirtier wastestreams. This product will drop the pH slightly. Floccin-I This blend works well in ink-laden, oily or other wastestreams where a slight reduction in pH helps in the coagulation/flocculation process. Floccin-J This blend performs well with wastewater where color removal, emulsion breaking is coupled with inks, starch and other inorganic/organic pollutants. Floccin-K This blend is enhanced to perform well in treating extremely strong emulsions and inks. Floccin-M This blend was designed basically for the herbicide industry for the removal of the zinc-based salts used in the agricultural market. Floccin-1106 This blend enhanced to perform well in treating extremely strong emulsions and inks with high total solids. These are general recommendations based on past experience with various industries. We generally recommend testing with 2 or 3 different products to determine the optimum, cost-effective product. For further assistance in solving your wastewater problems, contact us.
(Pronounced ``Flockin``)
The Floccin line is a series of many products custom designed to remove most contaminants from wastewater such as:
Our blends encapsulate the contaminants in a barrier, producing an easily disposable waste sludge and water that can often go right down the drain.
Each blend provides a multitude of reactions that simultaneously coagulate, break emulsified oils in water, change the pH, encapsulate the metals, and flocculate to separate the solids from the waste stream. For further information select one of the categories.
The Floccin Products are manufactured under stringent guidelines for uniformity, performance, and composition. Each manufacturing step has written procedures that are followed and documented with the corresponding material made that day. Every lot is tested and must pass the QA/QC test(s) before acceptance. All testing is performed onsite in a California state certified lab. Certificates of performance are available to our clients.
The Integrated Engineers blended flocculating agents perform multiple treatment with one product. The blends are designed to break emulsified oils as well as encapsulate the heavy metals or entrained oil in a strong flocculation.
All products come in a convenient granular form that virtually eliminates irritating dust. Where the granular form does not work in the waste stream, a powder form is available.
The Floccin products are formulated from chemicals that are either NSF 60 approved for drinking water application, FDA approved for direct human contact, or meeting the GRAS status as defined by the FDA.
Additional benefits to our clients are that the Floccin products operate over a wide pH range, generate a high shear strength floc and sludge, require no additional chemistry to dewater, simplify the operations by using just 1 product, and reduced operating costs.....
Floccin-A
This is a general flocculating agent blend that works well in many industries, including ink removal in corrugated box manufacture, paint, pressure washing, etc. The product does not affect pH.
Floccin-B, BK
This is a blend that is used to raise the pH of low pH wastestreams such as metal finishers, acid washing operations and similar processes.
Floccin-D
This blend has an enhanced capability for color removal as well as oil/grease reduction. Applications are for color removal, emulsified oil reduction and other similar processes. This product does not affect pH.
Floccin-E
This blend has the same applications as Floccin-D, however it has been enhanced to work well at slightly higher initial pH. This product will drop the pH slightly.
Floccin-F
This blend is used primarily for the treatment of wastestreams with soluble organics such as benzene, xylene, toluene and other industrial soluble organics.
Floccin-G
This blend works well with stronger emulsions, higher % solids and hard to treat water(s).
Floccin-H
This blend is essentially the same as Floccin I, but is enhanced to work better for dirtier wastestreams. This product will drop the pH slightly.
Floccin-I
This blend works well in ink-laden, oily or other wastestreams where a slight reduction in pH helps in the coagulation/flocculation process.
Floccin-J
This blend performs well with wastewater where color removal, emulsion breaking is coupled with inks, starch and other inorganic/organic pollutants.
Floccin-K
This blend is enhanced to perform well in treating extremely strong emulsions and inks.
Floccin-M
This blend was designed basically for the herbicide industry for the removal of the zinc-based salts used in the agricultural market.
Floccin-1106
This blend enhanced to perform well in treating extremely strong emulsions and inks with high total solids.
These are general recommendations based on past experience with various industries. We generally recommend testing with 2 or 3 different products to determine the optimum, cost-effective product. For further assistance in solving your wastewater problems, contact us.
