Sludge Set™ isused to rapidly dry cement fines based sludge produced at ready mix and precast concrete manufacturing operations to enable easy waste disposal.

Sludge Set™ is a non-hazardous material that is easy to use and extremely cost effective compared to other absorbents, filter presses and rotary vacuum systems that utilize filter media.

Sludge Set™ is a granular super absorbent drying agent that rapidly absorbs and retains large volumes of matter. It is capable absorbing up to 250X its own weight in water. Unlike other drying agents Sludge Set™ adds less than 1% free swell, which lowers transportation costs.

Sludge Set™ ensures compliance with federal, state and local disposal standards while offering a more cost effective and safer approach than lime, fly ash, diatomaceous earth and other traditional absorbents. Sludge treated with SludgeSet™ is suitable for Class 1 Industrial Landfills and approved incineration facilities.

Sludge Set™ Beneficial Properties:

– Non-Biodegradable

– Non-Exothermic

– Non-Hazardous contains no heavy metals, solvents, phosphates or any toxic materials

– Non-Flammable

– Not regulated by DOT

Allows treated solids to pass the Paint Filter Liquids Test (EPS 9096) and liquid release test (EPA 9095)

Sludge Set™ Waste disposal Properties including Incineration:

Sludge Set™ is a super absorbent drying agent consisting of carbon, hydrogen and oxygen. These elements are commonly found in municipal solid waste. Thermal degradation of Sludge Set™ starts to take place from near 400° F (204° C) and accelerates as the temperature rises. This completion of thermal degradation process is dependent upon the amount of Sludge Set™ and the rate of temperature rise. The complete combustion of Sludge Set™ associated with any combustible material in a properly functioning incinerator will produce only carbon dioxide and water.

APPLICATION RATES
Apply 15 to 25 lb of Sludge Set™ per 1,000# of sludge depending on water content of sludge. Laboratory testing is available at no charge to determine proper application rates.

APPLICATION
Load bottom lip of loader bucket with 50 to 100 lbs of Sludge Set™ and apply evenly to the sludge by manipulating the loader bucket evenly apply the Sludge Set™. Begin mixing with a loader bucket.

Allow 30 to 45 minutes for Sludge Set™ to absorb as much moisture as possible.

More Sludge Set™ may be added at areas within the basin as needed.

Sludge Set™ is available in 50# multi-wall paper bags. Store product in a dry area.

Keep out of reach of children.

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BIBKO North America, LLC, distributes concrete reclaiming systems from BIBKO GmbH throughout the United States and Canada via a network of authorized dealers.Based in Cedar Falls, Iowa, with regional offices in Lititz, Pennsylvania and Tracy, California, the company provides equipment and services to producers of concrete who must deal with the byproducts of concrete production in an environmentally responsible manner: visit ConcreteReclaiming.com

Sources: Bibko North America, LLC, Cedar Falls, Iowa; CP staff

“Concrete reclaiming equipment specialist Bibko NA has become the exclusive U.S. and Canadian market representative of the Model 5000 pH control systems for treating concrete operations’ process and commingled process-storm water.

A December 2011 distribution agreement with Wendell, N.C.-based Fortrans Inc. ensures that concrete producers will receive the full attention and support of Bibko NA’s dealer network. Dealer staff will be available to travel to a customer’s site, help with equipment selection and installation, and do follow-up service calls.

“Fortrans pH control systems are a perfect fit with our array of products and services for concrete and process water reclaiming and recycling,” said Bibko NA Director of Marketing and Sales Owen Blevins. “Concrete producers have long struggled with the proper disposal of concrete process water, which is highly alkaline. The Model 5000 line directly addresses that problem with safe, acid-free carbon dioxide injection and diffusion.”

Please see the complete story here

Bibko NA’s site, www.concretereclaiming.com, provides education, tools and resources about concrete reclaiming and water recycling.”

System economizes use of CO2 to neutralize process water pH, TSS

New in-line diffusion and injection technology overcomes maintenance, efficiency and cost obstacles long associated with using carbon dioxide to bring concrete operations’ process water to pH levels suited for environmental release or municipal sewer discharge. Covered by late-2011 patent filings, Fortrans’ technology positions ready mixed and precast producers to trade safety concern-clouded acid treatment methods for one using benign CO2.

See the complete article here

Lowering pH to minimum of 6.5 in very high temperature water with moderately high pH at 5,000 GPM flow with carbon dioxide.

Lowering pH levels in water derived from filter press applications with carbon dioxide at fixed base operations and mobile in field or on the go treatment.

