Solution for treatment of sludge produced in ceramic industry

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Hallo everybody,

I am looking for effective solutions and equipment available for treatment of sludge produced in industrial wastewater treatment plant in ceramic factory.

Wastewater is generated in production of elements and also in glazing operation . Produced sludge consists mainly mineral stuff (clay and kaolin).  Currently sludge is dewatered in drum filters with result of average 65% of dry solid content recovery. The goal is to obtain 85-90% dry solid recovery. I will be grateful for any information provided about treating this kind of sludge. 

Thank you in advance

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11 Answers

  1. Chamber filter press.

    Answered on by

  4. Dear All, thank you very much for your comments. The tests were done and chemical staff has been chosen.  Aluminum sulphate and low anionic polyelectrolyte based on acrylamide and sodium acrylate are being used in a process of wastewater treatment. The results of the treatment are satisfactory. Currently we are looking for the best solution to improve dewatering of sludge produced in the wastewater treatment. I consider implementing of drying to obtain 85-90% of dry solid content and so I am looking for the adequate technology and equipment. Regards from Poland

  5. Dear Serafin

    Sludge is a by-product of water treatment. Sludge is produced during the clarification and filtration process in the water treatment system. It is also produced from the accumulated solids removed from sedimentation basin or settling tank.

    Ceramics have characteristics that enable them to be used in a wide variety of applications including

    i) High heat capacity and low heat conductivity,

    ii) Corrosion resistance,

    iii) Electrically insulating, semi-conducting, or super conducting,

    iv) Non-magnetic and magnetic, and

    v) Hard and strong, but brittle.

    The Eco-pottery is made from water treatment sludge. During the process, the organic substances in the sludge were eliminated through burning, while the heavy metals were safely contained in the product.

    Furthermore, energy is saved during the production process since sludge is used as combustion during the burning process. Technically the Eco-pottery has demonstrated that the WTP sludge could be viably used in the mixture to produce pottery. The chemical composition, the energy properties of the sludge and the mineral contained in the sludge were analysed in a laboratory.

    Ceramic industry is capable of incorporating and reusing different types of industrial waste materials. Recently, the reuse of ornamental stone cutting sludge slime in this industry is becoming a common practice. This work investigates the changes in the physical and mechanical properties of the produced ceramic tiles from raw materials containing marble sludge slime produced in the ornamental stone processing industry.

    Following steps of the treatment process

    1. Flocculants (PAC, Aluminum sulfate, Sodium aluminate, sodium hydroxide, Calcium hydroxide, clay etc) and
    2.  Coagulants (anionic/cationc, high/low MW polyelectrolytes) applying as possible the flow parameters of your mix/sedimentation speed of your installation.

    Regards,

    Prem Baboo

     

    https://www.researchgate.net/publication/286624669_Ceramics_from_clays_and_by-product_from_biodiesel_production_Processing_properties_and_microstructural_characterization?ev=prf_pub

     

    https://www.researchgate.net/publication/51461365_Sludge_valorization_from_wastewater_treatment_plant_to_its_application_on_the_ceramic_industry?ev=prf_pub

     

  6. I was in contact some years ago with a Korean company named "AK Innternational", which was contructing a thermal filterpress, which seems to be a perfect application especially for dewatering inorganic sludge. You could se its operation at the video:

    http://www.youtube.com/user/AKIHyperX

    Now I found a US company at the following video:

    https://www.youtube.com/watch?v=b84nmNNv7TI

    If you are not interested on thermal/pressure separation, you could have better dewatered results using a decanter (Flottweg proposed).

    1 Comment

    1. Thank you very much, I consider thermal treatment/drying as I don't know any equipment applying e.g. pressure which could result with sludge dewatering at the level of 85-90% dry solids. Regards

  7. Dear Ms. Serafin,

    I gained some experience with handling transformed red mud, the micron-sized mineral residue of the bauxite refining, in a pilot-scale plant on Sardinia. Solid weight percentages of 65 - 70% are attainable by common drum filters or filter presses. We used an alfa-laval decanter centrifuge with similar results. I understand that with HiBar Steam Pressure Filtration you may reach about 75 solid wt%. To arrive at 85-90 solid wt%, we had to dry a several dm thick layer of our cake during a few weeks in the summer sun on a concrete pad and overturn it once.

    Regards, Hans

    1 Comment

    1. Thank you very much! I also consider thermal drying but with Polish climate we have to apply adequate equipment - too few sunny days

  9. Dear Serafin, are you using polyelectrolyte for coagulation of minerals? Anyway, and because every application has its specific differences, you have to make lab trials using different types and doses of flocculants (PAC, Aluminium sulfate, Sodium aluminate, sodium hydroxide, Calcium hydroxide, clay etc) and coagulants (anionic/cationc, high/low MW polyelectrolytes) applying as possible the flow parameters of your mix/sedimentation speed of your installation. According to my opinion this is the best way to find out if you can succeed a more stable and thick flock, in order to achieve better dehydration to your drum filters.

    1 Comment

    1. Thank you very much for your reply. Yes the chemical stuff (Aluminum ​sulphate and ​low anionic ​polyelectrolyte ​based on ​acrylamide and ​sodium acrylate ​) is being applied with positive results in both treatment and dewatering processes. I am not sure whether the highest dewatering result (up to 90% ds.) can be achieved only by using chemicals

  11. Dear Malgorzata Serafin, Please mail me the physical and chemical analysis report of the effluent and the flow rate of the effluent to be treated.We will design a suitable solution. Please mail to virafmehtain@yahoo.co.in visit-www.greenenviro.net