Flocculation Units
Continuous Flow Unit: Continuous Flow Flocculation Treatment This unit is designed for the same ease and simplicity of treatment as a batch treatment, yet with added technologies to assist the operator in mixing and filtration. In addition, improvements in the quality of collected waste and treated wastewater are achieved by using the highest performance FloccinAgentsTM available. Proven result for reduced TDS/EC levels, lower residual heavy metals and lower cost/gallon treated using this approach. The continuous process units range from 5 gpm thru 30 gpm. Additional options are available for increased flocculation with pre-ozonation, water purification with post-ozonation and increased efficiency of de-watering and drier sludge. Features Integral 304 SS Treatment Tank and Discharge Tank Filtration Table with Variable Speed Electrical Control(s) Mixing Motor and Variable speed Controller Discharge Sump Pump w/ independent float control 304 Stainless Steel Frame Variable Speed Relay Logic These are self-contained, durable units built for a long life in smaller processing facilities. They are fabricated of 304 stainless steel and PVC structures to prevent corrosion. The control panel and all electrical components are UL listed for safety and reliability. There is a wide blade variable speed mixing motor to optimize flocculation in the mixing tank. The variable speed, dewatering table coupled with the automatic dewatering paper feeder allows for the creation of drier sludge. Typical Specifications for Continuous Flow Unit: Integral 304 SS Treatment Tank and Discharge Tank Filtration Table with Variable Speed Electrical Control(s) 1/2 hp Mixing Motor and Variable speed Controller Discharge Sump Pump w/ independent float control 304 Stainless Steel Frame with Fork Lift Guides Variable Speed Relay Logic 120 VAC, 1¥Õ - 30 amp service Additional Treatment Options Economy Batch Unit (EBU) The Economy Batch Unit (EBU) is a low price alternative to other wastewater treatment systems available. The unit utilizes a 60 gallon mix chamber with 1/3 hp mixer where the FloccinAgent¢â is added and mixed with the wastewater, then the mixer is turned off and the drain valve is opened allowing the flocculated water to drain and dewater in the filter bag below the Mix Tank. The solids in the filter bag are allowed to drain and dry over time for easy disposal. Dewatering 60 gallons takes about 30 minutes (depends on specific water treated). Dewatering Bags can be used many times before disposal. Manual Batch Unit This unit is designed for ease and simplicity of batch treatment, yet with added technologies to assist the operator in mixing and filtration. In addition, improvements in the quality of collected waste and treated wastewater are achieved by using the highest performance Floccin materials available. Features for Ease of Use and Improved Performance: Variable Speed Filter Table Variable Speed Mixing Motor Float Activated Discharge Pump Durable * Safe * Efficient Available Options Vacuum assisted dewatering table Floccin Feeder¢â Automated mixing and process dump Full automation of subsystem functions Feeders: Compact Floccin Feeders for Transportation of Granular Products This is a family of Floccin feeders designed to feed granular Floccin products or similar granular materials for simple transfer, batch processing or continuous processing. They can lift up to 24 vertical feet and can be set up in a small area. Delivery rate can be as high as 10 lbs per minute. The units are available in three configurations. The standard unit is a stand-alone unit, where a predetermined amount of material is poured into the hopper and the valve is opened, delivering the material to the desired destination. The batch unit is programmed via a timer to deliver a preset amount of material on a repetitive, basis initiated by the user or by input signal. The continuous unit will deliver a preset rate of material continuously via an externally generated input signal on a demand basis as long as the signal is present. Large Floccin Feeders: Try one of our customized Floccin Feeders! 700 lb hopper capacity Variable feed with DC drive. Continuous feed rates from 0-11 lbs per min. Or Batch feed with timers. Custom built controls to match your needs. Easy interface to your existing equipment. Tank and floor mount models Mini Floccin Feeders: Complete With Variable Speed Control This line of feeders is perfect for users of small quantities of Floccin products. They were designed to attain even distribution of product and eliminate the formation of clumps formed by feeding manually. These containers are molded construction of heavy 3/16`` polyethylene. Slurry System The Slurry System is used to inject hydrated Floccin products into a pipe containing untreated wastewater. The dry granular or powder Floccin products are feed from a 2000 lb bag at a controlled rate to a hydration tank where they are hydrated in water with the aid of a variable speed mixer. The solution is then pumped into a pipe where the flocculation reaction occurs. All 304 stainless steel construction: Approx. dim. 3`-6`` X 3`-6`` x 5`-10``; Requires 6 feet of clear overhead space for placement of 2000 lb bag in basket. Variable feed rate from 5 lb./hr to 200 lb./ hr 70-gallon hydration tank, with dedicated drain 20 amp service at 110 VAC 1Hz Removable hydration tank cover Makeup water for slurry can be wastewater or fresh water Self-cleaning, ¨ú-hp output pump Ultrasonic level control and modulating valve All Slurry System control panels feature a programmable logic controller for complete automation including the startup and shut down procedures. It features Hand/Off/Auto controls on all functions. The hydration tank water level is monitored with a no contact ultrasonic sensor for precise reliable level measurement. For safety, an emergency stop (e-stop) is standard. The slurry system can be manually turned on and off, or interfaced to the customer`s existing control(s). The hydration tank mixer, and feeder speed is controlled using variable speed controllers.
