When the Clean Water Act was enacted, one of the intentions of this legislation was to reduce the untreated industrial wastewater burden on Publicly Owned Wastewater Treatment (POTW) plants in the same manner that industrial wastewater would only load the treatment plant to the same extent as ordinary household sanitary waste.

Industrial facilities that generated process wastewater had to begin pre-treatment of the water before it could be returned to the local POTW. They had to test for heavy metals, chemical oxygen demand, biological oxygen demand, pH, solvents and other chemicals that were contained in the wastewater stream and then treat to ensure removal of the contaminants.

The Clean Water Act also established limits on water discharged to the environment from an industrial facility property or discharged upon the grounds of the facility. There are many aspects of the Act that limit and seek to control hazardous chemical discharges.

Among the chemicals and oxygen demand levels prohibited to be returned without treatment or discharged, the Act also defined the pH limits of discharges to the environment to the point that any waste with a pH of 9.0 or higher was by definition hazardous waste. The act regulated and set limits on total suspended solids in the water being discharged, but left the actual limits up to the local and state agencies that administer the Clean Water Act on behalf of the Federal EPA.

The above limits on pH and total suspended solids has had an impact on ready mix and precast concrete producers. Many of the concrete production plants generate large amounts of high pH process water from rinsing and cleaning of equipment.  High pH water comes from rinsing the drums on the mixer trucks after returning from a delivery and from rinsing the exterior of the trucks after loading at the batch plant.

Storm water adds to the problem as this water can drain into the basins designed to contain and settle out the cementitious solids. The storm water becomes high pH process water at that point.

The high pH process water also contains dissolved solids and suspended solids that do not settle outin the basins. These solids are generally not removed by filtration especially the dissolved solids.

In addition, many of the job sites receiving the loads of concrete no longer allow the rinsing of the mixer trucks so the amount of concrete brought back to the production plant has been increased.

Whenever possible, the concrete producers will reuse the high pH water to batch fresh concrete. However, most state and federal paving or construction projects prohibit the reuse of the process water and specify that “Potable Water” must be used as concrete makeup water. The high pH water cannot be used for pre-wetting aggregate or dust control because it will contaminate the site.

The water may be reused for truck rinsing and cleaning provided the water is returned to the catch basins or pits.

The problem for the ready mix and to some extent the precast producers is the generation of excess process water (including storm water) that accumulates by normal business volume and specifically when the producer must use potable water in lieu of recycled water.

The producer must have an economical way to deal with this problem short of storing it or paying for it to be transported for disposal as industrial wastewater.

To simply discharge the water off the property can incur a future liability for fines but also for future fees for remediation of the property upon which the water was discharged.

In 2011, a company operating ready mixed concrete plants was fined $740,000 for violating the Clean Water Act. The company also was required to pay $8,000,000 into a remediation fund for site clean up at various locations

There are solutions available to the concrete producers:

Fortrans Inc. and BibKo NA market self-contained pH control systems that are guaranteed to solve this problem for the producers. The modestly priced systems use low cost C02 gas to automatically lower the pH of the process water and lower the total dissolved and suspended solids to meet the Clean Water Act limits for discharge to the environment.

Fortrans pH control systems can provide outstanding control and monitoring of stored process water. The treated water may be recycled for batching concrete, pumped to wash racks, used for irrigation or dust control.

New Technology for Solidification of Dredging Sludge and Slurries©

Marine dredging operations produce sludge and slurries from normal operations.

Some of the dredged materials contain hazardous or noxious products that must be solidified in order for the products to pass a standard EPA paint filter liquids test for landfill disposal. In some cases the material only requires solidification to be able to transport the material without leaking from the truck

Dredging companies may use cement, lime, diatomaceous earth or other absorbents to barge mix into the sludge to absorb and solidify the waste. Dewatering polymers are also available but generally require specialized equipment and decanting of the water produced. The decanted water may or may not be suitable for return to the dredged area due to contaminants leached into the clear water. In view of this, absorbents are more commonly used

Companies have tried dewatering polymers, pumping the material into trucks and transporting to drying beds, using loaders to remove the watery mixture and unloading the waste material on a large pile of other waste materials on the site that will eventually absorb the water.

Each of these procedures is time consuming and usually has pitfalls such as higher cost or rain extending the drying time and producing hazardous leachate coming from the drying operation. It is also time consuming to double handle the dried material from the drying area and transport for disposal.

There are environmental issues with land application of wet solid waste.  The leachate coming from the waste may contain hazardous materials that cannot be allowed to drain from the plant site or contaminate groundwater.

Polymer dewatering can be expensive requiring dispensing equipment and the treatment area must be equipped with agitation for efficient operation. Even after dewatering; the waste material may require additional drying before it can be transported.

There is new technology available to the dredging industry that involves the use of polymer based drying and solidification agents applied and mixed into the waste material These products are more efficient at solidifying waste materials containing water.

Typically the waste is solidified to the point it will pass a Paint Filter Liquids Test if required by the disposal site.

Using a product such as Sludge Set™, a polymer based absorbent, will require less mixing time and work better, since a single pound of Sludge Set™ will absorb 250 pounds of water .The product adds less than 1% free swell which will significantly reduce hauling costs. These types of product have excellent biodegradation properties (data available) and are not hazardous or toxic in of themselves.

These products are typically granular free-flowing powders that are easily distributed over the sludge or slurries and then mixed with bucket loader. Once the material is mixed into the sludge it will continue to absorb water such that continuous mixing is not necessary.