A large terminal operations company in the Midwest wanted to use carbon dioxide for pH control of boiler blow down water to see if they could achieve a cost reduction and greater safety by replacing a sulfuric acid treatment process with one of Fortrans Model 5000SK pH Control systems.

The pH of the boiler blow down water was 12.0 at a temperature of 90⁰F.The client generated between 15,000 and 40,000 gallons per day of this high temperature and high pH process water. Volume was seasonal: higher in winter and lower in the summer. Client advised that they had an indoor facility with a large sump where this water was collected and this was the area they wished to treat the process water.

Customer purchased a Model 5000SK skid mounted system that was installed in the sump area. Since this was a new application, Fortrans agreed to supply this system under a 45 day trial program. The terms of the program was that the unit could be returned at no charge if the operation was not successful.

The water was circulated by the Fortrans’ stainless steel submersible pump from the sump to our pH control system and returned pH adjusted water to the sump. The system achieved the required end point of 7.5 with the first 10 hours of operation and has maintained the entire contents of the sump at the 7.5 level continuously since operation was commenced. Exact savings as a result of this application were not revealed by the client. They did say the savings were very substantial in terms of initial cost and subsequent operating costs.

A ready mix concrete manufacturing operation needed to neutralize high ph process water resulting from rinsing of the interiors of concrete delivery trucks and rinsing of the exteriors following the loading process. The purpose was to be able to discharge excess process water and or storm water that drained into the process water detention basins. The treated water had to meet the following limits: The pH had to be under 9.0 and the total suspended solids had to be less than 30 PPM to comply with their discharge permit.

The client installed a Model 5000S with a modular in-line carbon dioxide feed system at their 25,000 gallon capacity sedimentation basin. The system fed carbon dioxide gas at 25 Liters per minute through 2” piping that was supplied with process water via a submersible pump and returned treated water to the sedimentation basin at the rate of 45 GPM or 64,500 GPD. After approximately 3 hours of circulating and treating the water, the pH of all of the water in the basin was 7.5 The TSS or total suspended solids was an average of 14 Mg/L after 3 hours settling time. The water was circulated while the plant was in operation and shut off at night.

While in operation, the system automatically detected a rise in pH over 8.25 and immediately began the carbon dioxide feed until the total basin pH was back to 7.5 The client was able to recycle treated water for rinsing trucks and supply recycled water into the concrete batching operation.( Non DOT mixes only). Treated water could also be used for irrigation of aggregate for easier batching operations. The treated water was also permitted to be discharged to the environment since it easily met the permit requirements as outlined above.

Note: This above case study has been replicated at hundreds of ready mix, precast and other concrete manufacturing operations in the USA and Canada over the last six years.

An open pit taconite mining operation in Minnesota had a problem with high pH groundwater infiltrating into the mine and the water had to be pumped out 24 hours per day to be able to continue mining operations. The high ph was a result of an alkaline blasting agent used to fracture the ore bearing rock so it could be mined. Some of the high pH resulted from natural sources within the mine. The customer wanted a pH control system that would neutralize the pH to levels that would meet their discharge permit limit of 8.5. The requirement was to control the pH of 3 to 4 MGD with a low operational cost and employee safety was paramount.

The customer installed a Fortrans Model 5000S modified to include two treatment loops within the system to feed carbon dioxide gas converted into carbonic acid (H2C03) by two Fortrans proprietary Injector/diffusers. Each loop was connected to a high head submersible pump via a tee fitting to serve both treatment loops. Each loop was circulating approximately 80 GPM. The carbon dioxide was fed into each loop and the water was returned to the large supply pit via 3”hoses. The supply pit was constructed within the mine to collect the groundwater from this area of the mine.

Upon completion of lab testing we determined the water to be treated had extremely low total alkalinity (<10 PPM) and very low conductivity plus high levels of naturally occurring carbon dioxide. Adjusting and maintaining a stable pH in water with this low level of alkalinity was challenging. Fortrans employed specialized process pH probes and a custom calibration process to treat this water successfully. The customer was able to maintain the desired pH at the discharge point.

The Model 5000S pH Control and Monitoring Series offers proven technology to enable operators of ready mixed concrete plants to control the pH and Total Suspended Solids of process water. After the pH is lowered to 7.5 the typical total suspended solids are between 10-18 mg/L without filtration. This enables the facility to meet the pH requirements as well as the 30 mg/L TSS most permits demand before the water can be released. The treated water may recycled to batch concrete, irrigate rock, rinse the interiors of the drums on the concrete trucks and rinse the exteriors of the trucks as well without staining or scaling of the finishes.