This unit is designed for the same ease and simplicity of treatment as a batch treatment, yet with added technologies to assist the operator in mixing and filtration. In addition, improvements in the quality of collected waste and treated wastewater are achieved by using the highest performance FloccinAgentsTM available. Proven result for reduced TDS/EC levels, lower residual heavy metals and lower cost/gallon treated using this approach. The continuous process units range from 5 gpm thru 30 gpm. Additional options are available for increased flocculation with pre-ozonation, water purification with post-ozonation and increased efficiency of de-watering and drier sludge.
Features
These are self-contained, durable units built for a long life in smaller processing facilities. They are fabricated of 304 stainless steel and PVC structures to prevent corrosion. The control panel and all electrical components are UL listed for safety and reliability. There is a wide blade variable speed mixing motor to optimize flocculation in the mixing tank. The variable speed, dewatering table coupled with the automatic dewatering paper feeder allows for the creation of drier sludge.
The Economy Batch Unit (EBU) is a low price alternative to other wastewater treatment systems available. The unit utilizes a 60 gallon mix chamber with 1/3 hp mixer where the FloccinAgent¢â is added and mixed with the wastewater, then the mixer is turned off and the drain valve is opened allowing the flocculated water to drain and dewater in the filter bag below the Mix Tank. The solids in the filter bag are allowed to drain and dry over time for easy disposal. Dewatering 60 gallons takes about 30 minutes (depends on specific water treated). Dewatering Bags can be used many times before disposal.
This unit is designed for ease and simplicity of batch treatment, yet with added technologies to assist the operator in mixing and filtration. In addition, improvements in the quality of collected waste and treated wastewater are achieved by using the highest performance Floccin materials available.
Features for Ease of Use and Improved Performance:
Available Options
This is a family of Floccin feeders designed to feed granular Floccin products or similar granular materials for simple transfer, batch processing or continuous processing. They can lift up to 24 vertical feet and can be set up in a small area. Delivery rate can be as high as 10 lbs per minute. The units are available in three configurations. The standard unit is a stand-alone unit, where a predetermined amount of material is poured into the hopper and the valve is opened, delivering the material to the desired destination. The batch unit is programmed via a timer to deliver a preset amount of material on a repetitive, basis initiated by the user or by input signal. The continuous unit will deliver a preset rate of material continuously via an externally generated input signal on a demand basis as long as the signal is present.
This line of feeders is perfect for users of small quantities of Floccin products. They were designed to attain even distribution of product and eliminate the formation of clumps formed by feeding manually. These containers are molded construction of heavy 3/16`` polyethylene.
The Slurry System is used to inject hydrated Floccin products into a pipe containing untreated wastewater. The dry granular or powder Floccin products are feed from a 2000 lb bag at a controlled rate to a hydration tank where they are hydrated in water with the aid of a variable speed mixer. The solution is then pumped into a pipe where the flocculation reaction occurs.
All 304 stainless steel construction:
All Slurry System control panels feature a programmable logic controller for complete automation including the startup and shut down procedures. It features Hand/Off/Auto controls on all functions. The hydration tank water level is monitored with a no contact ultrasonic sensor for precise reliable level measurement. For safety, an emergency stop (e-stop) is standard. The slurry system can be manually turned on and off, or interfaced to the customer`s existing control(s). The hydration tank mixer, and feeder speed is controlled using variable speed controllers.
