Shaftless Screw Conveyor Replaces Belt Conveyor for Biosolids Load Out System Floyd Branch WWTP in Richardson, TX

General Description

The city of Richardson, Texas was chartered in 1873 and has since grown into a fully developed residential and commercial city with a population of over 100,000 people. Over the years, the water and sewer utilities have undergone numerous improvements and additions. The Floyd Branch WWTP facility is permitted for 4.75 MGD. The plant underwent improvements to increase capacity and improve the biosolids load out system.

The existing biosolids load out system included a pivoting belt conveyor that loaded dumpsters. Due to difficulty with keeping the belt conveyor running without issues, the plant management decided to replace the belt conveyor with more reliable technology. KWS Environmental, in conjunction with plant operators, designed a shaftless screw conveyor to directly replace the existing belt conveyor. The new KWS design reused the existing conveyor support structure and pivoting mechanism. All the issues with the belt conveyor were eliminated with the new KWS design.

Design Parameters

1. Product Type – Dewatered Biosolids
2. Material Density – 60 Lbs. per Cubic Foot
3. Conveyor Capacity – 280 Cubic Feet per Hour
4. Duty – 5 Days a Week, 8 Hours per Day

KWS Advantages

KWS Environmental designed, manufactured and supplied a shaftless screw conveyor for the load out system that integrated with existing supports and control systems. Engineers from KWS made numerous site visits to discuss the issues with operations and maintenance personnel. Complete dimensions of the building and existing load out system were obtained while on site so drawings of the new system could be created. KWS designed the new shaftless screw conveyor to fit in the limited space allowed by dewatering building and existing chutes and supports. The new shaftless screw conveyor was designed to fit on the existing pivoting supports and discharge to dumpsters by rotating around a center axis to evenly load dumpsters or roll-off containers. A custom inlet transition between the existing inclined screw conveyor and the new KWS shaftless screw conveyor was designed to allow easy fit-up in the field.

Special Features

KWS Environmental provided a unique solution to the biosolids load out system that included a shaftless screw conveyor, structural supports, safety control devices and custom inlet chute. KWS provided oil-impregnated UHMW liners for extended life and reduced maintenance. The new shaftless screw conveyor utilized KWS-350 Ultra Strong Micro-Alloy spirals for long life. The KWS-350 spirals are the strongest and toughest in the industry and designed to outlast any other spiral on the market. Custom supports for the new shaftless screw conveyor were designed specifically to integrate to the existing bearing and support frame. Overall cost of the system was minimized greatly by reusing the existing pivoting support system.