Successful installation of the mechanical treatment systems on WWTP Pfaffenhofen and WWTP Kelheim

New equipment for the mechanical treatment stage on WWTP Pfaffenhofen:

HUBER Belt Screen EscaMax® connected to a HUBER Launder Channel for reliable and maintenance-free solids tranpsort without moved parts
HUBER Belt Screen EscaMax® connected to a HUBER Launder Channel for reliable and maintenance-free solids tranpsort without moved parts

Pfaffenhofen on the river Ilm is the biggest town of the district Pfaffenhofen in the administrative region Upper Bavaria. Pfaffenhofen is one of the 34 towns and municipalities in Bavaria which, in 2011, were awarded the seal of quality for sustainability by Bavarian State Minister Dr. Markus Söder. The Bavarian Ministry for the Environment and Health awards this seal of quality for the extraordinary commitment of municipalities in the field of sustainable community development and their membership in the project “Network of Sustainable Communities”.

HUBER Belt Screen EscaMax® provides 30% higher separation efficiency:

In 2011, the old mechanical treatment system was replaced by a new HUBER system. A HUBER Belt Screen EscaMax® with 6 mm perforation replaces the old 6 mm step screen (third-party product) and achieves a by 30% higher separation efficiency. The screenings volume increased from 61 t/a to 87 t/a. The increased separation efficiency prevents the risk of pump blockage and wear of downstream systems. The risk of scum layers in the digester is minimised. In this way, HUBER contributes its share to increasing the operating reliability on this wastewater treatment plant.

11,000 KJ/kg thermal value with HUBER screenings treatment system HUBER Launder Channel (HLC) and WAP/SL:

The HUBER system Launder Channel with WAP/SL has been installed to reduce disposal costs despite an increase in screenings volume. Until 2011, a trough conveyor was used to transport the screenings to a conventional wash press. A HUBER Launder Channel (HLC) was then installed to avoid wear parts, such as bearing shells, bearings or screw flights. The new system makes it possible to realize complex transportation ways without clogging and blockage and without the use of motors. The HUBER Launder Channel is fed with process water from downstream of the screen and flushes the screenings discharged from the screen into the Wash Press. It is also no problem to have a 90° bend. An advantage of this system is that the flush water serves also as wash water for the WAP/SL. No additional water is required. High-turbulence washing of screenings is the most efficient washing method for organic matter adhering to the screenings. An integrated impeller creates maximum turbulence. Dry substance contents in excess of 45 % are achieved with this system. Residual material becomes valuable material. Furthermore, the carbon-rich WAP/SL wash water improves denitrification, and up to 40% of the wash water is washed out organics which settle as primary sludge and lead to an increase in gas yield. This project is another example that money can be earned with the use of a WAP/SL unit. Short amortisation periods contribute to the full satisfaction of customers.

Machines supplied to WWTP Pfaffenhofen:

  • 1 HUBER Belt Screen EscaMax® 5000
  • 1 HUBER Launder Channel HLC-273
  • 1 HUBER Wash Press unit Super Launder WAP-SL-6

New equipment for the mechanical treatment stage on WWTP Kelheim:

The district town Kelheim in the administrative district Lower Bavaria lies on the river Danube and the Main-Danube Canal between Ingolstadt and Regensburg. The central wastewater treatment plant in Saal, east of the port of Saal, is designed for 70,000 PE and has been in operation since 1981.

At the beginning of 2012, the complete old mechanical treatment system on WWTP Kelheim was replaced by new HUBER systems: Two RakeMax® Multi-Rake Bar Screens, 3300 mm length, 6 mm bar spacing. The screens are designed to ensure that one screen has the capacity to handle the complete flow to the wastewater treatment plant. To increase the thermal value and reduce disposal costs the screenings and the organics contained within the screenings are additionally treated in a HUBER WAP/SL Wash Press, size 4. DR contents of up to 45% can only be achieved if the organics adhering to the screenings are solubilised because only solids can be dewatered. Two WAP/SL units are used to achieve this. An impeller is integrated in the HUBER WAP/SL Wash Press which creates high turbulence and ensures that the screenings are exposed to mechanical stress and the organics contained within the screenings are washed out. The carbon-rich wash water is returned to the system. The washed screenings are dewatered to up to 45% DR. How “clean” the screenings are is reflected by the quality factor. We guarantee a factor below 20 mg BOD5/gDR. Optimal screenings treatment reduces disposal costs and the carbon-rich wash water improves denitrification. Furthermore, the solids contained within the WAP/SL wash water (primary sludge), which amount to up to 40% of the wash water, lead to an increase in gas production.

Machines supplied to WWTP Kelheim:

  • 2 HUBER Wash Press units Super Launder WAP-SL-4
  • 2 HUBER Multi-Rake Bar Screens RakeMax®  3300

With these projects HUBER once again proves how competence and expertise which have been gathered over many years can successfully be applied in practice. HUBER has sold more than 1200 RakeMax® / EscaMax® screens and more than 650 WAP/SL Wash Press units and is a market leader in this field.

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