Pilot Units
Pilot Units Integrated Engineers has designed and built small portable pilot units capable of operating on site and simulating larger units in the actual environment where a designed plant would be operated. A relatively small expenditure allows for testing prior to commitment to design and purchase of a large facility. The Offer: Contact us and give us the specifications of the wastewater you discharge to determine if the desired system can meet the specification for a pilot study. Send a sample to our lab for testing, free of charge. Based on the tests, we will recommend a treatment process with a certain performance guarantee, such as 80% removal of BOD or 95% removal of TSS, etc. An agreement will be signed between the customer and Integrated Engineers and a purchase order will be issued for the cost of the treatability pilot study. We will assemble a pilot plant specially designed for your wastewater. An onsite pilot plant test will be performed proving treatability of the process. Integrated Engineers will write up the results, complete with economic analysis and environmental regulatory review to verify compliance. If Integrated Engineers designs and builds the plant, the cost of the pilot study will be deducted from the purchase price of a system. Pilot Aerobic Unit This unit consists of: Equalizing Tank Detention Tanks (2) Clarifier The pilot unit is sized to handle a flow of 10 gpm of industrial wastewater. Many of our clients prefer to do a small scale system treatibility to prove the performance of a larger system prior to the purchase. The system is a return activated sludge process. The process has an initial equalizing (EQ) Tank where coarse bubble diffusers provide some aeration and mixing of the incoming wastewater. A flow meter measures the flow rate into the EQ Tank. The EQ tank has a pH control system for the addition of acid or base as needed for the optimal pH range. The second and third tanks are fine bubble aeration tanks complete. The aeration system has flow gauges on each tank for airflow quantification. The final tank is the clarifier where the solids (sludge) is allowed to settle and is returned to the EQ Tank as well as Aeration Tank 1 and/or 2 depending on the process objectives. The EQ Tank can also be operated with a mixer (not shown) so it can perform as an anoxic selector for reduction of nitrates and phosphates. The unit is completely assembled on the trailer and clients enjoy the hands on experience of testing their wastewater. Pilot Anaerobic Unit This unit consists of: EQ Tank 2 Digester The anaerobic pilot unit is designed to operate at 10 gpm treating higher strength industrial wastewater upstream of an aerobic process or by itself. The unit has an initial equalizer (EQ) tank which allows a steady state flow control to the digesters. The temperature is adjusted in this tank with heat exchanger(s) to raise or lower the temperature to the mesophilic range (95-102 degrees F) or the thermophilic range (126-132 degrees F) prior to the digesters. The digesters flow in a series or parallel configuration. The digesters are fitted with high surface area contact media and re-circulation pumps to keep a cross flow of the influent relative to the media. The methane gas that is produced flows through a flow meter for quantification and BTU evaluation. Each of the digesters is fitted with digital thermistors with readouts so adjustments in the temperature can be made relative to the heat loss. Batch Pilot Unit This unit consists of: Automated Floccin Feeder Reaction Tank Filter Press Secondary Filter This batch pilot unit is sized to treat 20 gallons of industrial wastewater. The process is to fill the reaction tank, mix with the variable speed mixer, add the Floccin material, generate a floc and clear water, turn the mixer off, decant the clear supernatant through a filter to discharge, then pump the remaining sludge to the filter press. The unit simulates a smaller version of batch treatment systems commonly found in the corrugators, paint, ink and ceramic industries. The digesters flow in a series or parallel configuration. The digesters are fitted with high surface area contact media and re-circulation pumps to keep a cross flow of the influent relative to the media. The methane gas that is produced flows through a flow meter for quantification and BTU evaluation. Each of the digesters is fitted with digital thermistors with readouts so adjustments in the temperature can be made relative to the heat loss. Sequential Batch Reactor (SBR) The most advanced design technology for pilot testing This sequential batch reactor is automatic and treats using the 4 cycle steps of fill, aerate, settle, and decant. The unit is designed for pilot type testing of wastewater using wastewater direct from a facility or from a diluted concentrate. The pilot SBR is an ideal tool to model the bio-kinetics of wastewater and develop actual design parameters for each specific type of wastewater. Special features include: Adjustable process control timers for each cycle step Air flow rate meter in cubic feet/hour Effluent filter Continuous pH monitoring and control Nutrient addition in the fill cycle (N, P, Fe) Variable decant level Adjustable wastewater influent concentrations Skid mounted
Integrated Engineers has designed and built small portable pilot units capable of operating on site and simulating larger units in the actual environment where a designed plant would be operated. A relatively small expenditure allows for testing prior to commitment to design and purchase of a large facility.