Contact:
Robert C. Cooke
President
rcooke@fortransinc.com
919-365-8004

Sludge Set™ Used To Solidify a Cementitious Heavy Slurry at a Concrete Paving Operation

Fortrans Inc. became involved in a concrete paving project by providing a pH control system to treat high pH gray water. The pH system lowered the pH of the process water to 7.5 and lowered Total Suspended Solids to <30 mg/L to ensure the water met all EPA requirements for safe discharge to the environment.

In the process of closing the plant, the operations staff was tasked with clean up of the site and removing all cementitious waste contained in the lined earthen lagoons. The lagoons contained approximately 3 to 4 million pounds of heavy slurry which had to be dried for transport and disposal in a DOT approved class 1 industrial landfill.

The concrete waste was produced as the dump trucks that hauled concrete to the paving  machine returned to the plant site. The dump body was rinsed with a water cannon and the resulting heavy slurry was drained into the first of 3 weir type connected lagoons. The slurry accumulated over an 18 month period and then was extended to be able to deal with the grinding contractors waste slurry.

The landfill operator required that the slurry pass a 24 hour Paint Filter, Liquids Test before they would accept the waste.  The slurry could not be land applied for drying due to site constrictions and issues with high pH leachate contaminating or running off the property.

Fortrans offered to demonstrate our Sludge Set™ product used for solidifying various industrial waste streams so that the material would be solidified to the extent it would pass the paint filter liquids testing and also be transported in dump trucks without leaking from the truck bed.

The product was brought in for a demonstration. Documentation was provided showing nature and decomposition of drying agent in a landfill. The Sludge Set™ drying agent is non-hazardous, non-flammable and required no special equipment to mix into the waste. The Sludge Set™ claim is that it will absorb 250 lbs of water per lb of product.

The owner, DOT and landfill operator approved the material for use on this project. The Sludge Set™ was furnished as a dry powder in 50# multi-wall paper and plastic bag.

The owner furnished a extended boom (30’) bucket loader and modified the lower lip of the bucket by drilling ¾” holes to allow the Sludge Set™ to be evenly applied to the surface of the heavy slurry. The technicians loaded 50# of Sludge Set™ into the loader bucket per application

The lagoon was worked in sections. The bucket loader was used to apply the Sludge Set™ to one section of the lagoon and the operator of the loader used the bucket to mix the product into the slurry. The mixed material was transferred to another section and allowed to continue solidifying the slurry while the loader applied the Sludge Set™ powder to another section of the lagoon.

Once the second section was solidified to the operator’s satisfaction the solidified slurry was loaded into dump trucks for transport to the landfill.

This operation is ongoing until all concrete grinding operations are finished and the slurry produced is solidified and transported for disposal.

Fortrans Inc. announces new patent pending technology to mix gases into water and other media. The Dif-JET™ System is non-fouling and does not depend on bubble technology to mix gases into water.

DiF-JET™ single and combination Gas Infusion Systems are highly efficient at mixing beneficial gases such as oxygen, carbon dioxide, nitrogen and air into water or other media. DiF-JET™ inline non-fouling modules are very useful in raising oxygen levels in water for processes that require higher oxygen content.The devices may also be used to infuse nitrogen to enhance agricultural nutrition and reduce run off of nutrients.

DiF-JET™ Stainless Steel Systems are used for infusing ozone in odor elimination processes or sanitizing water.The system is useful for aeration in gold mining waste treatment operations.

DiF-JET™ Gas Infusion Systems equipped with floatation for aquaculture applications are also available.

The systems are non fouling and more efficient than conventional diffusion and or aeration processes and typically lower requirements for energy and equipment.

DiF-Jet™ Gas Infusion systems are very useful in replacing mechanical motor driven aeration systems.

The DiF-JET™ Gas Infusion Systems units will enhance production efficiencies in biological manufacturing processes by adding air or oxygen to speed up such processes. Reduction of Biological Oxygen Demand and Chemical Oxygen Demand in wastewater treatment or remediation of contaminated groundwater is another application.

The Dif-Jet™ combination oxygen and carbon dioxide systems are useful for pH reduction. The systems feature extremely high efficiency in producing large volumes of H2C03 (carbonic acid) from C02 gas and oxygen fed at low pressures and low or high volume flow rates. The patent pending dual C02 and oxygen Dif-Jet™ System provides the ability to convert C02 into H2C03 in without increasing the Chemical Oxygen Demand of the water being treated and may be operated for aeration purposes after optimum pH level has been reached.

The DiF-JET™ Gas Infusion Systems are available with variable flow rates and capacities for infusing oxygen, carbon dioxide, air or mixtures of gases. These features allow custom flow rates to suit the process. The modules can be designed to infuse mixtures of air, oxygen, nitrogen gas in specific ratios into specialized processes for aeration or production efficiencies.

DiF-JET™ Systems technology is exceptionally efficient compared to sparger technologies or mixtures of sparger stones, sparger lines, diffusers and mixers. Other benefits include non-fouling design and the fact that the gas infusion modules do not inhibit the flow of water such as is found with mechanical in-pipe diffusers or inline injector devices.

Fortrans’ various patent-pending gas infusion modules can be incorporated into inexpensive self contained systems for “bolt-on” applications where increased aeration levels are desirable. The individual modules may be incorporated into existing processes or for OEM equipment for water treatment. (Under License Only)

All DiF-JET™ Gas Infusion systems can be equipped with controls to monitor the process and control the duration of the feed or control by level of beneficial gases added to the process.

APPLICATIONS

• Aquaculture
• Agriculture
• Cement and concrete manufacturing
• Industrial wastewater
• Food processing
• Livestock holding areas
• Municipal wastewater
• Oil field operations

Febuary 2012

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.

Watch our short demo video now:

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.

Download Product Sheet

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.