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:
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