The Offer:
This unit consists of:
The pilot unit is sized to handle a flow of 10 gpm of industrial wastewater. Many of our clients prefer to do a small scale system treatibility to prove the performance of a larger system prior to the purchase.
The system is a return activated sludge process. The process has an initial equalizing (EQ) Tank where coarse bubble diffusers provide some aeration and mixing of the incoming wastewater. A flow meter measures the flow rate into the EQ Tank. The EQ tank has a pH control system for the addition of acid or base as needed for the optimal pH range. The second and third tanks are fine bubble aeration tanks complete. The aeration system has flow gauges on each tank for airflow quantification. The final tank is the clarifier where the solids (sludge) is allowed to settle and is returned to the EQ Tank as well as Aeration Tank 1 and/or 2 depending on the process objectives. The EQ Tank can also be operated with a mixer (not shown) so it can perform as an anoxic selector for reduction of nitrates and phosphates.
The unit is completely assembled on the trailer and clients enjoy the hands on experience of testing their wastewater.
The anaerobic pilot unit is designed to operate at 10 gpm treating higher strength industrial wastewater upstream of an aerobic process or by itself. The unit has an initial equalizer (EQ) tank which allows a steady state flow control to the digesters. The temperature is adjusted in this tank with heat exchanger(s) to raise or lower the temperature to the mesophilic range (95-102 degrees F) or the thermophilic range (126-132 degrees F) prior to the digesters.
The digesters flow in a series or parallel configuration. The digesters are fitted with high surface area contact media and re-circulation pumps to keep a cross flow of the influent relative to the media. The methane gas that is produced flows through a flow meter for quantification and BTU evaluation. Each of the digesters is fitted with digital thermistors with readouts so adjustments in the temperature can be made relative to the heat loss.
This batch pilot unit is sized to treat 20 gallons of industrial wastewater. The process is to fill the reaction tank, mix with the variable speed mixer, add the Floccin material, generate a floc and clear water, turn the mixer off, decant the clear supernatant through a filter to discharge, then pump the remaining sludge to the filter press. The unit simulates a smaller version of batch treatment systems commonly found in the corrugators, paint, ink and ceramic industries.
The most advanced design technology for pilot testing This sequential batch reactor is automatic and treats using the 4 cycle steps of fill, aerate, settle, and decant. The unit is designed for pilot type testing of wastewater using wastewater direct from a facility or from a diluted concentrate. The pilot SBR is an ideal tool to model the bio-kinetics of wastewater and develop actual design parameters for each specific type of wastewater.
