Water & Silt Management Systems

Traditionally lagoons have been used to settle the silt (- 63 micron) and reuse the water in the washing process. Nowadays due to environmental, planning or space restrictions, new solutions are available from PowerX Equipment.

PowerX Equipment is recognised as the market leader in the quarrying and aggregate recycling industries for water and silt management systems. We are able offer bespoke solutions for individual applications using the very best technology from the leading manufacturers in Europe together with our own products and processing experience.

At PowerX Equipment we pride ourselves on meeting the exact requirements of our customers rather than offering from a limited range of standardised products.

Filter Press

Filter presses are used to dewater sludge from the underflow of thickener tanks. Filter presses operate on a batch process and produce a dry silt cake that is typically between 20% and 30% moisture.

The basic principle involves thickened sludge being pumped under pressure in to the chambers within the press. Each filter plate is covered by a filter cloth and as the sludge is pumped in, the water drains through the filter cloth and exits the plates. When the water has sufficiently drained to the required moisture content, the press automatically opens and discharges the dry cakes into a stocking bay below.

Side Beam

The sidebar filter press is the cost-effective solution for producing high solids filter cake with extremely high clarity in the liquid effluent. It combines rugged construction, precision engineering, ease of operation and a wide range of features and options to tackle the most difficult dewatering problems.

It produces consistent results under varying influent conditions.

Sidebar construction, filter plate size range available from 250 mm x 250 mm to 1500 mm x 2000 mm.

Overhead Beam

The overhead filter press represents the state-of-the-art in filter press design and is available in a variety of sizes and styles to suit the most rigorous applications. The filter plates are suspended from the top which allows for excellent access and all the working mechanisms are protected. The continuously revolving chain mechanism allows for very quick discharge of the filter cakes.

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Centrifuge

Centrifuges dewater sludge on a continuous process using the principle of centrifugal force. Centrifuges are becoming more popular in the aggregates industry due to their compact size relative to the production levels, their lower capital cost and their lower operating costs. They produce a dry silt cake typically ranging from 35% to 45% moisture. 

The basic principle involves pumping thickened sludge into a rotating drum. Flocculent is added prior to the feed point to create strong bonds between the silt particles. The rotating drum causes the solids to settle on the drum and the water is discharged by gravity. A rotating screw conveys the dewatered solids to the discharge end of the centrifuge for stockpiling.

We work with our Italian partner, Gennaretti, who are experts in this method of dewatering. Gennaretti have built up extensive knowledge in the last 10 years of processing silts from aggregates. They are market leaders in this field due to their focus in this area and ongoing research and development program.

Thickeners

Deep Cone Thickeners

Deep Cone Thickeners are an effective alternative to traditional thickener tanks. Deep Cone Thickeners hold many advantages over traditional thickeners. Some of these advantages include no moving mechanical parts, lower flocculent consumption, smaller footprint and large storage area for sludge in the conical section. Due to their steep conical sides, higher densities of sludge can be achieved and gravity is utilised to transfer the sludge to the outlet. High density sludge means there is less dewatering required downstream.

Power X Equipment initially introduced Deep Cone Thickeners to the quarry industry in 2004 and due to their numerous advantages we have supplied more than 50 of these units to date.

Dynamic Thickeners

Dynamic Thickeners are commonly used for the separation of silt and water from sludge. They are circular tanks with a shallow cone section and internal rake. The sludge is fed into the top of the thickener where flocculent is added. The rake rotates slowly and gradually pulls the settled silt towards the central discharge port. By monitoring the torque level on the rake we can control the density at which the sludge is discharged.

The tanks are manufactured in sections and bolted together on site for ease of transport and their low level design is beneficial where height restrictions apply to a site.

Lamella Thickeners

The lamella principle uses several parallel inclined plates to create the maximum settling area possible given the space restrictions.

Conventional clarification equipment requires a much larger surface footprint in order to match the solids removal capacity of a lamella clarifier. Loading rates normally used for the design of conventional settlers can be applied to the sizing of a Lamella clarifier/settler by substituting the single-surface settling area of a conventional clarifier with the multi-surface settling are of a Lamella Plate.

The casing is typically made of coated or stainless steel and the lamellas are made of propylene. The effluent enters the lamella separator through the inlet channel on the top and flows to the bottom of the separator. The water is led back to the top, on its way the water flows through the lamellas, onto which the solid particles settle. The purified water flows to the top and reaches the outlet by passing a weir. The sludge slides down the lamellas and is collected in the sludge funnel. A rabble rake can be installed to prevent caking of the sludge. The sludge is discharged at intervals when the required density is achieved. Our Lamella Separators are manufactured in a wide range of sizes to suit all applications.

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Flocculent Systems

Flocculent Mixing Systems

Flocculent is used in the water treatment process to initially separate solids (- 63 micron) from water.

Flocculation occurs when destabilised particles are brought together by high molecular weight polymers such as Polyacrylamides. These polymers physically form a bridge between two or more particles, uniting the solids into loose three-dimensional structures. These structures are both denser and more porous than the untreated solids and so help in the typical/common forms of mechanical dewatering employed.

Duo offers a range of Flocculent Mixing Systems that automatically prepare a batch of flocculent by mixing the flocculent powder with water to achieve the required concentration. Our systems are size specific to each application to ensure the flocculent has sufficient time to mix prior to being dosed, ensuring the best results and minimising the amount of flocculent required in the process.

Automatic Flocculent Dosing Systems

Automatic flocculent dosing systems are metering systems that determine the consumption of the chemicals in the thickener process. Metering of the chemicals is achieved by precisely adjusting the flow of flocculent depending upon the level of silt in the in the sludge. The level of slit is continuously monitored.

The continuous monitoring of silt levels ensures the correct level of flocculent consumption resulting in economic savings as there is no overuse and the desired quality of filter cake is also guaranteed. Underuse of flocculent is also avoided which ensures clean reusable water at all times.

For more on Flocculent Mixing Systems…

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