The Model 5000S series cost 60% to 70% less to operate and maintain than acid based pH control systems and are much safer than acid systems. The systems do not require a separate tank and are guaranteed to perform to the owner’s satisfaction.

This system has been certified by an independent engineering firm to operate as specified. The units are shipped fully assembled and only require an electrical connection and a supply of carbon dioxide gas plus a C02 regulator.

The system will treat approximately 75,000 gallons over a 24 hour period. The system is also available as a skid mounted unit. (Model 5000SK) Higher capacity Systems are also available up to 200,000 GPD.

Over 500 of these systems are operating at ready mixed concrete plants in the U.S and Canada. The Systems are low maintenance, highly reliable and affordable. Fortrans has a wealth of knowledge in this technology and has provided concrete producers with an affordable and guaranteed solution for treating high pH process water over the last 8 years. One company in the Boston area saved approximately $400,000 per year in water storage and disposal costs after installing a Model 5000SK system.

Prevent EPA Fines for Discharge of High pH Process Water or Storm Water

• Eliminate the cost of storing or disposal of excess process water
• Treated water meets pH and total suspended solids limits for discharge
• Fortrans systems are safer and less costly to operate than acid based systems
• Use pH adjusted process water for recycling, rinsing trucks, dust control or irrigation
• Simple low maintenance design
• Reduce potable water usage
• Low cost solution

All standard Fortrans pH Control Systems include:

• The Fortrans exclusive non-fouling carbon dioxide diffusion and injection system (patent pending) adjusts the pH of process water and/or storm water automatically, on an as-needed basis. This carbon dioxide pH adjustment system is driven by a programmable logic controller that automatically maintains a preset pH (usually pH 7.5), for water stored in your detention basin. Target pH range is adjustable. Includes pH measurement cell, and fully automated operation. The Fortrans is highly reliable, and exceptionally economical to operate.

• High efficiency stainless steel submersible pump with stainless steel impeller, thermally protected continuous-duty motor, and float assembly to protect against run-dry condition. The standard system pump yields approximately 70,000 gallons per day from a typical 12 to 15 foot deep detention basin, and has capacity to pump from basins or pits 20 feet and more in depth.

• High quality swivel pump boom, 150 lb capacity, 2 feet high, with 30″ boom reach and 1000 lb manual winch.

• 2-inch pump connection and 2-inch discharge hoses (25 feet each) with cam lock quick connect fittings for quick and easy set-up.

• Electronic flow rate meter to indicate that the system is operating within a normal flow range, or to indicate that maintenance cleaning of the pump inlet, or the system hoses, is required.

• Factory installed industrial-duty surge suppressor to protect the system electronics.

• Red light fixture to warn that the system pH has exceeded the alarm set-point..

• A system enclosure that is best suited to your facilities needs.

• Feature an exclusive non-fouling carbon dioxide diffusion and injection system to precisely adjust the pH of process water in detention basins.

Fortrans pH Systems Benefit Detail

1. Optimize process and storm water treatment to comply with federal and local regulations. Eliminate costs of storing or disposal of excess process water.
2. Operational Cost Savings Fortrans pH control systems are exceptionally efficient, with 60% to 70% typical operational expense savings over acid-based pH adjustment systems. The Fortrans system reduces total suspended solids to EPA standards of less than 30 mg/l without additional chemicals or filters.
3. Maintenance Cost Savings An elegant design allows Fortrans pH control systems to operate automatically, 24 hours a day. Routine maintenance is simple and easy.
4. Safety. Fortrans pH control systems use carbon dioxide in lieu of hazardous acids. Employees will not need protective equipment or safety training for handling hazardous acids used in other pH control methods.
5. Proven Reliability Fortrans pH control systems, with our exclusive non-fouling C02 injection and diffusion technology provides a proven pH control solution, with hundreds of installations currently operating throughout the United States.
6. Performance. Fortrans guarantees their systems will perform to their customers, satisfaction, and we back this with a 30-day purchase price refund offer. (Less Shipping)

Download: pH Control and Monitoring Systems Sales Sheet

The Fortrans image and caption reference are in the top group on page 26. The general article reference to environmental upgrades is on the page 24-25 jump, although without equipment specifics. A typical story would have more on the batch plant and environmental management features; the uniqueness of the spun cast process trumped them here.

We would only feature a plant like this once or twice a decade.

Don Marsh
Editor
Construction Products

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