Special features include:
Case Studies: Corrugator Sheet Plant, Industrial Laundry and Treating Winery Wastewater
Corrugator Sheet Plant #1 A facility that made corrugated sheet board was using a specialty flocculant to treat their wastewater. Unfortunately, it treated the water only one half of the time to acceptable levels for reuse as starch makeup. The facility had paid $45,000 in the first 6 months of the year in chemical costs and $40,000 in haul-off costs to haul the majority of the treated water offsite. Integrated Engineers, Inc. developed a process to treat starch-laden wastewater using Floccin J. The process is to adjust the pH up to 10.2 to 10.5 with caustic and add 10lbs/1,500 gallons of wastewater making clear effluent and dry filter press cakes (and eliminated the use of DE as a press pre-coat). The chemical costs for the Floccin products were less than 50% of the previous chemical supplier and all of the water was of sufficient clarity and quality for reuse. Plant savings have been over $70,000/year and zero discharge to sewer or haul off. Corrugator Sheet Plant #2 The previous wastewater treatment was composed of the following chemicals: an acidic coagulant, caustic for pH adjustment, and an anionic polymer made down to 1% solution. The facility used 3-4 gallons of coagulant, 2-3 gallons of caustic, and 2-3 gallons of anionic flocculant (at a 1% solution). The operator stated that they had low solids, they tended to overdose which blinded the press. That required 3-4 hours to clean and restore the press to operation. Integrated Engineers, Inc treated the water using Floccin. The operator mentioned that during the test was the worst water due to the facilities clean up operations on the weekends. The wastewater treated easily with Floccin; making a good floc with clear treated water. The dewatered filter cake was extremely dry and released well from the filter plates. Floccin provided a significant savings for the facility, reduced the three chemicals to one, reduced labor, and provided superior finished water quality over the previous chemistry. Industrial Laundry This facility washes heavy industrial rags and towels from furniture manufacturing, ink roll towels, automotive and other operations. The wastewater process uses flow equalization for the 60,000 gpd flow, pH adjustment with sulfuric acid, coagulation, metal precipitation, flocculation followed by dissolved air flotation. The facility had difficulty meeting the effluent metals for Copper (1.5 ppm) and Zinc (1.0 ppm) on a consistent basis Integrated Engineers has proven that the use of only CO2 for pH adjustment and Floccin-1105 can improve effluent water quality at a reduced cost/gallon treated. Treating Winery Wastewater Many smaller wineries have outgrown their septic tanks, and larger wineries have outgrown their treatment ponds, a BioReactor gives increased capacity at a fraction of the cost of conventional pond treatment systems. Wineries traditionally treat their wine process wastewater with aerobic (aerated) ponds to biologically degrade the biochemical oxygen demand (BOD). The treated wastewater from these ponds needs to have a BOD of 40 ppm or less (depending on the location of the winery) before the winery can discharge the water to the vineyards for irrigation. Winery ponds require a large surface area (detention time) to treat the winery wastewater usually between 60-90 days for conservative design. Since the ponds have a large surface area, they need to include the capacity to hold a prolonged rain based on a 10-year rainfall event. An Alternative Solution Instead of ponds, there is another way to degrade the BOD down to the levels required for irrigation discharge. The solution is the use of a biological returned activated sludge system also called a bioreactor. A bioreactor is a more efficient biological process than a pond system. The BOD degradation in a bioreactor process involves a series of tanks either in ground (concrete) or above ground (steel or polyethylene). The oxygen is supplied with blowers and a fixed grid aeration system The EQ-Blower provides pre-aeration as well as mixing to the equalization tanks with coarse bubble diffusers. The second equalization tank is for further aeration and mixing as well as the reseeding of the activated sludge from the final clarifiers. After a detention time of 24-36 hours, the wastewater flows into the clarifier for settling of the solids forming sludge (sludge settling). The sludge is important since it has a high concentration of the biomass (bacteria) that needs to be returned to the aeration process, hence the name `returned activated sludge`. Either system will still require an irrigation pond, but there is a significant amount of money that can be saved with a bioreactor system. The pond system for the facility would have a comparative summary of the expenses of installing a pond treatment system, either clay or plastic lined ponds, the loss in vineyard grape production and other expenditures not usually accounted for by winery owners estimated at $363,900, while the bioreactor system resulted in a cost of $228,210, thus a savings of $135,690 or 37%. The traditional pond systems to treat winery wastewater requires a good deal of acreage due to the long detention times required for the degradation of BOD to the levels required for irrigation. A Bioreactor can save a significant amount of capital costs, increase the wineries wastewater capacity at a fraction of the costs of conventional pond treatment methods. Existing wineries can easily adapt the Bioreactor system into their process and new wineries can greatly benefit by utilizing these advantages from the start.
A facility that made corrugated sheet board was using a specialty flocculant to treat their wastewater. Unfortunately, it treated the water only one half of the time to acceptable levels for reuse as starch makeup. The facility had paid $45,000 in the first 6 months of the year in chemical costs and $40,000 in haul-off costs to haul the majority of the treated water offsite.
