KWS Manufacturing

Shaftless Vertical Screw Conveyor System for Transferring Class B Biosolids of Pembroke Pines, FL WWTP

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Plant Name and Location

Pembroke Pines WWTP
Pembroke Pines, Florida

General Description of the Application

BCR Environmental Corporation is an environmental solutions company transforming the way municipalities treat and manage biosolids and organic wastes. BCR has several industry-revolutionizing technologies that convert organic waste streams into safe, valuable, and marketable end products. KWS was excited to be selected by BCR as a partner responsible for the design, manufacture and commissioning of the materials handling portion of an innovative sludge treatment process which produces 40 CFR Part 503, Class B biosolids. The patented BCR Environmental CleanB System treats biosolids to meet Class B regulatory requirements for beneficial reuse in accordance with Title 40 Code of Federal Regulations (CFR) Part 503. CleanB is a simple, one-stage process that not only creates Class B sludge but destroys odor which widens the possible uses for the product.

KWS provided the shaftless screw conveyor system to elevate the stabilized, dewatered biosolids from two centrifuge dewatering units to a loading bay located outdoors. The proximity of the centrifuges to the loading area represented a special problem that required a unique solution.

Design Parameters of Application

The product conveyed is chemically treated, dewatered Waste Activated Sludge (WAS) with a dry solids content of 16-23%.

The system is to be implemented in two phases with influent conditions as follows:

PHASE I: BCR CleanB Process – Treatment & Dewatering

CleanB is BCR’s patented Class B biosolids treatment solution. The CleanB system chemically treats Waste Activated Sludge (WAS) and produces Class B biosolids in less than 10 minutes, compared to other technologies that can take weeks. CleanB is a simple, one-stage process that uses two chemicals: sulfuric acid (50%) and sodium chlorite (15%), which are combined in BCR’s patented Generating System to generate chlorine dioxide onsite. The chlorine dioxide is injected into the sludge stream for disinfection and deodorization.

Flowrate: 150 to 270 Gallons per Minute Total Solids: 0.8 to 1.0-percent

PHASE II: BCR Neutralizer Process – Neutralization

The Neutralizer solution is BCR’s patented Class A/EQ (Exceptional Quality) onsite biosolids treatment system. Neutralizer has become the most installed Class A/EQ biosolids management solution in the State of Florida because it is simple, safe, environmentally responsible, and cost effective for Environmental plants of almost any size.

Neutralizer treats Waste Activated Sludge (WAS) in a batch process to produce nutrient rich Class A/EQ fertilizer in accordance with U.S. Environmental Protection Agency (EPA) regulations. The process eliminates the need for complex Environmental infrastructure and requires only hours to achieve results that often take weeks with traditional Class A technologies. The fertilizer is pH adjustable and free from foul odors. By eliminating odors, air quality at the Environmental plant, the surrounding community, and the residuals application site is improved.

Flowrate: 100 to 175 Gallons per Minute Total Solids: 4.0 to 5.0-percent

End User or Owner

Pembroke Pines WWTP Pembroke Pines, Florida

Customer

BCR Environmental Corporation Jacksonville, FL

Advantages Provided by KWS

KWS worked closely with BCR through the design phase to provide a fully engineered system including design (mechanical, controls and instrumentation), manufacture in the US, delivery and commissioning services. Since KWS has significant experience with elevating dewatered biosolids using shaftless vertical screw conveyors, the existing space constraints were easy to design around. KWS provided a very efficient and compact design to transfer the dewatered biosolids from the centrifuges to the outdoor loading bays.

KWS’s ability to model the equipment using AutoDesk 3D Inventor was invaluable to integration into the plant and coordination with other process equipment. Design and approval time was reduced significantly and the project was completed ahead of schedule.

Special Features of KWS Design

KWS Shaftless Screw Conveyors are the most rugged and long-lasting in the industry. The KWS-350 shaftless spiral is manufactured from high-strength alloy steel with an average hardness of 350-BHN to provide wear resistance and many years of operating life. Our unique one-piece flanged drive shaft is machined from a single piece of bar stock and will not fatigue or fail. Transitions between shaftless screw conveyors were eliminated to create an efficient and compact layout. KWS also provided sensors and instrumentation that fully integrated with the main centrifuge control system.

Testimonial

"Today we began operating the entire system and the conveyors performed excellently. Thanks for coming down to the Pembroke Pines start-up and taking the time to visit with BCR. Your information and insight were extremely valuable and we look forward to working with KWS in the future."

Todd Chambers, Director of Customer Operations & Partnership – BCR Environmental Corporation

Biosolids / Sludge

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