Integrated Engineers, Inc. developed a process to treat starch-laden wastewater using Floccin J. The process is to adjust the pH up to 10.2 to 10.5 with caustic and add 10lbs/1,500 gallons of wastewater making clear effluent and dry filter press cakes (and eliminated the use of DE as a press pre-coat). The chemical costs for the Floccin products were less than 50% of the previous chemical supplier and all of the water was of sufficient clarity and quality for reuse. Plant savings have been over $70,000/year and zero discharge to sewer or haul off.
The previous wastewater treatment was composed of the following chemicals: an acidic coagulant, caustic for pH adjustment, and an anionic polymer made down to 1% solution. The facility used 3-4 gallons of coagulant, 2-3 gallons of caustic, and 2-3 gallons of anionic flocculant (at a 1% solution). The operator stated that they had low solids, they tended to overdose which blinded the press. That required 3-4 hours to clean and restore the press to operation.
Integrated Engineers, Inc treated the water using Floccin. The operator mentioned that during the test was the worst water due to the facilities clean up operations on the weekends. The wastewater treated easily with Floccin; making a good floc with clear treated water. The dewatered filter cake was extremely dry and released well from the filter plates.
Floccin provided a significant savings for the facility, reduced the three chemicals to one, reduced labor, and provided superior finished water quality over the previous chemistry.
This facility washes heavy industrial rags and towels from furniture manufacturing, ink roll towels, automotive and other operations. The wastewater process uses flow equalization for the 60,000 gpd flow, pH adjustment with sulfuric acid, coagulation, metal precipitation, flocculation followed by dissolved air flotation. The facility had difficulty meeting the effluent metals for Copper (1.5 ppm) and Zinc (1.0 ppm) on a consistent basis
Integrated Engineers has proven that the use of only CO2 for pH adjustment and Floccin-1105 can improve effluent water quality at a reduced cost/gallon treated.
Many smaller wineries have outgrown their septic tanks, and larger wineries have outgrown their treatment ponds, a BioReactor gives increased capacity at a fraction of the cost of conventional pond treatment systems. Wineries traditionally treat their wine process wastewater with aerobic (aerated) ponds to biologically degrade the biochemical oxygen demand (BOD). The treated wastewater from these ponds needs to have a BOD of 40 ppm or less (depending on the location of the winery) before the winery can discharge the water to the vineyards for irrigation.
Winery ponds require a large surface area (detention time) to treat the winery wastewater usually between 60-90 days for conservative design. Since the ponds have a large surface area, they need to include the capacity to hold a prolonged rain based on a 10-year rainfall event.
An Alternative Solution
Instead of ponds, there is another way to degrade the BOD down to the levels required for irrigation discharge. The solution is the use of a biological returned activated sludge system also called a bioreactor. A bioreactor is a more efficient biological process than a pond system.
The BOD degradation in a bioreactor process involves a series of tanks either in ground (concrete) or above ground (steel or polyethylene). The oxygen is supplied with blowers and a fixed grid aeration system
The EQ-Blower provides pre-aeration as well as mixing to the equalization tanks with coarse bubble diffusers. The second equalization tank is for further aeration and mixing as well as the reseeding of the activated sludge from the final clarifiers.
After a detention time of 24-36 hours, the wastewater flows into the clarifier for settling of the solids forming sludge (sludge settling).
The sludge is important since it has a high concentration of the biomass (bacteria) that needs to be returned to the aeration process, hence the name `returned activated sludge`. Either system will still require an irrigation pond, but there is a significant amount of money that can be saved with a bioreactor system.
The pond system for the facility would have a comparative summary of the expenses of installing a pond treatment system, either clay or plastic lined ponds, the loss in vineyard grape production and other expenditures not usually accounted for by winery owners estimated at $363,900, while the bioreactor system resulted in a cost of $228,210, thus a savings of $135,690 or 37%.
The traditional pond systems to treat winery wastewater requires a good deal of acreage due to the long detention times required for the degradation of BOD to the levels required for irrigation. A Bioreactor can save a significant amount of capital costs, increase the wineries wastewater capacity at a fraction of the costs of conventional pond treatment methods. Existing wineries can easily adapt the Bioreactor system into their process and new wineries can greatly benefit by utilizing these advantages from the start.
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